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New Holland - Workshop Manual - NH E215B PDF
New Holland - Workshop Manual - NH E215B PDF
E245B
Workshop
Manual
Workshop
Manual
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E215B
E245B PROVEN PERFORMANCE
E215B
E245B
WORKSHOP MANUAL
M0103
All the information and data contained in this manual are based upon most recent information available at the
time of its publication.
NEW HOLLAND KOBELCO has the right to implement, at any time, any modification without providing any
communication.
TO THE READER
• This manual is written for an experienced - If you have any questions or comments, or if you
technician to provide technical information found any errors regarding the contents of this
needed to maintain and repair this machine. manual, please contact:
ADDITIONAL REFERENCES
• The Workshop Manual consists of five parts: - The “Operational Performance Test” part includes
- “Safety Precautions” the information needed to carry out the machine
operational performance test.
- “Operational Principle”
- “Operational Performance Test”
- The “Troubleshooting” part includes the technical
- “Troubleshouting”
information needed for troubleshooting and
- “Repair Instructions” malfunction detection.
- The “Safety Precaution” part includes the - The “Repair Instruction” part includes information
recommended procedures that, if followed, can needed for maintenance and repair of the
avoid the risk of accident for operator and for staff machine, tools and devices needed for
related to the work and maintenance machine maintenance and repair, maintenance standards,
operations. removal/installation and assembly/disassembly
procedures.
- The “Operational Principle” part includes the
technical information concerning the operation of
main devices and systems.
IN - 1
E215B-E245B INTRODUCTION
PAGE NUMBER
• Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:
Example: T 1-2-3
Section number
T: Technical Manual
W: Workshop Manual
SYMBOLS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential
for personal injury or machine damage.
UNITS USED
A table for conversion from SI units to other system units is shown below for reference purposes.
Quantity To convert from Into Multiply by Quantity To convert from Into Multiply by
(SI) (Others) (SI) (Others)
Lenght mm in 0.03937 Pressure MPa kgf/cm2 10.197
L US qt 1.057 kW HP 1.341
IN - 2
INDEX E215B-E245B
MANUAL INDEX
OPERATIONAL PRINCIPLE
Section 1 GENERAL
Group 1 Specifications................................................................................. T1-1
Group 2 Component Layout ........................................................................ T1-2
Section 2 SYSTEM
Group 1 Mechatro control system................................................................ T2-1
Group 2 Hydraulic System........................................................................... T2-2
Group 3 Electrical System ........................................................................... T2-3
TROUBLESHOOTING
Section 5 TROUBLESHOOTING
Group 1 Troubleshooting (by error codes)................................................... T5-1
Group 2 Troubleshooting (by trouble) .......................................................... T5-2
Group 3 Troubleshooting (trouble diagnosis mode)..................................... T5-3
E215B-E245B INDEX
REPAIR INSTRUCTIONS
Section 2 UPPERSTRUCTURE
Group 1 Upperstructure ..............................................................................W2-1
Group 2 Pump Device.................................................................................W2-2
Group 3 Control Valve ................................................................................W2-3
Group 4 Swing Device ...............................................................................W2-4
Group 5 Pilot Valve .....................................................................................W2-5
Section 3 UNDERCARRIAGE
Group 1 Swing Bearing ..............................................................................W3-1
Group 2 Travel Device ...............................................................................W3-2
Group 3 Swivel Joint ..................................................................................W3-3
Group 4 Track Adjuster ..............................................................................W3-4
Group 5 Front Idler .....................................................................................W3-5
Group 6 Upper and Lower Roller ...............................................................W3-6
Group 7 Tracks ...........................................................................................W3-7
M0103
SAFETY PRECAUTIONS E215B-E245B
INDEX
Section 1 GENERALITIES
SAFETY PRECAUTIONS
GENERALITIES
Read the Operation and Maintenance Instruction Do not leave the machine until it has come to a
Manual carefully before starting, operating, complete stop.
maintaining, fuelling or servicing the machine. Always check height, width and weight limitations
Carefully read the explanation to each and all safety which may be encountered in the working site and
signs in the special section of this Manual before ensure the machine does not exceed them.
starting, operating, maintaining, fuelling or servicing Assess exact paths of gas ducts, water mains,
the machine. telephone lines, sewers, overhead and underground
Machine-mounted safety plates are colour coded electric lines and all other possible obstacles.
yellow with black borders when they refer to points Such paths should be opportunely defined by
where special ATTENTION must be paid and failure competent Authorities. If necessary, require that the
to observe them may cause a serious DANGER to service is interrupted or said installations are moved
the integrity of machine operators. They are white prior to starting the work.
with red borders and black lettering when they refer
You must know the working capacity of the machine.
to a FORBIDDEN practice.
Define the rear upperstructure swing area and
It is fundamental that all machine operators know
provide for opportune barriers to prevent access into
very well the meaning of each safety plate as this
it.
considerably decreases operating hazards and
accidents. Never exceed machine lifting capacity.
Do not allow unauthorised personnel to operate or Remain within the limits shown in the loading
service this machine. capacity chart which located on the machine.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get STARTING
caught in moving parts. Wear certified safety clothes Never start or operate a failed machine. Walk all
such as: hard hat, no-slip footwear, heavy gloves, ear around the machine before mounting.
protection, safety glasses, reflector vests, respirators Before operating the machine, make sure that any
every time the job requires it. Ask your employer possible dangerous condition has been properly
about safety regulations in force and protective removed. Before starting machine, check that
equipment. steering and attachment controls are in the neutral
Always keep the operator’s compartment, step position and the safety lever is in the LOCK position.
plates, grab-rails and handles clean and clear of Immediately report any malfunction of parts or
foreign objects, oil, grease, mud or snow to minimise systems to the maintenance managers for proper
the danger of slipping or stumbling. Remove mud or action.
grease from your shoes before operating the Prior to starting the engine, check, adjust and lock the
machine. driver’s seat for maximum riding comfort and control
Do not jump on or off the machine. Always keep both accessibility. Prior to operating the machine and/or
hands and one foot, or both feet and one hand in its attachments, check that bystanders are outside
contact with steps and/or grab rails. the machine operating range. Sound the horn.
Do not use controls or hoses as hand holds. Hoses Obey all hand signals, safety indications and signs.
and controls are movable parts and do not provide Due to the presence of flammable fluids, never
solid support. Besides, controls may be inadvertently check fuel level, refuel, charge the batteries in the
moved and cause unexpected movement of the presence of smoking materials, open flames or
machine or its attachments. sparks.
Never operate the machine or its attachments from Ensure that nobody is within the excavator operating
any position other than sitting in the driver’s seat. area before starting the machine, swinging the upper
Keep head, body, limbs, hands and feet inside the structure or moving in any direction.
operator’s compartment at all times to reduce Adjust all rear-view mirrors for maximum visibility of
exposure to external hazards. the area behind the machine.
Be careful of possible slippery conditions of the steps Ensure that engine speed is appropriate to the job to
and hand rails as well as of the ground around the be carried out.
machine. Wear protective boots or shoes with the
soles made of highly no-slip rubber
S1 - 1
E215B-E245B GENERALITIES
If any hydraulic control or system exhibits erratic properly protected against possible backlash in
performance or responds abnormally, have the case of cable or chain failure or detachment.
machine checked for air in the system. Be alert of soft ground conditions close to newly
Air in these circuits may cause incorrect movements constructed walls. The fill material and machine
with consequent accident hazard. Refer to the weight may cause the wall to collapse under the
Operation and Maintenance Instruction Manual machine.
about corrective action to be taken. In darkness, check area of operation carefully before
moving in with the machine. Use all lights provided.
Do not move into low visibility areas.
OPERATING If the engine tends to slow down and stall for
whatever reason under load or at idle, immediately
report this problem to the maintenance managers for
Do not run the engine of this machine in closed proper action.
buildings without proper ventilation capable to
Do not operate the machine until this condition is
remove harmful exhaust gases which concentrate in
corrected. Regularly check all exhaust system
the air.
components, as exhaust fumes are toxic for the
Keep the operator’s compartment free of foreign operator.
objects, especially if not firmly secured. Never use
Operators must know the performance of the
the machine to transport objects, unless proper
machine they are driving. When working on slopes or
securing points are provided.
near sudden level drops in the terrain, pay attention
Do not carry riders on the machine. Study and not to lose adherence and avoid loose soft ground
familiarise with escape routes alternative to normal since overturn or loss of machine control could result.
exit routes. For your personal safety, do not climb on
If noise level is high and exceeds 90 dB (A) over 8
or off the machine while it is in motion.
hours at the operator’s ear, wear approved ear
Make sure that bystanders are clear of the machine protection in compliance with local regulations.
operating range before starting the engine and
Do not operate the machine if you are extremely tired
operating the attachment. Sound the horn.
or feel ill. Be especially careful towards the end of the
Obey all hand signals, safety indications and signs. working shift.
When backing, always look to where the machine is Where removable counterweights are provided, do
to be moved. not operate the machine if they have been removed.
Be alert of the position of bystanders. Should When operating the machine, keep in mind height
someone enter the work area, stop the machine. limits of overhead doors, arches, overhead cables
Maintain a safe distance from other machines or and lines as well as width limits of corridors, roads
obstacles to ensure required visibility conditions. and narrow passages.
Always give way to loaded machines. Also, get to know load limits of the ground and
Maintain a clear vision of the surroundings of the paving type of the ramps you are to work on.
travel or work area at all times. Keep cab windows Beware of fog, smoke or dust that obscure visibility.
clean and repaired.
Always inspect the working area to identify potential
When pulling loads or towing through a cable or risks such as: inclines, overhangs, trees, demolition
chain, do not start suddenly at full throttle. Take-up rubble, fires, ravines, steep slopes, rough terrain,
slack carefully. Avoid kinking or twisting chains or ditches, crowns, ridge trenches,diggings in traffic
cables. areas, crowded parking lots, crowded service areas,
Carefully inspect the towing items for flaws or fenced zones. In such conditions, proceed with
problems before proceeding. Do not pull through a extreme care.
kinked chain or cable as the high anomalous stresses Whenever possible, avoid crossing over obstacles
existing in this condition may induce failures in the such as very rough terrain, rocks, logs, steps,
kinked portion. ditches, railroad tracks.
Always wear heavy gloves when handling chains or When obstructions must be crossed, do so with
cables. extreme care and at a square angle, if possible. Slow
Chains and cables should be securely anchored down.
using suitable hooks. Anchor points should be strong Ease up to the break-over point, pass the balance
enough to withstand the expected load. point slowly and ease down the other side also using
Keep anyone clear of anchor points and cables or the attachment, if necessary.
chains. To overcome deep trenches or sinking ground, place
Do not pull or tow unless the operator’s the machine perpendicular to the obstacle, drastically
compartments of the machines involved are reduce ground speed and start crossing using also
S1 - 2
GENERALITIES E215B-E245B
the attachment if necessary, only after assessing that The load must always be properly arranged in the
ground conditions allow the traverse safely and bucket; move with extreme care when transporting
without risks. oversize loads.
The gradient you may attempt to overcome is limited Do not lift and move the bucket overhead where
by factors such as ground conditions, load being persons are standing or working, nor downhill when
handled, machine type and speed, and visibility. working on a slope as this would decrease machine
There is no substitute for good judgement and stability. Load the bucket from the uphill side.
experience when working on slopes. Loads to be raised using the machine should be
Avoid operating the attachment too close to an exclusively hooked to the hitch specially provided.
overhang or high wall, either above or below the The excavator is no lifting and transportation means,
machine. Beware of caving edges, falling objects therefore it should not be used to position loads
and landslides. Remember that such hazards are accurately. Should it be exceptionally used to lift and
likely to be concealed by bushes, undergrowth and lay building components, special caution must be
such. taken as follows:
Avoid faggots, bushes, logs and rocks. Never drive
over them, nor over any other surface irregularities
- The machine must be equipped compulsorily with
that discontinue adherence or traction with the
the appropriate variant provided upon request.
ground, especially near slopes or drop-offs.
- Secure the loads to be raised using cables or
Be alert to avoid changes in adherence conditions
chains fastened with appropriate hooking
that could cause loss of control. Work with extreme
mechanisms.
care on ice or frozen ground and on stepped slopes
or near drop-offs. - Nobody should be allowed to remain under the
raised load or within the excavator operating range
The word “bulldozing” generally refers to work in
for any reason whatever.
virgin rough terrain, characterised by the presence of
all the perils and risks listed above. We emphasise
the danger represented in these conditions by large Never exceed specified loading capacity. Incorrect
tree limbs (possibly falling on the machine) and large fastening of slings or chains may cause boom/arm
roots (which may act as a leverage under the failure or failure of the lifting means with consequent
machine when up-rooted and cause the unit to bodily injuries and even death.
overturn). Always ensure that slings and chains used for lifting
Position the machine dependent upon the loading are adequate to the load and in good condition.
and unloading areas in order to swing leftwards to All loading capacities are referred to the machine
load to obtain best visibility. on a level surface and should be disregarded
Never use the bucket or attachment as a man lift when working on a slope.
or carry riders. Never use the machine as a work Avoid travelling across slopes. Proceed from uphill
platform or scaffolding. The machine must not be downhill and vice-versa. If machine starts slipping
improperly used for works not consistent with its sideways when on a slope, lower the bucket and
features (such as pushing railway cars, trucks or thrust bucket teeth into the ground.
other machines).
Working on slopes is dangerous. Grade the working
Always pay attention to people within the machine area if possible. Reduce work cycle time if it is not
operating range. possible to grade the working area.
Never move or stop the bucket, other loads or the Do not move full bucket or a load from uphill downhill
attachment above ground personnel or truck cabs. as this would reduce machine stability. Do not work
Ensure the truck driver is in a safe place before with the bucket turned to the uphill side.
loading the truck. Do not work with the bucket turned uphill as
Load trucks from side or rear. counterweights protruding downhill would reduce
Use only the type of bucket recommended machine stability on the slope and increase risk of
considering machine type, materials to be handled, overturning.
material piling up and loading characteristics, ground We recommend to work on slopes with the bucket
type and other typical conditions of the work to be downhill, after checking machine stability with the
performed. bucket empty and attachment retracted, by slowly
When transporting a loaded bucket, keep it as swinging the upper structure by 360°.
rolled-back as possible. Keep boom and arm as low Position the carriage at a right angle relative to
as possible. slopes, hanging walls, etc. to exit the working area
Ground speed should be adequate to the load and easily.
ground conditions. Standard use, provides for the travel controls at the
front and travel motors at the back. Should travel
S1 - 3
E215B-E245B GENERALITIES
motors be positioned at the front with regard to the - Look up the in the telephone directory.
actual travel direction. Remind relative to travel - Define together with the Company representative
direction that controls are reversed. which precautions should be taken to guarantee
Always check travel motor position before moving off. work safety.
Properly judge ground conditions with particular - All electric lines should be considered as operative
attention to consistency of the area you are going to live lines even though it might be well known that
work on. the line in question is out of work and visibly
Keep the machine sufficiently far from the ditch connected to the ground.
edge. - The Electric Power Company, if previously advised
Never dig under the machine. and involved in the work, as well as machine
Operator, Owner and/or any natural person or legal
Should it be necessary to dig under the machine,
entity having rent orleased the machine or being
always ensure that digging walls are opportunely
responsible at the time by contract or by law, are
propped up against landslide to prevent the machine
liable for the adoption of the necessary
from falling into the trench.
precautions.
Do not swing the upperstructure, raise the load or
- Decrease work speed. Reaction time could be too
brake abruptly if not required. This may cause
slow and distance evaluation wrong.
accidents.
- Warn all ground personnel to keep clear of the
Prior to beginning the work near gas distribution
machine and/or load at all times. If the load has to
mains or other public utilities:
be guided down for laying, consult the Electric
- Contact the company owner of the gas mains or its Power Company to know which precautions should
nearest branch before starting the work. Look up be taken.
the number in the telephone directory.
- Appoint a person in charge of signalling duties.
- Define together which precautions should be taken This person will have the responsibility of observing
to guarantee work safety. the machine, any part of it and/or the load
- Decrease work speed. Reaction time could be too approaching the electric lines from a standpoint
slow and distance evaluation wrong. more favourable than the Operator’s. This signal
- When working near gas mains or other public man (flag-man) must be in direct communication
utilities installations, appoint a person in charge of with the Operator and the Operator must pay
signalling duties. This person will have the undivided attention to the signals supplied.
responsibility of observing the machine, any part of When working in or near pits, in ditches or very high
it and/or the load approaching the gas mains from walls, check that the walls are sufficiently propped up
a standpoint more favourable than the Operator’s. to avoid cave-in hazards.
This signal man (flag-man) must be in direct Pay the utmost attention when working near
communication with the Operator and the Operator overhang walls or where landslides may take place.
must pay undivided attention to the signals Make sure that the support surface is strong enough
supplied. to prevent landslides.
- The gas distributing Company, if previously When digging, there is the risk of cave-ins and
advised and involved in the work, as well as landslides.
machine Operator, Owner and/or any natural
Always check ground conditions and conditions of
person or legal entity having rent or leased the
the material to be removed. Support everywhere it is
machine or being responsible at the time by
required to prevent possible cave-ins or landslides
contract or by law, are liable for the adoption of the
when:
necessary precautions.
- Digging near previous trenches filled with material.
Working near electric lines can be very dangerous,
therefore some special precautions must be - Digging in bad ground conditions.
observed. - Digging trenches subject to vibration from
Within this Manual, “work near electric lines” means railroads, working machines or highway traffic.
when the attachment or load raised by the excavator
(in any position) may reach the minimum safety
distance established by local or international Safety
STOPPING
Regulations.
To work without risks, keep maximum possible
distance from electric lines and never trespass When the machine is to be stopped for whatever
minimum safety distance. reason, always check that all controls are in the
neutral position and that the safety lever is on the lock
- Contact the Company owner of the electric lines or
position to guarantee risk-free start-up.
its nearest branch before starting the work.
S1 - 4
GENERALITIES E215B-E245B
Never leave the machine unattended with the engine Read all safety plates mounted on the machine and
running. observe instructions they contain before starting,
Prior to leaving the driver’s seat, and after making operating, repairing, fuelling or servicing the
sure that all people are clear of the machine, slowly machine.
lower the attachment until resting it safely to the Do not allow unauthorised personnel to repair or
ground. Retract possible auxiliary tools to the closed service the machine.
safety position. Follow all recommended maintenance and service
Check that all controls are in the neutral position. procedures.
Move engine controls to the shut-down position. Do not wear rings, wrist watches, jewellery, loose or
Switch off the key-start switch. Consult the Operation hanging garments, such as ties, torn clothing,
and Maintenance Instruction Manual. scarves, unbuttoned or unzipped jackets that can get
Park the machine in a non-operating and no-traffic caught in moving parts. Wear certified safety clothes
area. Park on firm level ground. If this is not possible, such as: hard hat, no-slip footwear, heavy gloves, ear
position the machine at a right angle to the slope, protection, safety glasses, reflector vests, respirators
making sure there is no danger of uncontrolled when required. Ask your employer about safety
sliding. regulations in force and protective equipment.
If parking in traffic lanes cannot be avoided, provide Do not use controls or hoses as hand holds. Hoses
appropriate flags, barriers, flares and other signals as and controls are movable parts and do not provide
required to adequately warn the oncoming drivers. solid support. Besides, controls may be inadvertently
Always switch off the key-start switch before moved and cause unexpected movement of the
cleaning, repairing, or parking the machine to prevent machine or its attachments.
accidental unauthorised start-up. Do not jump on or off the machine. Always keep both
Never lower the attachment or auxiliary tools other hands and one foot, or both feet and one hand in
than from sitting in the operator’s seat. Sound the contact with steps and/or grab rails.
horn. Make sure that nobody is within the machine Never service the machine with someone sitting in
operating range. Lower the attachment slowly. the driver’s seat, unless this person is an authorised
Securely block and lock the machine every time you operator assisting in the maintenance being carried
leave it unattended. Return keys to the safe place out.
previously agreed upon. Perform all necessary Keep the operator’s compartment, step plates, grab
operations for stopping as detailed in the Operation rails and handles clear of foreign objects, oil, grease,
and Maintenance Instruction Manual. mud orsnow to minimise the danger of slipping or
Drive the machine far from pits, trenches, rocky stumbling.
hanging walls, areas with overhead electric lines, and Clean mud or grease from your shoes before
slopes before stopping it at the end of the working climbing on the machine or driving it.
day. Never attempt to operate the machine or its
Align the upperstructure to the tracks in order to allow attachments from any position other than sitting in the
to easily get on and off the driver’s compartment. operator’s seat.
Move all controls to the position specified for machine Keep the driver’s seat free from foreign objects,
stopping. Refer the Operation and Maintenance especially if these are not secured.
Instruction Manual. Should it be necessary to move the attachment for
Never park on an incline without accurately blocking maintenance purposes, do not raise or lower the
the machine to prevent unexpected movement. attachment from any other position than sitting in the
Follow stopping instructions contained in the operator’s seat. Before starting the machine or
Operation and Maintenance Instruction Manual. moving its attachment, sound the horn and require
that nobody remains near the machine.
Raise the attachment slowly.
Always lock all moving components or parts of the
machine that must be lifted for maintenance
MAINTENANCE purposes using adequate external means as
required by local and national regulations. Do not
allow anyone to pass or stay near or below a raised
GENERALITIES
attachment. If you are not absolutely sure about your
safety, do not stay or walk under a raised attachment.
Carefully read the Operation and Maintenance Do not place head, body, limbs, hands, feet or fingers
Instruction Manual before starting, operating, near articulated cutting edges deprived of the
maintaining, fuelling or servicing the machine in any necessary guards, unless they are suitably and
manner. safely locked.
S1 - 5
E215B-E245B GENERALITIES
Never lubricate, repair or adjust the machine with the flammable fluids to clean parts. Use proprietary
engine running, except when this is specifically certified non-flammable, non-toxic solvents only.
required by the Operation and Maintenance When using compressed air to clean parts, wear
Instruction Manual. safety glasses with side shields. Limit pressure to
Do not wear loose clothing, jewellery near rotating max. 2 bars, in accordance with local and national
parts. safety regulations in force.
When service or maintenance require access to Do not run the engine of this machine in closed
areas that cannot be reached from the ground, use a buildings without proper forced ventilation capable to
ladder or step platform conforming to local or national remove toxic exhaust gases concentrating in the air.
regulations to reach the working area. If such means Do not smoke, nor allow open flames or sparks
are not available, use machine grab rails and steps. nearby while refuelling the unit or handling highly
Always perform all service or maintenance work with flammable materials.
the greatest care and attention.
Do not use open flames as light sources to look for
Shop and/or field service platforms or ladders should leaks or inspect anywhere on the machine.
be manufactured and maintained in accordance with
Make sure that all mechanical tools provided are in
local or national safety regulations in force.
good condition at all times. Never use tools with
Disconnect batteries and label all controls to warn mushroomed or damaged heads. Always wear eye
that service work is in progress, according to local protections with side shields.
and national safety regulation requirements.
Move with extreme care when working under, on or
Block the machine and all attachments to be raised near the machine or its attachments.
according to local and national safety regulation
In case of attachment tests during which the engine
requirements.
should be kept running, a qualified operator must sit
Do not check or fill fuel tanks or install batteries near in the driver’s seat at all times while the mechanic is
burning or smoking materials and open flames due to at work.
the presence of flammable vapours.
Keep hands and clothes far off moving parts.
The fuel filler pipe nozzle must be constantly kept in
Stop the engine and move the safey lever to the lock
contact with the filler neck and this even before fuel
position before starting adjusting or repairing an
starts flowing in. Keep this contact from the beginning
assembly.
to the end of the fuelling operation to avoid possible
generation of sparks due to static electricity. Do not carry out any work on the attachment without
prior authorisation. Observe maintenance and repair
Use a truck or trailer to haul a failed machine. Should
procedures.
it be necessary to tow it, provide for suitable danger
signals as required by the local norms and In case of field service, move the machine to level
regulations and observe recommendations given in ground and block it. If work on an incline cannot be
the Operation and Maintenance Instruction Manual. avoided, securely block the machine and its
Load/unload the machine on firm level ground attachments. Move the machine to level ground as
providing safe support to the wheels of the truck or soon as possible.
trailer. Use strong access ramps, with adequate Do not twist chains and cables. Never use a twisted
height and angle. Keep the trailer flatbed free of mud, chain or cable for lifting or pulling. Always wear safety
oil or slippery materials. Tie the machine securely to gloves to handle chains or cables.
the trailer and block carriages and upperstructure. Be sure chains and cables are firmly fastened and
Never align holes or slots using your fingers; that the anchor point is strong enough to withstand
alwaysuse appropriate aligning tools. the expected load.
Remove all sharp edges and burrs from re-worked Keep all bystanders clear of the anchor point, cables
parts. or chains. Do not pull or tow unless the operator’s
Use only approved and effectively grounded auxiliary compartments of the machines involved are
power sources for heaters, battery chargers, pumps fitted with proper guards against cable or chain
and similar equipment to reduce electrical shock backlash.
hazard. Keep the maintenance area clean and dry at all
Lift and handle heavy components using hoisting times.
devices of appropriate capacity. Ensure the parts are Clean immediately all water and oil spillage.
supported by appropriate straps and hooks. Do not pile up oily or greasy rags as they represent a
Use lifting eyes provided to this aim. major fire hazard. Always store them in closed metal
Pay attention to bystanders near the lifting area. containers.
Never pour gasoline or diesel fuel into open Before starting the machine or its attachment, check,
containers. Never use gasoline, solvents or other adjust and lock the operator’s seat. Also ensure that
nobody is within the machine or attachment
S1 - 6
GENERALITIES E215B-E245B
operating range before starting or operating the injuries are most likely to occur. Pay attention to
machine and/or its attachments. prevent possible part movements by means of
Sound the horn. blocks or by keeping clear of such zones when
motion may take place during maintenance or repair.
Rust inhibitors are volatile and flammable.
Move the hydraulic system lock safety lever to the
Prepare parts in well ventilated areas. Keep open
lock position when stopping the machine for
flames away.
whatever reason.
Do not smoke.
Always install the safety stays for the hood and other
Store containers in a cool well ventilated place where hinged covers before performing any maintenance or
they could not be reached by unauthorised people. repair work in the engine compartment.
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
TRANSFERS AND TRANSPORTATION
safety shoes and gloves, safety glasses when
splinters or other particles may be ejected.
Wear the appropriate welder’s equipment such as Before moving or transporting the machine, block
dark safety glasses or mask, hard hat, protective upperstructure swing to prevent accidental
clothing, safety gloves and footwear always while movement.
welding or arc-cutting. Wear dark safety glasses Pay particular attention during transfer on inclines,
when you are near a welding in progress. both uphill and downhill. Keep the bucket in a position
Do not look the welding arc without proper eye to provide a possible anchor point into the ground in
protection. case of slipping.
Become acquainted with all your jacking equipment During transfers on inclines, both uphill and downhill,
and their capacity. keep the upperstructure aligned with the carriages.
Do not travel across the slope.
Ensure that the jacking point on the machine is
appropriate for the load applied. Also, be sure the Never transfer the machine in the working site, in a
supports under the jack and between the jack and the crowded area, or near people without having at least
machine are appropriate and stable. one person charged with hand-signals who could
guide the Operator.
Any equipment supported by a jack represents a
possible hazard. Always support the load onto Sound the horn to inform that you are about to move
appropriate blocking means as a safety measure off.
before proceeding with service or maintenance work, It is necessary to know load limits of bridges and
in compliance with local or national safety dimensional limits of tunnels. Such limits must never
regulations. be exceeded. You should also know machine height,
Metal cables produce steel splinters. Always wear width, and weight. Have a signal-man help you when
certified protection clothes such as safety gloves and clearances are limited.
glasses while handling them. Check distance between boom/arm and dimensional
Do not use makeshift jacks to adjust track sag. Follow limits during transfer or transportation.
instructions given in the Repair Manual. Rough terrain may cause the machine to sway and
Handle all parts carefully. Keep hands and fingers roll to such an extent that boom/arm could get to
away from gaps, gears, and similar. Always use and contact electric lines or other obstacles. Cross
wear certified safety clothes such as safety glasses, obstacles at a right angle at low speed. Pay attention
gloves and footwear. to machine shaking when the centre of gravity
overcomes the obstacle.
The attachment is kept constantly in position by an oil
column trapped into the high pressure circuit. Lower Keep the bucket down at all times during transfers.
the attachment to the ground and relieve pressure Drive with the lights on and use appropriate signals
from all circuits prior to carrying out any type of and flags.
maintenance or repair work. Get to know and respect local and national
Do not service or repair the machine if it is parked regulations.
downhill. If this is unavoidable, in case of emergency, Consider boom/arm and upperstructure dimensions
block the carriages to prevent unexpected while turning.
movement, particularly if the work is to be carried out
Use a ramp to load the machine on a trailer. If a ramp
on the final reduction units or travel motors.
is not available, fabricate one using blocks. The ramp
Consult the Operation and Maintenance Instruction should be sufficiently strong to support machine
Manual for correct maintenance procedure. weight. Always load and unload on level surface.
Areas near articulated cutting edges where
mechanical parts are in motion are where personal
S1 - 7
E215B-E245B GENERALITIES
Tow the machine following the instructions contained Before any maintenance or repair, make sure that
in the Operation and Maintenance Instruction there are no fuel or electrolyte leaks from the
Manual. batteries. If any, correct prior to proceeding with
further work. Do not recharge batteries in confined
spaces. Ensure proper ventilation is provided to
avoid accidental explosions due to build-up of
ENGINE explosive gas released during charging.
Disconnect batteries before working on the electrical
Do not run the engine in closed buildings without system or carrying out any other type of work.
proper ventilation capable to remove harmful exhaust
fumes.
Do not place head, body, limbs, feet, hands or fingers
HYDRAULIC SYSTEM
near rotating fans or belts. Be especially careful near
blower fans.
Loosen the radiator cap very slowly to relieve system Pressure fluid escaping from a very small hole can be
pressure before removing it. Always top-up coolant almost invisible and still have sufficient force to
level with the engine off or idling if hot. See the penetrate the skin. Always check any suspected
Operation and Maintenance Instruction Manual. pressure leaks using a piece of cardboard or wood.
Keep the exhaust manifold and tube free from Do not use hands. If injured by escaping fluid, obtain
combustible matters. Fit the machine with shields medical attention immediately or serious infection or
and guards when working in the presence of reaction may develop.
combustible matter free in the air. Stop the engine and ensure pressure is relieved from
Do not refuel with the engine running, especially if all systems before removing side panels, housings,
hot, as this increases fire hazard in case of fuel guards and covers. See the Operation and
spillage. Maintenance Instruction Manual.
Never attempt to check or adjust fan belt tensions Always use gauges of adequate capacity for
when the engine is running. pressure testing. Refer to the Operation and
Maintenance Instruction Manual or Repair Manual.
Do not adjust the fuel injection pump when the
machine is operating.
Do not lubricate the machine with the engine running.
Do not run the engine with the air intakes open and
not protected. If this cannot be avoided for service
reasons, place protection meshes on all intakes TOOLS
before servicing the engine.
S1 - 8
SAFETY PRECAUTIONS E215B-E245B
ENVIRONMENTAL PROTECTION
S2 - 1
E215B-E245B SAFETY PRECAUTIONS
S2 - 2
SAFETY PRECAUTIONS E215B-E245B
S2 - 3
E215B-E245B SAFETY PRECAUTIONS
S2 - 4
SAFETY PRECAUTIONS E215B-E245B
S2 - 5
E215B-E245B SAFETY PRECAUTIONS
S2 - 6
SAFETY PRECAUTIONS E215B-E245B
S2 - 7
E215B-E245B SAFETY PRECAUTIONS
S2 - 8
SAFETY PRECAUTIONS E215B-E245B
AVOID OVERTURNING
• To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Pull the safety lever (pilot-control shut-off lever)
to the LOCK position.
- Turn auto-idle switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Prior to leaving the machine, close the windows,
the cab door and all panels.
S2 - 9
E215B-E245B SAFETY PRECAUTIONS
S2 - 10
SAFETY PRECAUTIONS E215B-E245B
S2 - 11
E215B-E245B SAFETY PRECAUTIONS
SP0030
S2 - 12
SAFETY PRECAUTIONS E215B-E245B
S2 - 13
E215B-E245B SAFETY PRECAUTIONS
S2 - 14
SAFETY PRECAUTIONS E215B-E245B
S2 - 15
E215B-E245B SAFETY PRECAUTIONS
SAFE MAINTENANCE
• To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Keep the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it
is in motion.
- Keep hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
4. Switch off the Auto-Idle.
5. Let the engine idle with no load for at least
five minutes until it has cooled down.
6. Move the key-start switch to the OFF
position to stop the engine.
7. Remove the ignition key from the start
switch.
8. Apply the "Maintenance in progress" tag
(see SAFETY PLATE in this Chapter).
This tag can be applied o the left-hand
control lever, safety lever or cab door.
9. Let the engine cool down.
- Do not leave the machine unattended if
servicing requires the engine running.
- If the machine is to be raised, place boom and
arm at an angle 90 to 110°. Lock machine
components which should be raised for
maintenance or repair using suitable supporting
means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or
replace as necessary. Refer to the Chapter
MAINTENANCE in this Manual.
- Keep all components in good condition and
properly install. Immediately repair any fault.
- Immediately repair any damage.Replace worn
or failed components. Remove grease, oil,
debris build-ups.
- Disconnect the negative cable (-) from the
battery before carry out any work on he
electrical sysem or arc-welding on he machine.
S2 - 16
SAFETY PRECAUTIONS E215B-E245B
S2 - 17
E215B-E245B SAFETY PRECAUTIONS
S2 - 18
SAFETY PRECAUTIONS E215B-E245B
S2 - 19
E215B-E245B SAFETY PRECAUTIONS
S2 - 20
SAFETY PRECAUTIONS E215B-E245B
PREVENT BURNS
S2 - 21
E215B-E245B SAFETY PRECAUTIONS
SP0047
- As pieces may fly off, be sure to keep body and
face away from air release plug to avoid injury.
Reduction gear oil is hot. Wait for gear oil to cool
down, then gradually loosen the air release plug
to release pressure.
S2 - 22
SAFETY PRECAUTIONS E215B-E245B
S2 - 23
E215B-E245B SAFETY PRECAUTIONS
PREVENT FIRES
• Check for Oil Leaks:
- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts
which may cause oil leaks.
- Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil-
cooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.
• Check for Shorts:
- Short circuits can cause fires.
- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10)
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
• Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
• Check Key-start Switch:
- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF
position to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.
• Check Heat Shields:
- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S2 - 24
SAFETY PRECAUTIONS E215B-E245B
SP0062
S2 - 25
E215B-E245B SAFETY PRECAUTIONS
S2 - 26
SAFETY PRECAUTIONS E215B-E245B
S2 - 27
E215B-E245B SAFETY PRECAUTIONS
NOTE:
S2 - 28
SAFETY PLATES E215B-E245B
SAFETY PLATES
S3 - 1
E215B-E245B SAFETY PLATES
3. Counterweight operating range safety plate. 9. Controls lock/unlock plate (safety lever).
4. Read-your-manual plate. 10. Hydraulic oil pressurised tank warning plate.
5. Boom and arm movement warning plate 11. Burns warning plate.
(Triple articulation version). 12. Safety distance plate.
6. Open windscreen warning plate aperta 13. No-stepping warning plate.
(inside the cab).
14. Special equipment movement warning plate
7. Tag indicating maintenance in progress.
8. Engine hood warning plate.
S3 - 2
SAFETY PLATES E215B-E245B
S3 - 3
E215B-E245B SAFETY PLATES
4 - Read-your-manual plate
SP0073
S3 - 4
SAFETY PLATES E215B-E245B
S3 - 5
E215B-E245B SAFETY PLATES
S3 - 6
SAFETY PLATES E215B-E245B
S3 - 7
E215B-E245B SAFETY PLATES
NOTE:
S3 - 8
OPERATIONAL PRINCIPLE
M0103
OPERATIONAL PRINCIPLE E215B-E245B
Section 1 GENERAL
Group 1 Specifications
Section 2 SYSTEM
Group 1 Mechatro Control System
Group 2 Hydraulic System
Group 3 Electrical System
GENERAL
CONTENTS
Group 1 - Specifications
Main components .............................. T1-1-1
Hydraulic components ....................... T1-1-5
Excavator performance...................... T1-1-8
Digging data E215B
(Monoblock Version) .......................... T1-1-9
Digging data E215B
(Triple Articulation Version) ............... T1-1-10
Transporting dimensions E215B
(Monoblock Version) .......................... T1-1-11
Transporting dimensions E215B
(Triple Articulation Version) ............... T1-1-12
Bucket applications as a function
of the arms E215B ............................. T1-1-13
Digging data E245B
(Monoblock Version) .......................... T1-1-14
Digging data E245B
(Triple Articulation Version) ............... T1-1-15
Transporting dimensions E245B
(Monoblock Version) .......................... T1-1-16
Transporting dimensions E245B
(Triple Articulation Version) ............... T1-1-17
Bucket applications as a function
of the arms E245B ............................. T1-1-18
SPECIFICATIONS E215B-E245B
MAIN COMPONENTS
T1-1-1
E215B-E245B SPECIFICATIONS
2
6
3 4
SM0012
T1-1-2
SPECIFICATIONS E215B-E245B
1
2
3
section A - A
SM0013
T1-1-3
E215B-E245B SPECIFICATIONS
2 7
1
3
4 6 2 8 7
3
1
SM0014
T1-1-4
SPECIFICATIONS E215B-E245B
HYDRAULIC COMPONENTS
HYDRAULIC PUMP
NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump.
CONTROL VALVE
Item STD VALVE
Model KMX15YD / B44041
Max. flow rate L/min 220 x 2
Main relief valve set pressure MPa 34.3 at 70 x 2 L/min
When power boost pressure 37.8 at 60 x 2 L/min
Over load relief valve set pressure MPa
Boom H, Bucket H, Arm R 39.7 at 30 L/min
Boom R, Bucket R, Arm H 37.8 at 30 L/min
Mass kg 232
T1-1-5
E215B-E245B SPECIFICATIONS
PILOT VALVE
ATTACHMENT TRAVEL
Model PV48K2004 6TH6NRZ
Primary pressure 5.0 MPa 4.9 MPa
Secondary pressure 0.6 ~ 3.2 MPa 0.54 ~ 2.35 MPa
Rated flow 20 L/min 25 L/min
Mass Approx. 2 kg Approx. 8 kg
T1-1-6
SPECIFICATIONS E215B-E245B
TRAVEL DEVICE
Item E215B E245B
Reduction gear unit Epicycloidal, three-stage planetary type
Model 710 C3 K
Gearbox ratio 1 : 55.2 1 : 43.2
Travel motor Two speed, axial piston swash plate type
Model MAG 170 VP MAG 170 VP
high speed 81.2 cm3/rev 112.6 cm3/rev
Displacement
low speed 129.3 cm3/rev 181.3 cm3/rev
Max. flow 220 L/min 246 L/min
CYLINDERS
Center distance
Cylinder bore / of pins
Use Rod Dia. Stroke Full extend B / Cushion Mass
Full retract A
(mm) (mm) (mm) (kg)
With cushion
Boom Ø 120 / Ø 85 1345 3200 / 1855 176
on rod side
With cushion
Arm Ø 135 / Ø 95 1558 3637 / 2079 255
on both sides
With cushion
Bucket Ø 120 / Ø 80 1080 2684 / 1604 153
on rod side
T1-1-7
E215B-E245B SPECIFICATIONS
EXCAVATOR PERFORMANCE
TRAVEL SPEED
Excavator
E215B E245B
Speed
First speed 3.6 km/h 3.2 km/h
Second speed 6.0 km/h 5.2 km/h
ENGINE DATA
MAIN SPECIFICATIONS
- Manufacturer ................................................................................................................................. CNH U.K.
- Model .........................................................................................................................................667TA/MEB
- Type ..................................................................................... Diesel, 4 stroke, direct injection, turbocharged
- Number of cylinder ...........................................................................................................................6 in-line
- Bore ................................................................................................................................................. 104 mm
- Stroke............................................................................................................................................... 132 mm
- Total displacement .........................................................................................................................6728 cm3
- Compression ratio ............................................................................................................................... 17.5:1
- Net power at flywheel (at 2000 rpm) (ISO 14396)............................................................................. 118 kW
- Torque (at 1200 rpm) ........................................................................................................................670 Nm
- Engine idle at no-load ...................................................................................................................... 800 rpm
INJECTION PUMP
- Type .................................................................................................................................VE6/12 F 1000 LV
- Injection order ............................................................................................................................. 1-5-3-6-2-4
BATTERY
- Voltage - Capacity............................................................................................................. 2 x 12 V - 100 Ah
STARTER MOTOR
- Manufacturer .................................................................................................................................... BOSCH
- Voltage - Output .......................................................................................................................... 24V - 4 kW
ALTERNATOR
- Manufacturer .................................................................................................................................... BOSCH
- Type .................................................................................................................................NCB1 28V 35-70A
- Voltage - Output ............................................................................................................................ 28V - 55A
T1-1-8
SPECIFICATIONS E215B
(Dimensions in mm)
T1-1-9
E215B SPECIFICATIONS
(Dimensions in mm)
T1-1-10
SPECIFICATIONS E215B
VERSIONS A B C D E F G H I L
(1) 9617 (1) 3133
(2) 9580 (2) 3044
E215BEL 3656 4451 1035 2800 2503 3027 948 471
(3) 9493 (3) 2884
(4) 9568 (4) 3044
(1) 9617 (1) 3133
(2) 9580 (2) 3044
E215BL 3656 4451 1035 2800 2503 3027 948 471
(3) 9493 (3) 2884
(4) 9568 (4) 3044
(1) 9617 (1) 3133
(2) 9580 (2) 3044
E215BLC 3656 4451 1035 2800 2503 3027 948 471
(3) 9493 (3) 2884
(4) 9568 (4) 3044
Arm: (dimensions in mm)
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 mm
M Track shoe width (mm) 500 600 700 600 700 800 900 600 700 800 900
N Gauge (mm) 2490 2590 2690 2800 2900 3000 3100 2990 3090 3190 3290
(*) Working weight (kg) 20590 20850 21120 20920 21190 21460 21730 20940 21210 21480 21750
Spec. ground pres. (bar) 0.55 0.47 0.40 0.47 0.41 0.36 0.32 0.47 0.41 0.36 0.32
T1-1-11
E215B SPECIFICATIONS
G E
D
H
F
I C
L
M A
N B NH0148
VERSIONS A B C D E F G H I L
(1) 9683 (1) 3062
(2) 9665 (2) 3014
E215BEL 3656 4451 1035 2800 2503 3027 948 471
(3) 9643 (3) 2954
(4) 9631 (4) 3237
(1) 9683 (1) 3062
(2) 9665 (2) 3014
E215BL 3656 4451 1035 2800 2503 3027 948 471
(3) 9643 (3) 2954
(4) 9631 (4) 3237
(1) 9683 (1) 3062
(2) 9665 (2) 3014
E215BLC 3656 4451 1035 2800 2503 3027 948 471
(3) 9643 (3) 2954
(4) 9631 (4) 3237
Arm: (dimensions in mm)
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 mm
M Track shoe width (mm) 500 600 700 600 700 800 900 600 700 800 900
N Gauge (mm) 2490 2590 2690 2800 2900 3000 3100 2990 3090 3190 3290
(*) Working weight (kg) 21220 21490 21760 21560 21830 22100 22360 21580 21850 22120 22390
Spec. ground pres. (bar) 0.57 0.48 0.42 0.48 0.42 0.37 0.33 0.48 0.42 0.37 0.33
T1-1-12
SPECIFICATIONS E215B
Slightly heavy digging work (specific weight of material < 1.5 t/m3)
T1-1-13
E245B SPECIFICATIONS
(Dimensions in mm)
T1-1-14
SPECIFICATIONS E245B
(Dimensions in mm)
T1-1-15
E245B SPECIFICATIONS
VERSIONS A B C D E F G H I L
(1) 9617 (1) 3141
(2) 9577 (2) 3050
E245B 3840 4645 1053 2800 2503 3045 970 486
(3) 9487 (3) 2886
(4) 9564 (4) 3044
Arm: (dimensions in mm)
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 mm
E245B
T1-1-16
SPECIFICATIONS E245B
G E
D
H
F
I C
L
M A
N B NH0148
VERSIONS A B C D E F G H I L
(1) 9684 (1) 3067
(2) 9665 (2) 3014
E245B 3840 4645 1053 2800 2503 3045 970 486
(3) 9641 (3) 2957
(4) 9634 (4) 3235
Arm: (dimensions in mm)
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 mm
E245B
T1-1-17
E245B SPECIFICATIONS
BUCKETS E245B
BUCKETS E245B
Slightly heavy digging work (specific weight of material < 1.5 t/m3)
T1-1-18
SECTION 2 E215B-E245B
SYSTEM
CONTENTS
1. PREFACE
This chapter explains only those related to the electro hydraulic conversion as mechatro control. This chapter
summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding
the conditions before and after each conversion, refer to the hydraulic system and the electric system.
T2-1-1
E215B-E245B MECHATRO CONTROL SYSTEM
ELECTRIC
CONTROLLER INPUT SIGNAL
HYDRAULIC
PILOT SECONDARY PRESSURE VOLTAGE OUTPUT L1
SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE
SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT
LH RH LH RH
OPTION PILOT VALVE
PILOT VALVE
PILOT VALVE FOR TRAVEL
FOR ATT
SE-9
SE-10
SE-11
LOW PRESSURE SENSOR
SE-4
(4)
SE-3
(3) L2
GAUGE CLUSTER L3
SENSOR BLOCK
SE-2
(2)
LCD DISPLAY
SE-1
FOR SELECTION (1)
FUEL GAUGE
COOLANT TEMP. GAUGE SE-8
(8)
SWITCH
SCREEN CHANGE SE-7
(7)
BUZZER STOP
L4
MODE (6)
WASHER
WIPER SE-5
(5)
OUTPUT VOLTAGE
TRAVEL
AUTO-IDLE
PSV-R
SERIAL COMMUNICATION
SERIAL COMMUNICATION
SHORT-CIRCUIT PROPORTIONAL
ACCEL DIAL VALVE VALVE
SE-16
SE-23
C-1 SE-22 L5
MECHATRO CONTROLLER ENGINE A1 A2 A3
GOVERNOR
MOTOR
SPEED SENSOR
M-2 SE-13
PSV -P1
P1 PUMP PROPORTIONAL VALVE
: HIGH PRESSURE SENSOR
(FOR P1,P2 : 2pcs) PSV -P2
: GOVERNOR MOTOR P2 PUMP PROPORTIONAL VALVE
SM0116
T2-1-2
MECHATRO CONTROL SYSTEM E215B-E245B
SE-29
P1 UNLOAD
ATTACHMENT BOOST
SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
N&B
BUCKET
P2 UNLOAD
OPTION
STRAIGHT
SWING
TRAVEL
PL1
SOL
P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM IN
L2 SOLENOID VALVE
L3
L4
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE
L5
P1 UNLOAD
P2 UNLOAD
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV SV
-A -D -C -B -2 -3 -1 -4
(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
SM0117
T2-1-3
E215B-E245B MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
VALVE OPTION
SWING
BOOM
STRAIGHT
SOLENOID
TRAVEL
P2 UNLOAD
P2 P1
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0118
1. On starting any one of operations, the control pilot secondary pressure switches spools and enters in
respective low pressure sensors.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3. Each unload pressure proportional valves output pilot secondary pressure according to the command
output by mechatro controller and switches each unload spools.
4. With this operation, the bleed opening according to lever manipulated movement is obtained, consequently
the pump pressure which is used to actuate each actuators are delivered and makes each actuator start
operating.
T2-1-4
MECHATRO CONTROL SYSTEM E215B-E245B
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2
pi
pi
P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0119
T2-1-5
E215B-E245B MECHATRO CONTROL SYSTEM
1. Positive control
1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each
low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator,
and consequently the working speed according to the lever manipulated movement will be obtained.
2. P-Q control
1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller
and the mechatro controller processes pilot signal and operates the command according to the input
voltage (load pressure).
2) The lower value between command values calculated by positive control and operated value found by
P-Q control {operated value found in item 1)} is selected and is output to each pump proportional valve
as command value.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator and
consequently working speed will be obtained according to lever movement.
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
SM0120
T2-1-6
MECHATRO CONTROL SYSTEM E215B-E245B
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
1. On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux
spool and is input to low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control
valve.
4. With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and
also with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are
switched and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during
boom up operation.
T2-1-7
E215B-E245B MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7
CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D
pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE
T2-1-8
MECHATRO CONTROL SYSTEM E215B-E245B
T2-1-9
E215B-E245B MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
1. On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input
to low pressure sensor.
2. The engine speed command output by accel potentiometer is input to mechatro controller.
3. Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes
pilot signal processing and outputs command according to the input voltage to P2 pump proportional valve
and P2 unload proportional valve.
4. And also outputs command according to input pressure output by potentiometer to reverse proportional
valve for arm 2 spool.
5. Each proportional valve outputs pilot secondary pressure according to each command output by mechatro
controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke
according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if
pump delivery rate is low due to low engine speed.
T2-1-10
MECHATRO CONTROL SYSTEM E215B-E245B
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
1. On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and
is input to low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control
valves.
4. With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the
command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and
consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out
operation.
T2-1-11
E215B-E245B MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
1. On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches
bucket spool and is input to low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload proportional valves and travel straight proportional valve.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel
straight valve of the control valve.
4. The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump
delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
T2-1-12
MECHATRO CONTROL SYSTEM E215B-E245B
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
MECHATRO
CONTROLLER
P1 PUMP PRESSURE pi : PROPORTIONAL VALVE
SECONDARY PRESSURE SM0126
T2-1-13
E215B-E245B MECHATRO CONTROL SYSTEM
1. On starting bucket digging operation, bucket digging operating pilot pressure switches bucket spool and is
input to low pressure sensor.
2. The engine speed command output by accel potentiometer is input to mechatro controller.
3. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload proportional valves and travel straight proportional valve.
4. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel
straight valve of control valve.
5. The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump
delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
6. ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary
pressure, and actuate stroke limiter and then controls the stroke of bucket spool.
The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and
pump delivery rate is low.
7. When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to
the pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control
the stroke limit of bucket spool.
T2-1-14
MECHATRO CONTROL SYSTEM E215B-E245B
BOOM UP CONFLUX
P1 UNLOAD
PILOT
TRAVEL RIGHT
VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
LOW
PRESSURE
SENSOR
SE-5 SE-7
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
1. During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low
pressure sensor on starting swing operation (or arm-in operation during swing operation), and swing
operation pilot secondary pressure switches swing spool and is input to low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve
for arm 2 spool.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel straight
spool, arm 2 spool.
4. With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the
command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are
switched enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently
the return oil on arm cylinder rod side is recirculated into arm cylinder head side.
5. Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery
rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with
minimum speed drop possible.
T2-1-15
E215B-E245B MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
OPTIONAL
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL
LOW
SE-10 SE-9 SE-11 PRESSURE
SENSOR
VALVE SIGNAL
TRAVEL STRAIGHT SIGNAL
pi
PILOT SIGNAL PROPORTIONAL
PROCESS VALVE PSV-R
IN SHORT-CIRCUIT
VALVE
ޓޓ
PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C
ޓޓ
PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
PILOT ޓ
SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
PILOTޓޓޓ
SECONDARY PRESSURE SM0128
T2-1-16
MECHATRO CONTROL SYSTEM E215B-E245B
T2-1-17
E215B-E245B MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1
SE-23 SE-22
ENGINE
(M-2)
PRESSURE
RELEASE
CONTROL ENGINE SPEED
CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D
MECHATRO
pi : PROPORTIONAL VALVE SM0130
CONTROLLER SECONDARY PRESSURE
1. Change mechatro controller to “PRESSURE DRAING MODE” by operating switch on gauge cluster.
For detail of changing mode method, refer to “Pressure draining (releasing) circuit” on GROUP 2 -
HYDRAULIC CIRCUIT.
2. Once mechatro controller decides it as pressure release control, regardless of each input signal (operating
pilot, accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to
minimum tilt angle.
2) Outputs command of pressure release to control step-by step motor (M2) and fixes engine speed to
pressure release control speed.
3) Outputs maximum command to P1 and P2 unload proportional valves and each pilot secondary
pressure fixes P1 and P2 unload valves to the maximum opening.
3. Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump
pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
4. Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure)
to be released by operating each control lever and switching spool with the unload valve opened.
T2-1-18
MECHATRO CONTROL SYSTEM E215B-E245B
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR
BUCKET
OPTION
SE-29 VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
A MODE
B MODE
GAUGE CLUSTER
pi
1. Nibbler circuit
1) Select A mode through gauge cluster.
2) Nibbler display appears on gauge cluster.
3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of
main control valve.
4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output.
It is in normal when there is no output from sensor in A mode, and in cases of other than above, error
display is output to gauge cluster.
2. Breaker circuit
1) Select B mode through gauge cluster.
2) Breaker display appears on gauge cluster.
3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in B mode, and in cases of other than above, error
display is output to gauge cluster.
T2-1-19
E215B-E245B MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
PILOT VALVE
TRAVEL
P2 P1
SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
T2-1-20
MECHATRO CONTROL SYSTEM E215B-E245B
3. MECHATRO CONTROLLER
3.1 SUMMARY OF MULTI DISPLAY
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
1. Controls
SWING PARKING
BRAKE RELEASE
GAUGE SWITCH
CLUSTER
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.
FUSE &
STARTER SWITCH RELAY BOX
ACCEL DIAL
DETAIL A
SM0133
A
2. Gauge cluster
11
No. Name
22:00 1 Engine coolant temperature gauge
2 Fuel level gauge
H 3 Screen change switch
4 Buzzer stop switch
1 5 Work mode select switch
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 Select switch
10
6 11 Multi display (LCD)
4 9 8 5 7
SM0134
T2-1-21
E215B-E245B MECHATRO CONTROL SYSTEM
SM0135
S mode
10:25 "S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.
㧿
H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.
㧴
B mode
10:25 For the work with breaker, select "B mode" without fail.
㧮
A mode
10:25 For the work with crusher (nibbler), select "A mode".
㧭
T2-1-22
MECHATRO CONTROL SYSTEM E215B-E245B
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow
rate in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 210L/min. The adjustment (increase
or decrease) of flow rate is changeable by 10L/min step.
10:25 Flow
rate 130 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m
Enter
H A A
(a) (b) (d)
Increase/Decrease
Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 130 L/m rate 130 L/m
A B
(b) (c) SM0141
T2-1-23
E215B-E245B MECHATRO CONTROL SYSTEM
Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
Hydraulic oil 5,000 Hr
NOTE:
• The display automatically changes to the main screen, if switch is not operated for 30 seconds.
• For the setting procedure of maintenance time to be performed to the coming oil change in each type and
filter replacement, see the paragraph 3.6 “SET PROCEDURE OF MAINTENANCE SCHEDULE”.
T2-1-24
MECHATRO CONTROL SYSTEM E215B-E245B
CLOCK DISPLAY
MACHINE CONDITION
H
MULTI DISPLAY INDICATIONS
SM0146
T2-1-25
E215B-E245B MECHATRO CONTROL SYSTEM
• Warning table
W006
CPU W004
W001 W010
W008
NOTE: Error codes were stored as trouble history, and displayed on the monitor by the
trouble history display function.
T2-1-26
MECHATRO CONTROL SYSTEM E215B-E245B
Warning Condition
Trouble
Level Buzzer sounds
Priority Screen Condition Only Engine History
(*) Type Auto Manual Code
Key ON Run
(**) Stop Stop
Data from Mechatro controller
1 DATA COMMUCATION ERROR O O 3 x O
is not received
The swing parking brake
1 SWING BRAKE DISENGAGED O O 2 O O W001
switch is turned ON
Engine is stopped after engine
A 1 ENGINE STOP O 1 O x
oil pressare low warning
Impossible to drain hyd.
2 FAIL DRAIN HYD. PRESSURE O O 1 x O
Pressure
2 DRAINING HYD. PRESS. Possible to drain hyd. Pressure O 4 x O
T2-1-27
E215B-E245B MECHATRO CONTROL SYSTEM
ALPHABET
A B C D E F G H I K R
Controller Low pressure High pressure Proportional Proportional Potentiometer
valve for valve for Solenoid valve Speed sensor Communication Battery relay Relay output
memory sensor sensor etc.
Option
04 Arm in
selector
Washer motor
Bucket
05 digging
07 Swing
10 Travel left
Selector
11 position
13
14
PSV-R Short
15 Cricuit valve
Engine stop
17 P2 side option
relay
Safety lock
18 lever relay
Adjustment
21 data sector 1
Safety relay
Adjustment
22 data sector 2
Hourmeter
23 sector 1
Hourmeter
24 sector 2
Proportional
25 valve adjust
Cluster
31 communication
LAST DIGIT
Larger than Larger than
0 normal range normal range
Transistor
1 - OFF failure/
Transistor ON Transistor ON
2 - Wrong output Wrong output
failure failure
Over run
Transistor ON
3 - Disconnection Disconnection Disconnection Disconnection failure / Disconnection Disconnection Time is over
Power source Power source Power source Contact point Power source
4 -
short circuit short circuit short circuit is melted and short circuit
adhered
Obnormal
5 data
T2-1-28
MECHATRO CONTROL SYSTEM E215B-E245B
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns
to No.1. (No.1 No.2 No.3 No.1 ...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then
returns to No.3. (No.3 No.2 No.1 No.3 ...)
4) Turn key switch OFF and the display of service diagnosis mode is closed.
T2-1-29
E215B-E245B MECHATRO CONTROL SYSTEM
2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 1000 No load setting rpm B-1 BOOM RAISE
MEAS 1000 Actual rpm 0.4 V 0.0 M Sensor voltage / Pressure converted value
G-5 ENG PRS. LIVE Engine oil pressure B-2 BOOM LOWER
WATER TEMP 20 °C OFF Coolant temperature sensor / Coolant tempreature switch 0.4 V 0.0 M Sensor voltage / Pressure converted value
B-3 ARM OUT
MODE H Work mode 0.4 V 0.0 M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 0.3 V Potentiometer voltage B-4 ARM IN
POS. 0% Voltage % indication 0.4 V 0.0 M Sensor voltage / Pressure converted value
G-1 MOTOR STEP 30 Number of step B-5 BUCKET DIG
POS. 0% Step % indication 0.4 V 0.0 M Sensor voltage / Pressure converted value
COIL A 1.5 A A phase current B-6 BUCKET DUMP
COIL B 1.5 A B phase current 0.4 V 0.0 M Sensor voltage / Pressure converted value
G-2 LIMIT SW. OFF Limit switch
3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. OFF Set value in computer 0.4 V 0.0 M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-9 TRAVEL (R)
SWITCH OFF Switch 0.4 V 0.0 M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL (L)
COMP. ON Set value in computer 0.4 V 0.0 M Sensor voltage / Pressure converted value
MEAS. ON Measured value B-16 P1 OPT.
RELEASE SW OFF Switch 0.4 V 0.0 M Sensor voltage / Pressure converted value
F-3 1/2-TRAVEL B-17 P2 OPT.
COMP. OFF Set value in computer 0.5 V 0.0 M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-18 DOZER 1
SWITCH OFF Switch 0.0 V 0.0 M Sensor voltage / Pressure converted value
B-19 DOZER 2
0.0 V 0.0 M Sensor voltage / Pressure converted value
SM0149
T2-1-30
MECHATRO CONTROL SYSTEM E215B-E245B
8 18
NO.8 PROPO-VALVE NO.18 DIGITAL INPUT
D-1 P1 UN-LOAD(BP-CUT) DI1 OFF ON/OFF indication
COMP. 750 mA 3.0 M Set value in computer / Converted value from pressure DI2 ON ON/OFF indication
MEAS. 750 mA 3.0 M Measured value / Converted value from pressure DI3 OFF ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) DI4 OFF ON/OFF indication
COMP. 750 mA 3.0 M Set value in computer / Converted value from pressure DI5 OFF ON/OFF indication
MEAS. 750 mA 3.0 M Measured value / Converted value from pressure DI6 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 --- ON/OFF indication
Mechatro
COMP. 350 mA 0.6 M Set value in computer / Converted value from pressure DI8 OFF ON/OFF indication
controller
MEAS. 350 mA 0.6 M Measured value / Converted value from pressure DI9 OFF ON/OFF indication
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
COMP. 750 mA 0.0 M Set value in computer / Converted value from pressure DI11 --- ON/OFF indication
MEAS. 750 mA 0.0 M Measured value / Converted value from pressure DI12 --- ON/OFF indication
DI13 ON ON/OFF indication
DI14 --- ON/OFF indication
9 19
NO.9 PROPO-VALVE NO.19 DIGITAL INPUT
E-1 P1 PUMP DI15 --- ON/OFF indication
COMP. 417 mA 1.0 M Set value in computer / Converted value from pressure DI16 ON ON/OFF indication
MEAS. 417 mA 1.0 M Measured value / Converted value from pressure DI17 ON ON/OFF indication
POWER SHIFT 0 mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 30 L Flow rate of pump P1 DI19 --- ON/OFF indication
E-2 P2 PUMP DI20 OFF ON/OFF indication
COMP. 417 mA 1.0 M Set value in computer / Converted value from pressure DI21 --- ON/OFF indication
MEAS. 417 mA 1.0 M Measured value / Converted value from pressure DI22 --- ON/OFF indication
POWER SHIFT 0 mA Power shift DI23 ON ON/OFF indication
FLOW RATE 30 L Flow rate of pump P2 DI24 OFF ON/OFF indication
DI25 ON ON/OFF indication
DI26 --- ON/OFF indication
DI27 OFF ON/OFF indication
DI28 --- ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
1.2 V 77% Fuel level DI30 --- ON/OFF indication
H-10 HYD.OIL TEMP DI31 --- ON/OFF indication
0.0 V 0 ͠ Hydraulic oil temperature DI32 --- ON/OFF indication
GLOW --- Glow switch DI33 ON ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 --- ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 --- ON/OFF indication
ENG OIL FILTER --- Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 --- ON/OFF indication
DOUBLE FLOW ON Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW --- Command from grid heater DI39 --- ON/OFF indication
HEATER OFF Engine oil level DI40 OFF ON/OFF indication
ENG OIL LEVEL OK Coolant level DI41 --- ON/OFF indication
COOLANT LEVEL OK DI42 ---
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH NIB Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. --- Set value in computer MEAS. OFF Measured value
MEAS. --- Measured value DO5 COMP. --- Set value in computer
F-6 MEAS. --- Measured value
COMP. --- Set value in computer DO6 COMP. --- Set value in computer
MEAS. --- Measured value MEAS. --- Measured value
DO7 COMP. OFF Set value in computer
MEAS. OFF Measured value
15 22
NO.15 PROPO-VALVE NO.22 DIGITAL OUTPUT
D-11 P1 I-TRAVEL DO8 COMP. ON Set value in computer
COMP. 0 mA 0.0 M Set value in computer / Converted value from pressure MEAS. ON Measured value
MEAS. 0 Ma 0.0 M Measured value / Converted value from pressure DO9 COMP. OFF Set value in computer
D-12 P2 I-TRAVEL MEAS. OFF Measured value
COMP. 0 mA 0.0 M Set value in computer / Converted value from pressure DO10 COMP. --- Set value in computer
MEAS. 0 mA 0.0 M Measured value / Converted value from pressure MEAS. --- Measured value
D-15 P1 BY PASS VALVE DO11 COMP. OFF Set value in computer
COMP. 347 mA 0.6 M Set value in computer / Converted value from pressure MEAS. OFF Measured value
MEAS. 347 mA 0.6M Measured value / Converted value from pressure DO12 COMP. --- Set value in computer
D-16 P2 BY PASS VALVE MEAS. --- Measured value
COMP. 0 mA 0.0 M Set value in computer / Converted value from pressure DO13 COMP. --- Set value in computer
MEAS. 0 mA 0.0 M Measured value / Converted value from pressure MEAS. --- Measured value
DO14 COMP. --- Set value in computer
MEAS. --- Measured value
SM0150
T2-1-31
E215B-E245B MECHATRO CONTROL SYSTEM
SM0151
T2-1-32
MECHATRO CONTROL SYSTEM E215B-E245B
31 34
NO.31 BOOM NO.34 TRAVEL
C-1 P1 PUMP 0.2 M Pump pressure sensor C-1 P1 PUMP 0.2 M Pump pressure sensor
C-2 P2 PUMP 0.0 M Pump pressure sensor C-2 P2 PUMP 0.0 M Pump pressure sensor
E-1 P1-PSV 417 mA Command current E-1 P1-PSV 417 mA Command current
E-2 P2-PSV 417 mA Command current E-2 P2-PSV 417 mA Command current
D-1 P1-UL(BPC) 750 mA Command current D-1 P1-UL(BPC) 750 mA Command current
D-2 P2-UL(BPC) 750 mA Command current D-2 P2-UL(BPC) 750 mA Command current
B-1 BOOM RAISE 0.0 M Boom up pressure sensor D-3 S-TRAVEL 350 mA Command current
B-2 BOOM LOWER 0.0M Boom down pressure sensor B-9 TRAVEL(R) 0.0 M Travel right pressure sensor
G-3 ENG SPEED 1000 Engine actual speed B-10 TRAVEL(L) 0.0 M Travel left pressure sensor
POWER SHIFT 0 mA Power shift current Pi-P1 0.0 M Pilot pressure at travel straight (P1 side)
Pi-P2 0.0 M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0 mA Power shift current
32 35
NO.32 ARM,SWING NO.35 OPT
C-1 P1 PUMP 0.2 M Pump pressure sensor C-1 P1 PUMP 0.2 M Pump pressure sensor
C-2 P2 PUMP 0.0 M Pump pressure sensor C-2 P2 PUMP 0.0 M Pump pressure sensor
E-1 P1-PSV 417 mA Command current E-1 P1-PSV 417 mA Command current
E-2 P2-PSV 417 mA Command current E-2 P2-PSV 417 mA Command current
D-1 P1-UL(BPC) 750 mA Command current D-1 P1-UL(BPC) 750 mA Command current
D-2 P2-UL(BPC) 750 mA Command current D-2 P2-UL(BPC) 750 mA Command current
D-3 S-TRAVEL 350 mA Command current D-3 S-TRAVEL 350 mA Command current
D-6 ARM-IN-2 750 mA Command current E-3 OPT RELIEF 110 mA Command current
B-3 ARM OUT 0.0 M Arm out pressure sensor B-16 P1 OPT 0.0 M P1 side option pressure sensor
B-4 ARM IN 0.0 M Arm in pressure sensor B-17 P2 OPT 0.0 M P2 side option pressure sensor
B-1 BOOM RAISE 0.0 M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 0.0 M Swing pressure sensor DOUBLE FLOW SW OFF Conflux/ Single selector switch
G-3 ENG SPEED 1000 Engine actual speed G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0 mA Power shift current POWER SHIFT 0 mA Power shift current
SM0152
41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2230 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 515 mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
7 mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 35.0 M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 930 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 565 mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 565 mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 0 0 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 0 0 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 0 0 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 0 0 Angle adjustment
SM0153
T2-1-33
E215B-E245B MECHATRO CONTROL SYSTEM
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
T2-1-34
MECHATRO CONTROL SYSTEM E215B-E245B
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 12.5~16.5 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 12.5~16.5 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 550~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 550~750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 200 mA D-6 ARM-IN-2 400 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 3.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 mA
T2-1-35
E215B-E245B MECHATRO CONTROL SYSTEM
T2-1-36
MECHATRO CONTROL SYSTEM E215B-E245B
T2-1-37
E215B-E245B MECHATRO CONTROL SYSTEM
T2-1-38
MECHATRO CONTROL SYSTEM E215B-E245B
1. How to display
1) Turn starter switch on.
2) Press buzzer stop switch continuously 5 times and the trouble history screen is displayed.
(Example)
No errors NO ERROR
SM0154
3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
• Press washer switch ( ) A, and the item moves upward.
• Press wiper switch ( ), and the item moves downward.
5) Turn starter switch off, and the display is disappeared.
NOTE: all the stored items are erased. It is impossible to erase data partially.
T2-1-39
E215B-E245B MECHATRO CONTROL SYSTEM
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are
automatically actuated, the sensor detects the machine status and the mechatro controller identifies
the normal condition or failed condition of the system.
For details of how to use, refer to Chapter: “TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".
T2-1-40
MECHATRO CONTROL SYSTEM E215B-E245B
time is stored. H
SM0156
NOTE:
1. After displaying the display for setting by pressing the display change switch, set the respective
maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does
not sound.
T2-1-41
E215B-E245B MECHATRO CONTROL SYSTEM
1) Turn starter key switch on and display main screen (a) for operator, and then press select switch (8)
and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2) In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and
then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4) Select any of "Y•M•D•H•M" in operation of FEED (4) and FEED (5) and vary the values in
operations of FEED (6) and FEED (7).
5) After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting
is completed, and then the screen returns to main screen (a).
T2-1-42
MECHATRO CONTROL SYSTEM E215B-E245B
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555
Adjustable range
11111~99999 Increase/Decrease
(Default 55555) SM0158
1) Turn starter key switch on and display main screen (a), and press select switch (8) and display
"SWITCH STATUS CLOCK CONTRAST" select screen (b).
2) In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.
3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and
then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4) Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5) Vary the values by pressing the desired figure in operations of FEED (4) and FEED (5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) 99999 (clear) * The initial set value is 55555.
6) Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).
T2-1-43
E215B-E245B MECHATRO CONTROL SYSTEM
• LANGUAGE/LOGO
Function Explanation Note Range Default
All language data is stored in 15
LANGUAGE To change language ISO
one gauge cluster languages
LOGO To change Company Logo 5 Logos NHK
• ADJUSTING MODE 1
Function Explanation Note Range Default
To change wiper control, when special
RISE-UP WIPER CAB is installed on demolition OFF is for special CAB ON/OFF ON
machine
P1 OPT SENSOR To activate the self-diagnosis when P1 Switch to ON when 2PB is
ON/OFF OFF (*)
ACTIVE OPT pressure sensor is failed installed
P2 OPT SENSOR To activate the self-diagnosis when P2 Switch to ON when N&B
ON/OFF OFF (*)
ACTIVE OPT pressure sensor is failed option is installed
Only for EU, to activate the priority
PRIORITY MODE ON/OFF OFF
valve
To use P1 option pedal for P4-rotation
LEFT PEDAL
circuit, releasing auto accel. And not ON/OFF OFF
ACTIVE
activating unload valve
1:No selector valve
SELECT OPT Switch to ON when N&B
2:Selector Valve + Mechanical relief 1 or 3 1 or 3 (*)
SYSTEM option is installed
3:Selector Valve + Electrical relief
ADJ OVERLOAD To change the pressure for overload
10 - 27 18
PRESS alarm in EU
ENG SPEED To activate the engine speed
ON/OFF OFF
DISPLAY information for customer
6, 8, 10, 12,
AUTO ACCEL To change auto accel control type 18
14, 16, 18
To change the starting MODE X: return to default MODE
START MODE S, H, B, A, X S
(S,H,B,A) when key sw is ON
To cancel the low temp. mode to
CANCEL LOW OFF = Low Temp. Mode
prevent hydraulic hunching at low ON/OFF OFF
TEMP MODE ACTIVE
temp.
DRAIN HYD. To activate the drain hydraulic When switch is ON, this
ON/OFF OFF
PRESS pressure function function starts.
20 - 35
15 Mpa (at
To adjust Pressure and Flow for Pressure
ADJ OPT HAMMER Follow setting procedure 220 L/min)
Hammer (9set) 30 - 220
220 L/min
Flow rate
20 - 35
15 Mpa (at
To adjust Pressure and Flow for Pressure
ADJ OPT NIBBLER Follow setting procedure 220 L/min)
Nibbler (9set) 30 - 220
220 L/min
Flow rate
(*) Autodetect
T2-1-44
MECHATRO CONTROL SYSTEM E215B-E245B
SELECT LANGUAGE
FRA
(E)
FEED
SM0070
T2-1-45
E215B-E245B MECHATRO CONTROL SYSTEM
4. By pressing SELECT button (2) you enter the (C) PRESET BY FACTORY
FEED
decrease it.
4. Set the desired pressure value (for example: 11),
display (G), press SELECT button (2) to 63
memorise it. ADJ OVERLOAD PRESS
63
ADJ OVERLOAD PRESS
(G) 11
FEED
63
ADJ OVERLOAD PRESS
11
FEED
5
SM0073
T2-1-46
MECHATRO CONTROL SYSTEM E215B-E245B
(M)
10:25
PR
S
SM0072
T2-1-47
E215B-E245B MECHATRO CONTROL SYSTEM
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
SM0159
2) List of connectors
Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
24 RXD3 Reception RS232C communication
25 DL EARTH / OPEN(5V㧕
26 GP 0V
27 CANH1 CAN communication
Spare
28 CANL1 CAN communication
29 DO 20 Spare Output EARTH/OPEN
30 DO 21 Safety relay Output EARTH/OPEN
31 DO 22 Spare Output EARTH/OPEN
32 DO 23 Extra pressure release Output EARTH/OPEN
33 DO 24 Spare Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN
SM0160
T2-1-48
MECHATRO CONTROL SYSTEM E215B-E245B
Connector No. Pin No. Port name Function Input/putput Signal level
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A28 Spare Input 0.5~4.5V
21 +5VA Power output 5V
22 D1 37 Spare Input GND / OPEN
Connector No. Pin No. Port name Function Input/putput Signal level
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
15 +5VA Power output 5V
16 Reserved
SM0161
T2-1-49
E215B-E245B MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN104 1 GA 0V
2 A17 Boom head (Over load) Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A18 Spare Input 0.5㨪4.5V
6 GA 0V
7 GA 0V
8 A19 Extra pressure source Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A20 Spare Input 0.5~4.5V
12 GA 0V
13 A21 Engine coolant
Input Resistor
14 GA temperature
15 A22
Fuel level Input Resistor
16 GP
17 A23 Resistor
Spare Input
18 GA
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
21 +5VA Power output 5V
22 +5VA Power output 5V
23 A25 Extra pressure source Input 0.5~4.5V
24 GA 0V
25 GA 0V
26 A26 Spare Input 0.5~4.5V
27 +5VA Power output 5V
28 DI 1 Starting point of accel motor Input GND / OPEN
Connector No. Pin No. Port name Function Input/putput Signal level
CN105 1 +24V 20~32V
Battery relay output side
2 +24V 20~32V
T2-1-50
MECHATRO CONTROL SYSTEM E215B-E245B
Connector No. Pin No. Port name Function Input/putput Signal level
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ Accel motor A phase Output 1.5A
4 F1- Accel motor A phase Output 1.5A
5 F2+ Accel motor B phase Output 1.5A
6 F2- Accel motor B phase Output 1.5A
7 OIL Oil level (spare) 0
8 OILG
9 D11+ OPT changeable relief 2 Output +0~800mA
10 D11- -0~800mA
11 D12+ Spare Output +0~800mA
12 D12- -0~800mA
13 D13+ Bypass valve Output +0~800mA
14 D13- -0~800mA
15 D14+ Spare Output +0~800mA
16 D14- -0~800mA
17 GND Battery (-) 0V
18 D12+ Spare Output +0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shiled GND
23 CANH2 Proportional vlave expand unit CAN communication
24 CANL2 CAN communication
Connector No. Pin No. Port name Function Input/putput Signal level
CN107 1 DI 3 Grid heater feedback Input +24V/OPEN
2 DI 8 Engine coolant temperature Input EARTH / OPEN
3 DI 9 E/G oil pressure Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
5 DI 11 Spare Input EARTH / OPEN
6 DI 12 Spare Input EARTH / OPEN
7 DI 13 E/G coolant level Input EARTH / OPEN
8 DI 14 Spare Input EARTH / OPEN
9 DI 15 Spare Input EARTH / OPEN
10 DI 20 Heater temperature of fuel filter Input EARTH / OPEN
11 DI 28 Spare Input EARTH / OPEN
12 DI 32 Hand control nibbler Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
14 DI 39 Spare Input EARTH / OPEN
15 DI 40 Heater temperature Input EARTH / OPEN
16 DI 41 Spare Input EARTH / OPEN
17 Reserved
SM0163
T2-1-51
E215B-E245B MECHATRO CONTROL SYSTEM
Connector No. Pin No. Port name Function Input/putput Signal level
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Water separator Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 Spare Input GND / OPEN
6 DI 16 Wiper rise up㩩 Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
8 DI 18 ATT boost Input GND / OPEN
9 DI 19 Spare Input GND / OPEN
10 DI 21 Spare Input +24V / OPEN
11 DI 22 Spare Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation Input GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
15 DI 26 Spare Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 Spare Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
22 DI 34 Spare Input +24V / OPEN
23 DI 35 Spare Input +24V / OPEN
24 Reserved
25 H1+ Spare 0~5V
26 H2- 0V
27 H2+ Spare 0~5V
28 H2- 0V
Connector No. Pin No. Port name Function Input/putput Signal level
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Spare Output GND / OPEN
6 DO 6 Reserved Output GND / OPEN
7 DO 12 Spare Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Grid heater Output GND / OPEN
15 Reserved
16 GP 0V
17 TXD2 Tranmission RS232C communication
18 RXD2 Reception RS232C communication
Spare
19 RTS RS232C communication
20 CTS RS232C communication
21 SHG2 Shiled GND
22 DO 10 Spare SV 24V/OPEN
SM0164
T2-1-52
MECHATRO CONTROL SYSTEM E215B-E245B
4. BUZZER
1. MULTI
DISPLAY LCD
2. COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
5. SCREEN
CHANGE
SWITCH ETC.
SM0165
3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller,
displays them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
T2-1-53
E215B-E245B MECHATRO CONTROL SYSTEM
1 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17
20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2
11 22 1 3 1 3
13 26 13 26 9 20 CN14 CN15
1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3
T2-1-54
MECHATRO CONTROL SYSTEM E215B-E245B
2) Circuit diagram
SM0167
T2-1-55
E215B-E245B MECHATRO CONTROL SYSTEM
SM0168
T2-1-56
MECHATRO CONTROL SYSTEM E215B-E245B
SM0169
T2-1-57
E215B-E245B MECHATRO CONTROL SYSTEM
COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM
Tightening torgue
Vout
29.434.3N.m (21.725.3lbf.ft)
PF1/4
Vcc GND
SPECIFICATION :
PRESSURE RANGE : 0 3.0 MPa
RATED VOLTAGE : 5.0+0.5V DC
OUTPUT CHARACTERISTIC INSURANCE RESISTANCE : 50M OR MORE
(BETWEEN BODY AND EACH TERMINAL AT
50V DC MEGGER)
SM0171
T2-1-58
HYDRAULIC SYSTEM E215B-E245B
1. SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety, mass
volume handling and low fuel consumption.
Performance Device Function Features Performance Device Function Features
• Travel straight • Travel straight at combined operation • Electric flow controlled variable displacement • Pump delivery rate control by a current
pump command to the solenoid proportional valve
Pump of the variable displacement pump
• Travel 2-speed change & Auto 1st (low) • 1-2 travel speed change and low speed / high • Positive flow rate control • Flow control by positive pilot control pressure
speed return torque at heavy duty
Mass handling capability
Travel
• Auto parking brake • Automatic braking when parking • Hydraulics backup control • Backup control by hydraulic when the electric
flow controlled variable displacement pump
fails.
• Motor overrun protection • Prevents overrunning of travel motor on the • Boom up conflux circuit • Speed up of boom up operation
• Travel pilot operation • Prevents hunting by the built in travel • Arm conflux circuit • Speed up of arm operation
Attachment
• Reverse rotation protective function • Easy positioning to protect it from swinging • Bucket conflux circuit • For speed-up of bucket operation (digging &
back when stops swinging. dump)
• Swing priority circuit • Easy operation of stable swing speed, arm • Optimum operation by work mode select • Efficient operation in all work modes
Swing
(simultaneous operation of arm in and swing slanted leveling, swing press digging (H,S,A,B)
motions)
• Automatic swing parking brake • Swing parking brake when operating at on a • Auto accel • Reduce fuel consumption and noise by
consumption
computer
slope lowering engine speed when control lever is
Low fuel
Micro
in neutral position.
• Hydraulic pilot control system • Light action with operating lever
Easy operability and safety
• Pilot safety lock system • Cut out of pilot circuit by safety lock lever.
• Lock valve (boom / arm) • Protect boom and arm from unexpected drop
Attachment
(Natural fall).
• Holding valve for boom (Option) • Prevention of boom falling when boom head
side piping breaks
• Emergency manual valve for lowering • For safety, this valve lowers risen attachment
attachment to the ground, if the machine stops with
engine trouble, and the pressure in the
cylinder of attachment can be released.
• Pressurized hydraulic oil tank • To prevent hydraulic oil from entering dust
and to promote self suction ability of pump
• Suction strainer • Remove dust on suction side.
• Line filter; pilot circuit • To prevent pilot operating circuit from
malfunctioning
• Return circuit oil filter • To prevent hydraulic oil from contamination
Others
• Cooling hydraulic oil by oil cooler • To prevent hydraulic oil from being deteriorated.
• Pressure draining circuit • To release the main circuit pressure for piping
repair work.
• Main control valve with optional valve • Optional piping and additional work are easy
• Switching of return line for N&B machine in • Switching of return line for N&B machine is
the cab (Option) able to change with a switch in the cab
T2-2-1
E215B-E245B HYDRAULIC SYSTEM
2. HYDRAULIC CIRCUITS AND COMPONENTS
HYDRAULIC DIAGRAM READING KEY
Item Component name
1 Hyd. pump assy
2 Control valve (main)
3 Swing motor unit
4 Travel motor unit
5 Boom cylinder (RH & LH)
6 Arm cylider
7 Bucket cylinder
8 Swivel joint
9 Pilot valve (ATT)
10 Pilot valve (travel)
11 Inline filter
12 Suction strainer
13 Solenoid valve assy
14 Return filter
15 Air breather
16 Restrictor
17 Shuttle valve
18 Short-circuit valve
19 Low pressure sensor block
T2-2-2
HYDRAULIC SYSTEM E215B-E245B
HYDRAULIC CIRCUIT (MONOBLOCK VERSION)
SM0077
T2-2-3
E215B-E245B HYDRAULIC SYSTEM
3. N&B HYDRAULIC CIRCUIT (OPTION)
N&B HYDRAULIC CIRCUIT READING KEY
Item Component name
50 Selector valve
51 Stop valve
52 Pilot valve
53 Overload relief valve
The hydraulic circuit for N&B is used to add to
standard circuit
Selection condition and proportional valve
command when any of nibbler single & conflux flow
or breaker in service.
Command signal of solenoid proportional valve
SELECTION
(W:O, W/O: -)
Electromagnetic
Conflux/single flow command signal of P1 P2 Travel P1 P2
changeover switch selector valve (50) Pump Pump Straight Unload Unload
(W:O, W/O: -)
Conflux flow of
Conflux “ON” - O O O O O
nibbler
Single flow of
Conflux “OFF” - - O - - O
nibbler
Breaker Conflux “OFF” O - O - - O
When using nibbler, according to specification of
nibbler installed.
Adjust overload relief valve (53) of optional port to
customize specification ordinary set pressure.
T2-2-4
HYDRAULIC SYSTEM E215B-E245B
N&B HYDRAULIC CIRCUIT
51
53
52
53
50
SM0078
T2-2-5
E215B-E245B HYDRAULIC SYSTEM
4. 4. HOLDING VALVE FOR BOOM & ARM
(OPTION)
HOLDING VALVE FOR BOOM
The holding valve for boom prevents the boom
falling in case of head side cylinder piping breaks.
HOLDING VALVE FOR ARM
The holding valve for arm prevents the arm falling in
case of rod side cylinder piping breaks.
HYDRAULIC CIRCUIT READING KEY
Item Component name
54 Holding valve for boom cylinders
55 Holding valve for arm cylinder
T2-2-6
HYDRAULIC SYSTEM E215B-E245B
HOLDING VALVE FOR BOOM & ARM HYDRAULIC CIRCUIT
54 55
SM0079
54
T2-2-7
E215B-E245B HYDRAULIC SYSTEM
5. POSITIONING CIRCUIT
(TRIPLE ARTICULATION VERSION)
HYDRAULIC POSITIONING CIRCUIT READING
KEY
Item Component name
56 P1 OPT valve
57 Holding valve for positioner cylinder
58 Positioner cylinder
59 Positioning pilot valve
OPERATION
When the operation for positioning is performed, the
pilot proportional secondary pressure is delivered
through port A of the positioning pilot valve (59) and
flows to PAo1 port of the P1 OPT valve (56) then,
the spool of P1 OPT valve (56) is switched. The
pressure oil by P1 pump is supplied to (R) side of
positioner cylinder (58) through Ao1 port of P1 OPT
valve (56). On the other hand, the return oil from (H)
side of positioner cylinder returns to the tank circuit
thorough Bo1 port of P1 OPT valve (56).
The holding valve (57) prevents the positioning
falling in case of rod side cylinder piping breaks.
T2-2-8
HYDRAULIC SYSTEM E215B-E245B
POSITIONING CIRCUIT (TRIPLE ARTICULATION VERSION)
57
R
POSITIONING
CYLINDER
H 58
59
56
SM0080
T2-2-9
E215B-E245B HYDRAULIC SYSTEM
6. COLOR CODING STANDARD FOR 7. NEUTRAL CIRCUIT 7.3 PUMP POSITIVE FLOW CONTROL
HYDRAULIC CIRCUITS This section describes the following. (1) Type: The operation is maintained until the
Blue 7.1 Bypass cut valve and unload valve control Electric flow controlled variable displacement opening of spool sleeve is closed.
Feed, drain circuit pump.
7.2 Safety lock lever and pilot circuit
less than 0.44 MPa (64 psi) 7.3 Pump positive flow control (2) Principle:
Green The current command I to the pump’s solenoid 7.4 PUMP P-Q CURVE CONTROL OPERATION
7.4 Pump P-Q (Pressure-Quantity) curve control
Return, make up circuit, proportional valve controls the delivery rate of (1) Type:
0.44~0.59 MPa (64~86 psi) the pump. Electrical flow control type variable pump
Purple 7.1 OPERATION OF BY-PASS CUT VALVE AND (3) Operation: (2) Principle:
Secondary pilot pressure, UNLOADING VALVE HOUSED IN CONTROL 1) Flow rate rise operation (Eg. P1 pump) Perform an operation of the value from pump
(including proportional vlave) VALVE By operating any of control levers, the high pressure sensor to P-Q curve control value,
0.59~5 MPa (86~725 psi) operating secondary pressure of pilot valve and send a command to the pump solenoid
(1) By-pass cut valve
Red On starting engine, P1 and P2 unloading rises, and the rising pressure is transformed proportional valve.
Primary pilot pressure, proportional valves (PSV-D, PSV-B) output to the rise of output voltage corresponding (3) Operation:
(including proportional vlave) secondary pressure according to the command to the pressure input by the low pressure The pump high pressure sensor converts the
5 MPa (725 psi) output by mechatro controller, and this pressure sensor. Mechatro controller signal- pressure to the output voltage corresponding to
Orange exerts on PBp1 and PBp2 ports, and processes this change of voltage, resulting the pump delivery pressure.
Main pump drive pressure, consequently the by-pass cut spool is switched in rise of command current value I to the The mechatro controller converts the voltage
5~34.3 MPa (725~4970 psi) to CLOSE side. pump proportional solenoid valve and output by the high pressure sensor to the P-Q
The by-pass cut spool is usually held on CLOSE consequently the pump flow rate rises. This curve control value. On the other hand, select
Blue tone
side after the engine started. And it is switched is called "Positive Control System". the pump positive control command current
At valve operation
to OPEN side only when failure occurred on As the pump command current value rises, value from the low pressure sensor in lower
Red valve the secondary pressure of proportional
pump proportional valve and mechatro order, and the values are output to respective
When solenoid proportional valve (reducing) is solenoid valve also rises. On the regulator
controller. pump proportional valve as a command current.
operating attached on the pump, the spool (652)
(2) Unloading valve With this operation, the pump power is
Red solenoid through piston (643) is pushed leftward, and controlled so as not to be exceed the engine
In active and exciting On starting engine, like by-pass cut valve, the stops at the position where being in
secondary pressures output by P1 and P2 power, therefore engine dose not stall.
proportion to the force of pilot spring (646).
Displaying the flow circuit and standby circuit when unloading proportional valves (PSV-D, PSV-B) The tank port connected to the large bore of
operating. exert on PCb and PCa ports, consequently the servo piston (532) opens, and the piston
Regarding the electrical symbols in this manual, P1 and P2 unloading valves are switched to moves leftward by delivery pressure P1 of
refer to the electric circuit diagram. OPEN side. the small bore resulting in the increase of tilt
angle ( ).
7.2 SAFETY LOCK LEVER AND PILOT CIRCUIT The servo piston (532) and spool (652) are
(1) Purpose: connected to feedback lever (611).
To protect attachment from unexpected Therefore when servo piston moves
movement for safety. leftward, the spool (652) also moves
rightward by means of feedback lever. With
(2) Principle:
this movement, the opening of spool sleeve
Cut pressure source of pilot valve for operation.
closes gradually, and the servo piston stops
(3) Operation: at the position the opening closed
If the safety lock lever (red) is pushed forward completely.
after the engine starts, the limit switch (SW-11) 2) Flow rate reduction operation
is turned on. The timer relay is actuated one As the current value I of mechtro controller
second later which causes the solenoid (SV-4) reduces, the secondary pressure of
of the solenoid valve block (13) to be energized solenoid proportional valve reduces, and
and makes the pilot operating circuit to stand by. spool (652) is moved rightward by the force
of pilot spring (646). With the movement of
spool, the delivery pressure P1 usually flows
into the large bore of piston through the
spool.
The delivery pressure P1 flows in the small
bore of servo piston, but the servo piston
moves rightward due to the difference of
area, resulting in the reduction of tilt angle.
Similarly, when the servo piston moves
rightward, the spool (652) is moved leftward
by the feedback lever.
T2-2-10
HYDRAULIC SYSTEM E215B-E245B
NEUTRAL CIRCUIT: Positive control function at safety lock lever down (unloked position)
651 652
611
643 646
532
SM0081
T2-2-11
E215B-E245B HYDRAULIC SYSTEM
8. TRAVEL CIRCUIT 8.2 2-SPEED TRAVEL SOLENOID COMMAND
CIRCUIT AND AUTO 1st SPEED RETURN
This section describes the following.
FUNCTION
8.1 Travel forward pilot simultaneous operation
1) Purpose:
circuit
Change travel motor speed with switch.
8.2 2 speed travel solenoid command circuit and
auto 1-speed return function (2) Principle:
If the switch is turned, an electric signal is
8.3 Travel main circuit
issued. It excites the 2-speed travel solenoid
8.4 Travel motor function which in turn converts the primary pilot pressure
and the self pressure to a tilting angle of the
8.1 TRAVEL FORWARD PILOT variable displacement motor.
SIMULTANEOUS OPERATION CIRCUIT (3) Operation:
(1) Purpose: If the rabbit marked switch on the gauge cluster
Light operating force and shockless operation is pressed, the solenoid (SV-3) of the
(2) Mechatronics : proportional valve block (13) is excited and
changes the proportional valve. Then the
1) If the travel lever with damping mechanism
solenoid command pressure is issued from port
is operated for travel right, left and forward
A3, enters the Ps port of the travel motor (4),
motions, the secondary pilot proportional
opens the oil passage to the 2nd speed select
pressure comes out of the 3, 1 ports of P/V
piston, and causes the motor to run in the 2nd
(10). The higher of the pressures is
speed tilting mode by its self pressure.
selected, comes out of the 6, 5 ports and
However, when the main circuit pressure rises
acts upon the low pressure sensors (SE-9)
above 27.3 MPa (3960 psi) (E245B) and 28 MPa
(SE-10).
(4060 psi) (E215B), the motor’s self pressure
2) The pilot secondary pressure flows to PAr pushes the 2nd speed select piston back to the
and PAL ports of the control valve (2), 1st speed.
moves the travel spool, and switches the
main circuit.
3) The low pressure sensor output voltage is 8.3 TRAVEL MAIN CIRCUIT
input into mechatro controller. The mechatro (1) Operation:
controller performs signal processing and The delivery oil from Pump A1 and A2 ports by
outputs current corresponding to the changing the travel spool with the operation of
increase of flow rate to P1 pump travel pilot flows into P1 port on the left side
proportional valve (PSV-P1) and P2 pump motor (4) and P2 port on the right side motor (4)
proportional valve (PSV-P2), and at the through C,D ports of swivel joint (8) from AL, AR
same time the command current is output to ports of C/V, and rotates the travel motor.
P1 unloading valve (PSV-D) and P2
unloading valve (PSV-B).
4) The secondary pressures output by P1 8.4 TRAVEL MOTOR FUNCTION
pump proportional valve (PSV-P1) and P2 (1) Function:
pump proportional valve (PSV-P2) exert on 1) Prevents the motor from over running on a
pump regulator, actuating the pump on the slope.
delivery flow rate increase side. 2) Check valve that prevents cavitation of the
5) The secondary pressure delivered in P1 hydraulic motor.
unloading valve (PSV-D) and P2 unloading 3) Shockless relief valve and anti cavitation
valve (PSV-B) is fed to PBp1, PCb, PBp2 valve when inertia force stops.
and PCa ports provided in control valve (2).
4) High/Low 2 step speed change mechanism
The secondary pressure from proportional
and auto 1st speed return at high load.
valve which has exerted on PBp1 and PBp2
ports holds the by-pass cut spool on CLOSE 5) Travel parking brake.
side, like the operation in the lever neutral
position.
The secondary pressure from proportional
valve which has exerted on PCb and PCa
ports switches the unloading spool in
CLOSE side.
T2-2-12
HYDRAULIC SYSTEM E215B-E245B
TRAVEL CIRCUIT: Travel 2nd speed, RH & LH simultaneous operation.
SM0082
T2-2-13
E215B-E245B HYDRAULIC SYSTEM
9. BUCKET CIRCUIT 5) The secondary pressure delivered in travel bucket spool and returns to tank circuit from
priority proportional valve (PSV-C) is led to Bc port of C/V (2).
This section describes the following.
PTb port provided in control valve (2) and References:
9.1 Bucket digging pilot circuit shifts the travel priority valve one stage. • In bucket dumping operation, the travel
9.2 Auto accel operation priority valve also switches like digging
9.3 Flow control in the work mode 9.2 AUTO ACCELERATION OPERATION operation, resulting in confluence with travel
9.4 Bucket digging travel priority main circuit straight.
(1) Principle:
9.5 Bucket spool stroke limiter Auto acceleration actuates according to signals • When the bucket operation and other
from low pressure sensor. operation are simultaneously performed, the
travel priority valve does not actuate,
(2) Operation:
resulting in single flow of bucket circuit.
9.1 PILOT CIRCUIT FOR BUCKET DIGGING <When lever is set to neutral position>
(1) Mechatronics : In the event where the sensor does not receive
signal for 4 seconds or more even though the 9.5 BUCKET SPOOL STROKE LIMITER
1) When the operation for bucket digging is
acceleration dial is set to MAX position, the (1) Purpose:
performed, the pilot proportional secondary
engine speed should be raised to 1050 rpm. To secure simultaneous operability of boom and
pressure is delivered through port 1 of the
<When lever is operated> arm on boosting up attachment pressure (Pump
right pilot V (9), flows to PAc port, and acts
When the pressure 0.6MPa (87psi) is input to flow rate decreases.) and to prevent cavitations
on the low pressure sensor (SE-1), and at
low pressure sensor in STD specification (travel, at low engine speed
the same time the bucket spool is switched.
bucket, swing, arm), proportional voltage from
2) The voltage output by low pressure sensor (2) Operation:
low pressure sensor inputs in mechatro
(SE-1) inputs in mechatro controller. The On boosting up attachment pressure, pilot
controller, and then the engine speed returns to
mechatro controller performs signal primary pressure exerts on PCc port of C/V(2)
the dial set position corresponding to the lever
processing and outputs current through attachment booster solenoid valve,
operation.
corresponding to the increase of pump flow operates stroke limiter of bucket spool, and
rate to pump proportional valves (PSV-P1) throttle oil path of spool. As a result, P1 pump
and (PSV-P2) on the P1 and P2 pump sides, 9.3 FLOW CONTROL IN THE WORK MODE pressure increases, making the simultaneous
and at the same time the command current operation of boom up and bucket digging
(1) Principle:
is output to P1 unloading valve (PSV-D), P2 possible.
When the engine speed is intermediate speed
unloading valve (PSV-B) and travel priority Even though the engine speed is low, similarly
or lower, command current value to have the
proportional valve (PSV-C). the cavitations can be prevented by actuating
pump delivery rate constant is output.
In the following pages, the relation of the stroke limiter.
operation of low pressure sensor to both the (2) Operation:
increase of pump flow rate and unloading Even if the engine speed specified by
proportional valve is the same. Therefore acceleration potentiometer is low speed, as the
the explanation is omitted. delivery rate corresponds to the intermediate
speed, the actuator moves earlier than the
3) The secondary pressure output by P1 pump
movement equivalent to the control lever angle
proportional valve (PSV-P1) and P2 pump
rate in light load operation.
proportional valve (PSV-P2) exerts on pump
regulator, actuating the pump onto the
delivery flow increase side. 9.4 BUCKET DIGGING AND TRAVEL PRIORITY
4) The secondary pressure delivered in P1 CONFLUENCE (CONFLUX) MAIN CIRCUIT
unloading valve (PSV-D) and P2 unloading (1) Operation:
valve (PSV-B) is led to PBp1, PCb, PBp2
1) The oil delivered through A1 port of P1
and PCa ports provided in control valve (2).
pump goes into P1 port of C/V (2), opens
The secondary pressure from proportional
load check valve LCc through parallel circuit
valve which has exerted on PBp1 and PBp2
and enters in bucket spool.
ports holds the by-pass cut spool on CLOSE
side, like the operation in the lever neutral 2) On the other hand, the oil delivered through
position. A2 port of P2 pump goes into P2 port of C/V
The secondary pressure from proportional (2), confluences with oil from P1 pump
valve which has exerted on PCb and PCa through travel priority valve, and goes into
ports switches the unloading spool in bucket spool. (Confluence of oil from 2
CLOSE side. pumps)
3) 3)With the function of pilot circuit, the oil flow
is switched from bucket spool, and is fed into
bucket cylinder head side through Ac port of
C/V (2). On the other hand, the return oil
from cylinder rod (R) side is throttled by
T2-2-14
HYDRAULIC SYSTEM E215B-E245B
BUCKET CIRCUIT: Bucket digging (Travel priority conflux), Auto-accelation and Standby flow rate constant control
SM0083
T2-2-15
E215B-E245B HYDRAULIC SYSTEM
10. BOOM CIRCUIT
This section describes the boom raise conflux
operation.
10.1 Boom up pilot circuit
10.2 Boom up 2 pumps conflux main circuit in C/V
10.1 BOOM RAISE PILOT CIRCUIT
(1) Operation:
1) If boom up operation is performed, the
secondary pilot proportional pressure from
the right pilot valve (9) gets out of port 4 and
acts upon the low pressure sensor (SE3). At
the same time, the pressure acts upon the
PAb and PB1 ports.
2) The secondary pressure which enters the
PAb port of C/V (2) shifts the boom spool.
The secondary pressure which enters the
PB1 port shifts the boom conflux spool.
10.2 BOOM UP 2 PUMPS CONFLUX MAIN
CIRCUIT IN C/V
(1) Purpose:
Boom up speed up
(2) Principle:
Confluxing oil from 2 pumps
(3) Operation:
1) The oil delivered through A1 port of P1
pump flows into C/V (2) P1 port, and
branches into bypass circuit and parallel
circuit. Since P1 unloading valve is closed,
the boom spool is moved and bypass circuit
is closed, the oil opens load check valve
LCb through parallel circuit and flows into
boom spool.
2) Then the oil passes through boom spool,
opens lock valve of boom lock valve CRb,
and is led into (H) side of boom cylinder
through C/V (2) Ab port.
3) Meanwhile, the oil delivered from the A2
port of the P2 pump enters the P2 port of C/
V (2) and due to shut off the P2 unloading
valve, the oil then passes through the
parallel circuit and via the restrictor on the
circumference of the boom conflux spool,
pushes the load check valve CCb open from
the boom conflux circuit, and combines the
oil delivered by the P1 pump internally.
4) The return oil from boom cylinder (R) side
flows into tank circuit through boom spool
from C/V (2) Bb port.
T2-2-16
HYDRAULIC SYSTEM E215B-E245B
BOOM CIRCUIT : Boom up operation, Confluence function.
SM0084
T2-2-17
E215B-E245B HYDRAULIC SYSTEM
This section describes boom lower operation. 10.5 CONSTANT RECIRCULATION FUNCTION
10.3 Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
10.4 Prevention of natural fall by lock valve and (1) Purpose:
actuation at lowering Prevention of cavitation during boom lowering
10.5 Constant recirculation function of boom down motion.
main circuit (2) Principle:
The oil returning from the boom cylinder head
(H) is recirculated to the rod (R).
10.3 BOOM DOWN PILOT CIRCUIT
(1) Operation: (3) Operation:
When the oil is supplied to the boom cylinder rod
1) If the boom down operation is performed, (R) side during boom down operation, the boom
the secondary pilot proportional pressure moves faster than it should do in some cases by
comes out of port 2 of the right pilot valve (9) the self weight of the attachment.
and acts upon the low pressure sensor (SE- On that occasion, the circuit pressure on the rod
4). (R) side is on the negative side.
At the same time, the pressure acts upon The oil supplied to the boom cylinder rod (R)
the PBb port of C/V (2). flows into the A1 port of the P1 pump and the P1
2) The voltage output of the low pressure port of C/V. The oil then passes through the
sensor (SE-4) enters the mechatro boom spool and goes out of the Bb port.
controller and processed in it. On that occasion, the oil returning from the head
3) Then, the proportionl secondary pressure (H) goes through the recirculation path in the
fed into C/V (2) PBb port and branches off in boom spool, pushes the check valve in the spool
two lines and switches boom spool and open, is recirculated to the Bb port and is
releases boom lock valve. supplied to the rod (R). When the (R) pressure
is larger than the head (H) pressure, the check
valve in spool closes.
10.4 PREVENTION OF NATURAL FALL BY LOCK
Thereupon, the recirculation is stopped.
VALVE AND ACTUATION AT LOWERING
(1) Purpose:
Prevention of natural fall when the lever is
neutral
(2) Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation:
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line
on the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from
making a natural fall.
T2-2-18
HYDRAULIC SYSTEM E215B-E245B
BOOM CIRCUIT: Boom down operation & Prevention of natural boom falling.
SM0085
T2-2-19
E215B-E245B HYDRAULIC SYSTEM
11. SWING CIRCUIT as the swing spool is shifted, the oil pushes the
load check valve LCs open through the parallel
This section describes the following operations.
circuit, enters the B port of the swing motor via
11.1 Swing left pilot circuit the Bs port of C/V (2), and rotates the swing
11.2 Swing auto parking brake motor counterclockwise.
11.3 Swing main circuit
11.4 Swing motor circuit
11.4 SWING MOTOR CIRCUIT
(1) Anti cavitation circuit at swing deceleration
11.1 PILOT CIRCUIT FOR LEFT SWING
(2) Shockless relief valve that prevents the swing
(1) Operation: motor from being reversed.
1) When the left swing operation is performed,
the pilot proportional secondary pressure is
delivered through port (1) of left pilot V (9),
and the secondary pressure acts on PBs
port of C/V (2), and simultaneously flows out
from Pss port of C/V and acts on low
pressure sensor (SE-5).
2) The voltage output by the low pressure
sensor is input in the mechatro controller,
and is signal-processed.
3) Then, the secondary pressure led into PBs
port of C/V (2) switches the swing spool.
11.2 SWING AUTO PARKING BRAKE
(1) Purpose:
Swing lock in neutral position and parking
(2) Principle:
Release mechanical brake only when required
to operate swing and arm in.
(3) Operation:
1) The swing parking system excites the swing
parking SOL (SV-1) usually if the key switch
is turned on and works by the action of the
mechanical brake.
2) The mechanical brake is released if the
swing parking solenoid is de-excited only
when the secondary operating pressure in
the swing and arm in actions acts upon any
of the low pressure sensors (SE-5, 7).
3) The swing parking solenoid (SV-1) is excited
five seconds after the pressure of the swing
low pressure sensors (SE-5) is reduced to
zero.
In the case of arm in operation, the swing
parking solenoid (SV-1) is excited the
moment the pressure of the arm in low
pressure sensor (SE-7) is reduced to zero.
This causes the mechanical brake to
operate.
11.3 SWING MAIN CIRCUIT
(1) Operation:
The oil delivered from the A2 port of the P2
pump enters the P2 port of C/V (2) and is
branched off into the bypass line and the parallel
circuit. However, since the bypass line is closed
T2-2-20
HYDRAULIC SYSTEM E215B-E245B
SWING CIRCUIT: Swing operation (LH)
SM0086
T2-2-21
E215B-E245B HYDRAULIC SYSTEM
12. ARM CIRCUIT 3) The return oil from arm cylinder (R) side
flows in Ba port of C/V (2) and passes
This section describes the following operations.
through the Ba port because the arm lock
12.1 Arm in, light-load operating pilot circuit valve CRar is open, and is flowed into arm 2
12.2 Arm in, light-load variable normal recirculation spool through arm 1 spool.
main circuit / internal conflux main circuit 4) Because arm 2 spool is switched to normal
recirculation position, causing restriction of
12.1 ARM IN, LIGHT-LOAD OPERATING PILOT passage to tank, the return oil from arm
CIRCUIT cylinder (R) side flows into arm cylinder (H)
side.
(1) Purpose:
Speed-up and Anticavitation when the arm is at • Because, at light load, the pressure in
light loaded. cylinder rod (R) side is higher than that in
the head (H) side, it opens the check valve
(2) Principle:
housed-in arm 2 spool and is recirculated
The oil returning from the arm cylinder rod (R) is
in the head (H) side, resulting in the speed
recirculated variably to the head (H) at arm 2
up of arm-in operation at light load.
spool in C/V.
5) Cavitations prevention control in arm-in
(3) Operation: operation.
1) When the arm in operation is performed, the Command current is output to arm 2
secondary pilot proportional pressure gets solenoid proportional valve by signal
out of port 4 of the left pilot valve (9) and acts processing of E/G speed and arm-in pilot
upon the low pressure sensor (SE-7). pressure, accordingly the arm 2 spool is
At the same time, the pressure is branched switched to neutral (cavitations prevention)
off in two flows, acts upon the PAa1 port and position, resulting in cavitations prevention.
the PLc2 port, changes over the arm spool
and the arm lock valve CRar releases. Position of arm 2 spool
2) The output voltage by the low pressure
Neutral position
sensor is input into mechatro controller, and (Anticavitation position)
is pilot signal-processed, and is output to Normal recirculation position
P1, P2 pump proportional valve (PSV-P1), Recirculation
(PSV-P2) and arm 2 inverse proportional
valve (PSV-A).
3) The secondary pressure from pilot From arm out
proportional valve, which is reduced by arm P/V
2 inverse proportional valve (PSV-A) From arm 2 inverse
proportional valve
switches arm 2 spool.
SM0195
12.2 ARM-IN, LIGHT-LOAD VARIABLE NORMAL Reference:
RECIRCULATION, INTERNAL CONFLUX In light-load arm-in operation (normal
MAIN CIRCUIT recirculation, conflux), when the attachment
(1) Operation: to which the circuit in P1 pump side is
applied is operated, the meter-in path of arm
1) The P2 pump delivery oil flows in travel left
2 spool is closed, resulting in single flow
section through P2 port of C/V (2) and is
operation.
branched off in by-pass circuit and parallel
circuit, but because arm 1 spool is switched,
Spool position at arm in,
the delivery oil which goes through parallel light load and combined operation
circuit opens load check valve LCa and is (This position is not shown in hydraulic diagram)
flowed into arm 1 spool. Meter-in passage
Neutral position
2) On the other hand, P1 pump delivery oil (Close)
flows in P1 port of C/V (2), and the flows in
travel straight section and travel right
tandem path. Then because arm 2 spool
was switched, the delivery oil opens load Normal recirculation opsition
check valve LCAT2, goes through arm 2 Arm 2 spool
SM0196
spool, and confluences with P2 pump
delivery oil in the valve section, and then is
flowed into arm cylinder head (H) side
through Aa port of C/V (2).
T2-2-22
HYDRAULIC SYSTEM E215B-E245B
ARM CIRCUIT: Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function
SM0087
T2-2-23
E215B-E245B HYDRAULIC SYSTEM
This section describes the following operations. 4) The return oil returns directly into tank circuit
12.3 Arm in, heavy load operating pilot circuit because arm 2 spool is switched to
(recirculation cut) recirculation cut position.
12.4 Arm in, heavy load operating sequence
confluxed main circuit Position of arm 2 spool
Neutral position Recirculation cut position
12.3 ARM IN, HEAVY LOAD OPERATING PILOT
From
CIRCUIT
arm out
(1) Operation: P/V
From arm 2 inverse
1) 1)In arm-in operation, when the heavy proportional valve
loading is applied to arm and the P2 pump
pressure increases to the set pressure, the SM0197
voltage output by P2 pump pressure sensor
(SE-23) is converted to signal (signal
processing) by mechatro controller,
consequently the current of arm 2 solenoid
proportional valve is controlled according to
the load pressure and the arm variable
recirculation is cut.
When the recirculation is cut, internal
confluence is held similarly to that in light
load operation.
2) Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.
12.4 ARM IN, HEAVY LOAD OPERATING
RECIRCULATION CUT MAIN CIRCUIT
(1) Purpose:
Speed up for arm in operation
(2) Principle:
Cut the recirculation and reduce rod pressure.
(3) Operation:
1) P2 pump delivery oil flows in the travel left
section through P2 port of C/V (2) and
branched off in by-pass circuit and parallel
circuit. Consequently the arm spool is
switched and pushes and opens load check
valve LCa through parallel circuit, and flows
in the arm spool.
2) On the other hand, P1 pump delivery oil
flows in P1 port of C/V (2), and flow in travel
right tandem passage through travel straight
section. Then because arm 2 spool was
switched, the delivery oil opens load check
valve LCAT2, and confluences with P2
pump delivery oil in the valve section, and is
flowed into arm cylinder head (H) side
through Aa port of C/V(2).
3) The return oil from arm cylinder (R) side
flows in Ba port of C/V(2) and is flowed to
arm lock valve CRar, but because the arm
lock valve CRar is open, the return oil goes
through arm lock valve CRar and flows in
arm 2 spool.
T2-2-24
HYDRAULIC SYSTEM E215B-E245B
ARM CIRCUIT: Arm in (Heavy load) operation, Arm confluence & recirculation cut function
SM0088
T2-2-25
E215B-E245B HYDRAULIC SYSTEM
This section describes the following operations. 12.7 NATURAL FALL PROTECTION WITH ARM
12.5 Arm out pilot circuit LOCK VALVE
12.6 Arm out 2 pumps conflux main circuit (1) Purpose:
12.7 Natural fall protection with arm lock valve To prevent the arm from falling naturally by the
weight of the arm and bucket.
(2) Principle:
12.5 ARM OUT PILOT CIRCUIT
Complete seat of the return circuit against the
(1) Operation: arm spool of the arm cylinder (R) side circuit.
1) When the arm out operation is performed, (3) Operation:
the secondary pilot proportional pressure
gets out of port 8 of the left pilot valve (9), 1) When the secondary pressure for arm
and acts upon the low pressure sensor (SE- operation disappears and the arm cylinder
8). At the same time, the oil is branched off stops, the pressure on the rod (R) side
in two flows and act upon the PBa1 and passes through the selector of the lock valve
PBa2 ports of C/V (2). from the Ba port of C/V, acts the back
pressure on the lock valve CRar and seats
2) The operating proportional secondary
the lock valve.
pressure flowed in PBa1 port of C/V (2)
switches the arm 1 spool. 2) Since the oil flow into the arm spool from the
lock valve is shut off completely, natural fall
3) Then, the operating secondary pressure
of the arm due to oil leaks through the arm
flowed in PBa2 port of C/V (2) switches the
spool is prevented.
arm 2 spool valve.
12.6 ARM OUT 2 PUMPS CONFLUX MAIN
CIRCUIT
(1) Purpose:
Arm out operation speed up.
(2) Principle:
The oil delivered by the P1 pump is confluxed
with that delivered by the P2 pump in C/V (2).
(3) Operation:
1) P1 pump delivery oil opens load check valve
(LCAT2) by switching arm 2 spool and
confluxes with P2 pump delivery oil just
short of the arm lock valve.
2) And, P2 pump delivery oil flows through arm
1 spool and confluences with P1 delivery oil,
opens lock valve of arm lock valve CRar with
free flow and is flowed into arm cylinder rod
(R) side through Ba port of C/V(2).
3) On the other hand, the return oil from arm
cylinder (H) side flows in Aa port, and
returns into tank circuit through arm 1 spool
and arm 2 spool.
The return line which does not pass through
boost check valve is used for this return
circuit to reduce the pressure loss.
T2-2-26
HYDRAULIC SYSTEM E215B-E245B
ARM CIRCUIT: Arm out operation, Confluence function
SM0089
T2-2-27
E215B-E245B HYDRAULIC SYSTEM
13. COMBINED CIRCUIT because the travel straight spool is shifted
and exerts on the right travel operation.
This section describes only the difference in
(In travel straight operation, P2 pump
combined operation.
delivery oil exerts on travel operation.)
13.1 Boom up / travel, pilot circuit
4) However, a portion of the flow is led to the
13.2 Boom up / travel, main circit spool of short-circuit valve notch restriction.
The speed of attachments like travel, boom,
13.1 BOOM UP / TRAVEL, PILOT CIRCUIT etc. is adjusted by the circuit of restriction.
(1) Operation:
<Operation: Different point of pilot circuit from
independent operation >
1) The mechatro controller outputs command
current to travel priority solenoid
proportional valve (PSV-C) and to short-
circuit solenoid proportional valve (PSV-R)
after signal processing.
And the solenoid proportional valve outputs
secondary pressure and acts on PTb port
and short-circuit valve.
2) Then the pressure of PTb port switches the
travel priority valve. And the secondary
pressure of solenoid valve in short-circuit
valve switches spool of short-circuit valve 1
step.
13.2 BOOM UP / TRAVEL, MAIN CIRCUIT
(1) Purpose:
To insure straight travel movement during travel
operation even if the attachment is operated.
(2) Principle:
The travel action and the attachment action are
actuated by separate pumps.
(3) Operation:
1) P1 pump delivery oil flows through P1 port of
C/V(2) and branches off in P1 parallel circuit
and spool of short-circuit valve.
P2 pump delivery oil flows through P2 port of
C/V(2) and branches off in P2 tandem circuit
and spool of short-circuit valve.
2) The delivery oil flowed into P1 parallel circuit
of P1 pump opens check valve CT1 and
LCb and flows in boom spool, which exerts
on boom up operation.
The delivery oil flowed into travel priority
spool of P1 pump opens check valve CT2
because the travel priority spool is shifted,
and flows in boom conflux spool and exerts
on boom up operation with the internal oil
conflux.
(In travel straight operation, P1 pump
delivery oil exerts on operation of
attachment.)
3) The delivery oil flowed into P2 tandem circuit
of P2 pump flows in left travel spool to travel
leftward.
The delivery oil flowed into travel priority
spool of P2 pump flows in right travel spool
T2-2-28
HYDRAULIC SYSTEM E215B-E245B
COMBINED CIRCUIT: Boom up & Travel forward 1st speed operation, Travel priority function.
SM0090
T2-2-29
E215B-E245B HYDRAULIC SYSTEM
In this section, the independent operation is omitted Position of arm 2 spool
and describes difference in combined operation.
13.3 Swing / Arm in light load, pilot circuit
13.4 Swing / Arm in, swing priority main circuit Position of forced recirculation
Neutral position Meter-in passage
13.3 SWING / ARM IN LIGHT LOAD, PILOT (Close)
CIRCUIT
From From arm 2
(1) Operation: arm out inverse
P/V proportional valve
1) On operating swing (left) and arm in motions
Normal recirculation position
simultaneously, mechatro controller outputs Arm 2 spool SM0198
command current to travel priority solenoid
proportional valve (PSV-C) and arm 2
solenoid inverse proportional valve
according to signal processing, and this
proportional valve outputs secondary
pressure, which acts on PTb port and PAa2
port of C/V(2).
2) PTb port pressure switches the travel
priority spool, and the PAa2 port pressure
switches the arm 2 spool to the forced
recirculation position.
13.4 SWING / ARM IN, SWING PRIORITY MAIN
CIRCUIT
(1) Purpose:
Stable swing speed.
(2) Principle:
Raise the oil pressure flowing to arm cylinder,
and give a priority of the delivery of P2 pump to
swing operation.
(3) Operation:
1) The swing main circuit operates with P2
pump flow. But on P2 pump circuit side, the
flow goes to the swing circuit and arm circuit
simultaneously because the swing circuit
and arm circuit are parallel. Then since the
return oil from arm cylinder rod (R) side is
restricted in the arm 2 spool because the
arm 2 spool is switched to forced
recirculation position, the pressure of return
oil is raised, causing the rise of circuit
pressure on the arm cylinder head (H) side.
2) At the same time meter-in of arm 2 spool
closes and arm in conflux is therefore
cancelled, and delivery oil from P2 pump
and P1 pump are combined in the parallel
circuit on P2 pump side because the travel
straight spool was switched.
The conflux oil of P1 and P2 delivery oil in
high pressure flows in swing side taking
priority over all others.
This operation is called "Swing Priority
Circuit".
T2-2-30
HYDRAULIC SYSTEM E215B-E245B
COMBINED CIRCUIT: Swing / Arm in operation, swing priority function
SM0091
T2-2-31
E215B-E245B HYDRAULIC SYSTEM
T2-2-32
HYDRAULIC SYSTEM E215B-E245B
PRESSURE DRAINING (RELEASING) CIRCUIT: at pressure release mode
651 652
611
643 646
532
SM0092
T2-2-33
E215B-E245B HYDRAULIC SYSTEM
T2-2-34
ELECTRICAL SYSTEM E215B-E245B
SM0004
T2-3-1
E215B-E245B ELECTRICAL SYSTEM
A - CAB CONTROL
Electrical components
10 1
2
16
4
14
5
13
12 6
11 7
8
15
T2-3-2
ELECTRICAL SYSTEM E215B-E245B
Cluster Gauge
SM0003
T2-3-3
E215B-E245B ELECTRICAL SYSTEM
10
12
13
14
VIEW I
15
6 7 8 16
4 17
3 19
10
1 a-a
2 20
9
b-b
DETAIL a-a
c-c
11
I 2 3 4 5 6 7
1 E
8
8
W Br
18
VIEW E
DETAIL c-c
DETAIL b-b SM0098
T2-3-4
ELECTRICAL SYSTEM E215B-E245B
SM0010
T2-3-5
E215B-E245B ELECTRICAL SYSTEM
SM0008
FUSE No. PROTECTED CIRCUIT Rating FUSE No. PROTECTED CIRCUIT Rating
(A) (A)
FUSE 1 Cab Work Light 20 FUSE 19 Air Conditioner 5
FUSE 2 Cab Work Light 20 FUSE 20 Work Light 20
FUSE 3 Monitor 5 FUSE 21 DC-DC Converter 10
FUSE 4 Wiper , Washer 20 FUSE 22 Opt.8 (Bucket Control) 5
FUSE 5 Option 1 20 FUSE 23 Opt.8 (Roof Wiper) 15
FUSE 6 Option 3 20 FUSE 24 Option 20
FUSE 7 Air Conditioner 15 FUSE 25 Safety Look Lever 10
FUSE 8 Air Conditioner 5 FUSE 26 Mechatro Controller 5
FUSE 9 Opt. (Hand Control) 5 FUSE 27 Mechatro Controller 20
FUSE 10 Relay, Hour Meter 5 FUSE 28 Engine Controller (ECU) 15
FUSE 11 Cigarette Lighter 10 FUSE 29 Engine Controller (ECU) 15
FUSE 12 Horn, Horn Relay 10 FUSE 30 Monitor (Back Up) 5
FUSE 13 Radio 10 FUSE 31 Fuel Supply Pump 15
FUSE 14 Starter Key Switch 20 FUSE 32 Mechatro Contr. (Back Up) 5
FUSE 15 Room Lamp, Tuner 5 FUSE 33 Spare 5
FUSE 16 Opt.2 (Auto Grease) 10 FUSE 34 Spare 10
FUSE 17 Option 4 10 FUSE 35 Spare 15
FUSE 18 Solenoid Valve 10 FUSE 36 Spare 20
T2-3-6
ELECTRICAL SYSTEM E215B-E245B
RELAYS
SM0009
1 - Window washer motor relay (RLY 32) 16 - Wiper motor relay (RLY 29)
2 - Wiper motor reversing relay (RLY 30) 17 - Discharge pressure relay (RLY 17)
3 - Cab working light relay (RLY 9) 18 - Grease (forward) relay (RLY 27)
4 - Cab working light relay (RLY 11) 19 - Grease (reverse) relay (RLY 35)
5 - Working light relay (RLY 6) 20 - Safety relay (RLY 4)
6 - Alternator relay (RLY 28) 21 - Bucket control relay (RLY 10)
7 - Auto-Idle stop relay (RLY 24) 22 - Travel alarm relay (RLY 8)
8 - Lever look relay (RLY 26) 23 - Revolution right relay (RLY 12)
9 - Auto-Idle stop relay (RLY 23) 24 - Nibbler open relay (RLY 15)
10 - Engine emergency stop relay (RLY 25) 25 - Revolution left relay (RLY 13)
11 - Horn relay (RLY 5) 26 - Reserve relay (RE-RLY 5)
12 - Nibbler close relay (RLY 16) 27 - Reserve relay (RE-RLY 6)
13 - Reserve relay (RE-RLY 1) 28 - Reserve relay (RE-RLY 4)
14 - Reserve relay (RE-RLY 2) 29 - Reserve relay (RE-RLY 3)
15 - Wiper motor relay (RLY 31)
T2-3-7
E215B-E245B ELECTRICAL SYSTEM
7 2
SM0005
T2-3-8
ELECTRICAL SYSTEM E215B-E245B
14 3
4 2
28
15
13
1
30
29
26 27
16
17
18
19
12 11 6 7 8 9
5 10
25 24 23 22 21 20
SM0006
1 - Extra valve selector press sensor (SE-29) (opt.) 16 - P1 opt. sensor valve (SE-20)
2 - Pomp P2 proportional solenoid valve (PSV-P2) 17 - Travel right sensor (SE-9)
3 - Pump P1 proportional solenoid valve (PSV-P1) 18 - Travel left sensor (SE-10)
4 - Swing sensor (SE-5) 19 - P2 Opt. sensor valve (SE-11)
5 - Lever lock solenoid valve (SV-4) 20 - Bucket digging sensor (SE-1)
6 - Power boost solenoid valve (SV-2) 21 - Bucket dump sensor (SE-2)
7 - P2 Unload proportional solenoid valve (PSV-B) 22 - Boom raising sensor (SE-3)
8 - Travel priority prop. solenoid valve (PSV-C) 23 - Boom lowering sensor (SE-4)
9 - P1 Unload proportional solenoid valve (PSV-D) 24 - Arm in sensor (SE-7)
10 - Arm 2 inverse prop. solenoid valve (PSV-A) 25 - Arm out sensor (SE-8)
11 - Two speed select solenoid valve (SV-3) 26 - Pump P1 sensor (SE-22)
12 - Swing parking brake solenoid valve (SV-1) 27 - Pump P2 sensor (SE-23)
13 - Short-circuit proportional solenoid valve (PSV-R) 28 - Relief adjustment prop. solenoid valve 1 (PSV-E)
14 - Extra dis-press solenoid valve (SV-11) (opt) 29 - Relief adjustment prop. solenoid valve 2 (PSV-I)
15 - Extra dis-press sensor (SE-28) (opt) 30 - Selector E&N solenoid valve (SV-13)
T2-3-9
E215B-E245B ELECTRICAL SYSTEM
15
18
1
17
19
13
4
14
16
12
10 9 3 8 5 6-7 11
SM0007
T2-3-10
ELECTRICAL SYSTEM E215B-E245B
4 5
6 SM0011
T2-3-11
E215B-E245B ELECTRICAL SYSTEM
T2-3-12
ELECTRICAL SYSTEM E215B-E245B
ELECTRICAL SYSTEM DIAGRAM (No. 1)
19
17
1
20
31
26
16 18
21
10
25
14
3
9 15 22 35
4
11 23
34
29
30
2 24
12
13
5
6
7
32
33
28
27 8
SM0093
T2-3-13
E215B-E245B ELECTRICAL SYSTEM
ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 2)
Item Description Code
35 Mechatro Controller C-1
36 Cluster gauge C-2
37 Water separator restriction switch SW - 36
38 Accel potentio pressure sensor SE -16
39 Bucket digging sensor SE - 1
40 Bucket dump sensor SE - 2
41 Boom raising sensor SE - 3
42 Boom lowering sensor SE - 4
43 Arm in sensor SE - 7
44 Arm out sensor SE - 8
45 Swing sensor SE - 5
46 Travel right sensor SE - 9
47 Travel left sensor SE - 10
48 Pump P1 sensor SE - 22
49 Pump P2 sensor SE - 23
50 P1 option sensor (2PB) SE - 20
51 P2 option sensor (Hammer) SE - 11
52 Engine coolant temperature switch SW - 6
53 Engine coolant thermo sensor SE - 14
54 Fuel level sensor SE - 15
55 Engine speed sensor SE - 55
56 Power boost switch right SW - 22
57 Power boost switch left (opt.) SW - 23
58 Swing parking release switch SW - 4
59 Swing parking brake solenoid valve SV - 1
60 Two-speed select solenoid valve SV - 3
61 Power boost solenoid valve SV - 2
62 P2 Unload proportional solenoid valve PSV - B
63 Travel priority proportional solenoid valve PSV - C
64 P1 Unload proportional solenoid valve PSV - D
65 Arm two-speed inverse proportional solenoid valve PSV - A
66 Pump P1 proportional solenoid valve PSV - P1
67 Pump P2 proportional solenoid valve PSV - P2
68 OPT. Relief adjustment proportional solenoid valve 1 PSV - E
69 OPT. Relief adjustment proportional solenoid valve 2 PSV - I
70 Short-circuit proportional solenoid valve PSV - R
71 Short-circuit proportional solenoid valve M-2
T2-3-14
ELECTRICAL SYSTEM E215B-E245B
ELECTRICAL SYSTEM DIAGRAM (No. 2)
35 58
37
59
60
61
38 62
39
63
40
64
41
65
42
66
43
44 67
45
46
47
48
49
50
51
52
36 53
54 68
55 69
70
71
56
SM0094
57
T2-3-15
E215B-E245B ELECTRICAL SYSTEM
ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 3)
Item Description Code
35 Mechatro Controller C-1
72 Engine oil pressure switch SW - 7
73 Air filter restriction switch SW - 8
74 Engine oil level sensor SE -12
75 Engine coolant level switch SW - 24
76 Conflux/single select switch SW - 15
77 Lever lock switch SW - 11
78 Lever lock relay R- 26
79 Operating lever lock solenoid valve SV - 4
80 Heavy lift switch SW - 35
81 Extra dis. Pressure relay opt. R - 17
82 Extra dis. Pressure solenoid valve opt. SV - 11
83 Extra dis. Pressure sensor opt. SE - 28
84 Prevent spark relay R - 31
85 Wiper motor relay R - 29
86 Wiper motor reversing relay R - 30
87 Window washer motor relay R - 32
88 Wiper motor M-3
89 Washer motor M-4
90 Wiper interlock switch SW - 19
91 Selector detect sensor opt. SE - 29
92 Selector solenoid opt. SV - 13
93 Air conditioner ampl. C-4
94 Receiver drier E - 10
95 Air compressor clutch E - 11
96 Cigarette lighter E - 14
97 Room light L-5
98 Horn relay R-5
99 Horn high E-5
100 Horn low E-6
101 Horn switch right opt. SW - 5
102 Horn switch left opt. SW - 10
T2-3-16
ELECTRICAL SYSTEM E215B-E245B
ELECTRICAL SYSTEM DIAGRAM (No. 3)
35
93
94 95
72
73
82
74 81
83
75
96
76 88
84 85
97
86
78 79
77
89
87
80 90
98
99
100
91 101
102
92
SM0095
T2-3-17
E215B-E245B ELECTRICAL SYSTEM
ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 4)
Item Description Code
35 Mechatro Controller C-1
103 Revolution left nibbler relay R - 13
104 Revolution right nibbler relay R - 12
105 Diode D - 16
106 Diode D - 17
107 Revolution right nibbler switch SW - 33
108 Revolution left nibbler switch SW - 34
109 Revolution right nibbler solenoid valve SV - 6
110 Revolution left nibbler solenoid valve SV - 7
111 Pressure sensor boom head (for overload alarm) SE - 26
112 Overload alarm select switch SW - 12
113 Working light relay R-6
114 Working light switch SW - 55
115 Boom working light right L-6
116 Boom working light left L-1
117 Frame working light L-2
118 Engine room light switch SW - 16
119 Engine room light L - 11
120 Fuel supply pump (automatic fuel stop) M - 11
121 Auto grease motor opt. M-8
122 Fleet link opt. -
123 Antenna GPS -
124 Antenna GSM -
T2-3-18
ELECTRICAL SYSTEM E215B-E245B
ELECTRICAL SYSTEM DIAGRAM (No. 4)
35 115
113
116
112 117
114
111
118 119
109
104 107
120
105
106
121
110
108
103
123 124
122 SM0096
T2-3-19
E215B-E245B ELECTRICAL SYSTEM
ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 5)
Item Description Code
35 Mechatro Controller C-1
125 12 V Socket E - 23
126 DC – DC converter E - 22
127 Tuner E-7
128 Antenna -
129 Speaker left E-8
130 Speaker right E-9
131 Quick coupler operation solenoid valve SV - 14
132 Quick coupler operation switch SW - 64
133 Diode D - 22
134 Thermo switch for heater SW - 52
135 Seat heater opt. E - 26
136 Cab working light relay 1 R-9
137 Cab working light relay 2 R - 11
138 Cab working light switch SW - 26
139 Cab working light front 1 L-7
140 Cab working light front 2 L-8
141 Cab working light front 3 L - 15
142 Cab working light front 4 L - 16
143 Cab working light back 1 L - 18
144 Cab working light back 2 L - 17
145 6P Connector -
T2-3-20
ELECTRICAL SYSTEM E215B-E245B
ELECTRICAL SYSTEM DIAGRAM (No. 5)
135
134
136
139
131
138 140
132 141
133
142
137 143
144
127
128
129
126
130
145
125
SM0097
(1)
T2-3-21
E215B-E245B ELECTRICAL SYSTEM
WIRING HARNESS
CLUSTER GAUGE WIRING HARNESS ASSEMBLY READING KEY
ASSEMBLY CABLES ON THE CONNECTORS
- The connector view on the cable
are from “X” side
SM0199
SM0251
T2-3-22
ELECTRICAL SYSTEM E215B-E245B
CLUSTER GAUGE WIRING HARNESS ASSEMBLY
SM0099
T2-3-23
E215B-E245B ELECTRICAL SYSTEM
PLATFORM WIRING HARNESS ASSEMBLY READING KEY
ASSEMBLY CABLES ON THE CONNECTORS
- The connector view on the cable
are from “X” side
SM0253 SM0199
T2-3-24
ELECTRICAL SYSTEM E215B-E245B
PLATFORM WIRING HARNESS ASSEMBLY
SM0252
T2-3-25
E215B-E245B ELECTRICAL SYSTEM
UPPER FRAME WIRING HARNESS ASSEMBLY READING KEY
ASSEMBLY CABLES ON THE CONNECTORS
- The connector view on the cable
are from “X” side
SM0199
SM0255
T2-3-26
ELECTRICAL SYSTEM E215B-E245B
UPPER FRAME WIRING HARNESS ASSEMBLY
SM0254
T2-3-27
E215B-E245B ELECTRICAL SYSTEM
ENGINE WIRING HARNESS (KSB & STOP) READING KEY
SM0257
WIRING DIAGRAM
1 2
3
4
SM0258
ASSEMBLY CABLES ON THE CONNECTORS
1 To engine coolant temperature sensor (SE-14)
2 To operator’s compartment wiring assembly, connector [CN-2M]
3 To KSB solenoid - The connector view on the cable
are from “X” side
4 To engine stop solenoid (SV-15)
SM0199
T2-3-28
ELECTRICAL SYSTEM E215B-E245B
ENGINE WIRING HARNESS (KSB & STOP)
SM0256
T2-3-29
E215B-E245B ELECTRICAL SYSTEM
T2-3-30
COMPONENT OPERATION
M0103
COMPONENT OPERATION E215B-E245B
COMPONENT OPERATION
CONTENTS
Group 7 - Cylinders
Outline..................................................... T3-7-1
Construction ............................................ T3-7-2
Boom cylinder .................................... T3-7-2
Arm cylinder ....................................... T3-7-3
Bucket cylinder................................... T3-7-4
Positioning ........................................ T3-7-5
Operation ................................................ T3-7-6
OUTLINE
Dr 5 B3 3 a5
a3
PSV1 PSV2
A1 A2
PH1
PH2 a4
PSV1 PSV2
2 a3 4 a4
PH1 PH2
a1 a2
Dr3 B3
a5
A3
1 Dr B1
SM0745
T3-1-1
E215B-E245B HYDRAULIC PUMP ASSY
4 4
2 2
SM0746
T3-1-2
HYDRAULIC PUMP ASSY E215B-E245B
Specifications
NOTE: the max. input power and the max. input torque of the main pump include those of the gear pump.
T3-1-3
E215B-E245B HYDRAULIC PUMP ASSY
HYDRAULIC PUMP
MAIN PUMP
953 806 789 532 (Three Bond N° 1305N) 724 901 808 954 717 151 152
886 214 548 531 702 792 534 A
535 732
717 211
261
406
824
774
111
B B
127
123
710
212
401 251 490 271 153 156 157 468 313 124 710 116 467 466 312 885 314 141 271 113
728 727 725
05
04
Nm
401 M20 430 546
406 M8 29
407 M6 12 725
414 M10 57 727
466 PF 1/4 36
467 PF 3/8 74
468 PF 3/4 170
490 NPTF1/16 8.8
531,532 M24X2 240
806 M16 130
808 M20 240 A B-B
407 325
SM0747
111 Drive shaft (F) 313 Valve plate (R) 717 O-ring; 1B G145 (Q.ty 4)
113 Drive shaft (G) 314 Valve plate (L) 724 O-ring; 1B P8 (Q.ty 16)
116 Gear #1 325 Sensor block 725 O-ring; 1B P11 (Q.ty 9)
123 Roller bearing (Q.ty 2) 326 Cover 727 O-ring; 1B P14 (Q.ty 3)
124 Needle bearing (Q.ty 2) 401 Socket bolt; M20X210 (Q.ty 8) 728 O-ring; 1B P24 (Q.ty 4)
127 Bearing spacer (Q.ty 3) 406 Socket bolt; M8X20 (Q.ty 4) 732 O-ring; 1B P18 (Q.ty 2)
141 Cylinder block (Q.ty 2) 407 Socket bolt; M6X55 (Q.ty 3) 774 Oil seal
151 Piston (Q.ty 18) 466 VP plug; PF1/4 (Q.ty 2) 789 Back up ring; P18 (Q.ty 2)
152 Shoe (Q.ty 18) 467 VP plug; PF3/8 (Q.ty 2) 792 Back up ring; G35 (Q.ty 2)
153 Retainer plate (Q.ty 2) 468 VP plug; PF3/4 (Q.ty 4) 806 Nut; M16 (Q.ty 2)
156 Spherical bushing (Q.ty 2) 490 VP plug; NPTF1/16 (Q.ty 4) 808 Nut; M20 (Q.ty 2)
157 Cylinder spring (Q.ty 18) 531 Tilting pin; M24X2 (Q.ty 32) 824 Snap ring (Q.ty 2)
211 Shoe plate (Q.ty 2) 532 Servo piston M24×2 (Q.ty 2) 885 Valve plate pin (Q.ty 2)
212 Swash plate (Q.ty 2) 534 Stopper (L) (Q.ty 2) 886 Spring pin (Q.ty 4)
214 Tilting bushing (Q.ty 2) 535 Stopper (S) (Q.ty 2) 901 Eye bolt M10 (Q.ty 2)
251 Swash plate support (Q.ty 2) 546 Spacer (Q.ty 2) 953 Socket screw; M16X35 (Q.ty 2)
261 Seal cover (F) 548 Feed back pin (Q.ty 2) 954 Set screw; M20 (Q.ty 2)
271 Pump casing (Q.ty 2) 702 O-ring; 1B G35 (Q.ty 2) 04 Gear pump
312 Valve block 710 O-ring; 1B G95 (Q.ty 2) 05 PTO unit
T3-1-4
HYDRAULIC PUMP ASSY E215B-E245B
354
434
351
B3
353 435
312
311
Dr4 a3 A3
728
710 308 850
732 310 309
355
307 434
466
725
Nm
312 M14 x 1.5 29
433 M8 17
434 M8 17
435 M10 33
466 G 1/4 16
SM0748
T3-1-5
E215B-E245B HYDRAULIC PUMP ASSY
125 468
711
118
11 262
728
117
414
126 825
128
710
10 435
12 886
826
SM0749
T3-1-6
HYDRAULIC PUMP ASSY E215B-E245B
Operation
SM0750
ROTARY GROUP
The rotary group consists of shaft (111), cylinder
block (141), piston (151), shoe (152), plate (153),
spherical bushing (156), and cylinder spring (157).
The shaft is supported by bearings (123) and (124) The sub group of the piston-shoe is pressed against
at its both ends. The shoe, which is caulked to the the shoe plate by the cylinder spring, via the retainer
piston, forms a spherical joint and relieves it of thrust plate and the spherical bushing, so that it moves
force that is generated by load pressure. smoothly over the shoe plate. The cylinder blocks
Further, the piston is provided with a pocket so it (141) are also pressed against valve plates (313) or
moves lightly on shoe plate (211), taking hydraulic (314) by the action of cylinder spring (157).
balance.
111
312 313
124
116
124
314
141
157
156
153
151
211
152
SM0245
T3-1-7
E215B-E245B HYDRAULIC PUMP ASSY
251
SM0246
111
885
116
314
141
PTO GROUP
SM0247
The PTO group is composed of 1st gear (116), 2nd
gear (117) and 3rd gear (118). The 2nd and the 3rd
gear are supported by bearings (125) and (126)
117
respectively and installed to the valve block.
Now, if the shaft is driven by the engine, the cylinder
block rotates together by the spline linkage. If the
swash plate is inclined, the pistons arranged in the
cylinder block make reciprocating motion with
respect to the cylinder while rotating with the 126
cylinder block. If we keep an eye on a single piston,
it makes a motion away from the valve plate (oil
suction process) in the first 180° and a motion
toward the valve plate (oil delivery process) in the
remaining 180°. If the swash plate is not inclined 118
125
(zero tilting angle), the piston does not stroke i.e.
delivers no oil.
The shaft rotation is taken up by the 1st gear (116) 125
and transmitted to the 2nd gear (117) and the 3rd
gear (118), in that order, to drive the gear pump that
is linked to the 3rd gear. SM0248
T3-1-8
HYDRAULIC PUMP ASSY E215B-E245B
REGULATOR
Construction
B B- B 418 079
D
541 B
722 543 755 545 439 730 643 924
725 466 755
724 644 645 728 801
708
A -A
734
653 654
897 876 874 755 655 836 651 652 601 624 629 630
A
412 612 858 641 628
814
615 627
802
614
613 753
A
611 756
631
875
898
732 763
733 887
622 621 623 625 626
662 642
466
545 541
543 755
E
755
E- E D- D
496
SM0249
T3-1-9
E215B-E245B HYDRAULIC PUMP ASSY
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
T3-1-10
HYDRAULIC PUMP ASSY E215B-E245B
T3-1-11
E215B-E245B HYDRAULIC PUMP ASSY
T3-1-12
HYDRAULIC PUMP ASSY E215B-E245B
T3-1-13
E215B-E245B HYDRAULIC PUMP ASSY
Pd1
CL
a3
B SM0898
T3-1-14
HYDRAULIC PUMP ASSY E215B-E245B
T3-1-15
E215B-E245B HYDRAULIC PUMP ASSY
T3-1-16
HYDRAULIC PUMP ASSY E215B-E245B
T3-1-17
E215B-E245B HYDRAULIC PUMP ASSY
T3-1-18
HYDRAULIC PUMP ASSY E215B-E245B
250
Q 2000min-1:
(H mode)
200 1800min-1:
(S mode) [2] [1]
150
[3]
Q [ L/min ]
100
50
Q (2000min-1)
0 5 10 15 20 25 30 35 40
Pd [MPa]
250
[4] 91kW : At emergency mode
718mA Input revolution ;2000 min-1
220L Input horse power ;114 kW
Input torque ;544 N.m SM0999
T3-1-19
E215B-E245B HYDRAULIC PUMP ASSY
NOTE:
T3-1-20
PILOT VALVE E215B-E245B
OUTLINE
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
Model PV48K2004
Operating torque Refer to the curve below
Max. primary pressure 6.9 MPa (1000 psi)
Primary pressure 5.0 MPa (725 psi)
Rated flow 20 L/min (5.3gal/min)
Weight Approx. 1.9 kg (4.2 lbs)
A
PORT 1, 3 PORT 2, 4
2.21(1.63) 2.29(1.69)
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
SECONDARY PRESSURE SECONDARY PRESSURE
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
P T
1 3 2 4
HYDRAULIC SYMBOL
SM0591
T3-2-1
E215B-E245B PILOT VALVE
CONSTRUCTION
****312
302
501
***301
*212
213
151
211
214
216- 2 216- 1
241- 2 241- 1
201- 2
201- 1
**217
101 221
Tightening Tightening
No. Parts Q.ty torque No. Parts Q.ty torque
Nm (lbf•ft) Nm (lbf•ft)
101 Casing 1 216-2 Spring seat 2
151 Plate 1 **217 Washer 2 (Shim) 4
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
*212 Push rod 4 ***301 Joint: M14 1 47.1 (34.7)
213 Seal 4 302 Circular plate 1
214 O-ring: 1B P20 4 ****312 Adjust nut: M14 1 68.6 (50.6)
216-1 Spring seat 2 501 Boots 1
T3-2-2
PILOT VALVE E215B-E245B
OPERATION
509
221
201
216
201
PORT (2,4) PORT (1,3)
SM0594
P PORT
T3-2-3
E215B-E245B PILOT VALVE
T3-2-4
PILOT VALVE E215B-E245B
Tightening torque
Port size N.m (lbf.ft) Port name Function
Specifications
P T
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol SM0597
Performance characteristics
Secondary pressure
[MPa (psi)] Secondary pressure
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram SM0598
T3-2-5
E215B-E245B PILOT VALVE
The hydraulic remote control valve in TH6NR type is operated with directly-operated pressure-reducing valve.
The pilot control equipment TH6NR in double foot pedal type is made up of the actuating section which is
equipped with 2 foot supports (1), 4 pressure-reducing valves (11), 4 damper system (12) and body (6).
Every pressure-reducing valve is made up of control spool (2), control spring (3), return spring (4) and plunger
(5).
The damper system is made up of plunger (8), orifice (9) and return spring (10).
In stationary condition, the pedal is held in neutral position by return spring (10).
In operation, the foot pedal pushes the plunger (5) used for pressure-reducing valve and plunger (8) used for
dumper system.
The hydraulic oil fed into damper chamber is restricted in the orifice (9) by the pressure corresponding to the
operating speed. [Similarly, when the foot pedal returns to the neutral position with the return spring, the
hydraulic oil trapped in the damper chamber is forced out. Consequently the return speed is controlled by the
flow rate of hydraulic oil led through orifice (9).]
Simultaneously, the plunger (5) is pushed against return spring (4) and control spring (3). The control spring
(3) first moves the control spool (2) downwards, and then closes the passage between control port and the
return pipe to tank port (T). At the same time, the control port is connected to passage (7). When the control
spool reaches to the position the force of control spring (3) balances the pressure of control port (1 or 2), it
starts retaining the condition.
The pressure of control port is proportional to the stroke of plunger (5) and the position of pedal (1) according
to the mutual relations between the control spool (2) and control spring (3). The closed circuit pressure control
makes proportional control of selector valve and high responsibility of hydraulic pump and motor possible in
relation with the characteristics of foot pedal (1) position and control spring (3)
5
3
8 10
3
11 12
4
10
9
9
7 6
2
SM0599
T3-2-6
CONTROL VALVE E215B-E245B
CONTROL VALVE
PBa2 PAo
PBp1 PBp2
PBp1 PBp2 PAa2
Arm 2 Option
PBo
PBo
PAc PAa1
Bucket Arm 1
PAa
PAb
(P4)
Boom Swing
(P3)
PBr PCa
Travel right P2 unload
(T3)
PTb
Travel priority PBL Travel left
PAa2 PBo
A VIEW A
CT1
T2
P1 unload
PCb PAL PTb
Travel PL
PCb
priority Ar
CMR1 CMR2
USE FOR YN30V00101
PAr Br
PB1 Travel
F1
PBr PAr
1
Ab right
XAb PAb CP1 (HEAD)
PBs Bb Boom
PBb
PBb (ROD)
LCb CRb PC
PCc PBa1 Pss PAc PBc
Ac Bc
(HEAD) (ROD)
LCc Bucket
MU PBa2 PAo PCAP2 LCAT2
PAa2
Arm 2 PBa2
PBp1 PBp2
T3-3-1
E215B-E245B CONTROL VALVE
PTb
PBL
CT2
P2
CP2
CT1
P1
Pcb PAL
T1
T2
CT2 PCb PAL
Travel left PBL
PAL AL BL
CP2 P2 unload
USE FOR YN30V00101
PCa PAr
Boom PB1
F1
PB1 PCa
conflux CCb Bs
PBs As PBs
Swing PAs
Pss Aa PBb
LCs
PCc PBa1 Pss
Arm 1 PLc2 CRa (HEAD)
PBa1 PAa1
Ba
LCa
(ROD) MU PBa2 PAo
PAo Option PBo
Ao Bo
LCo
PBp1 PBp2
(P2)
SM0825
T3-3-2
CONTROL VALVE E215B-E245B
T3-3-3
E215B-E245B CONTROL VALVE
SPECIFICATIONS
Item Specifications
Model KMX15YD/B44041
Maximum flow rate [L/min (gal/min)] 220 (58) 2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 70 2L/min (18.5 2gal/min)]
When power boost pressure 37.8 (5480) [at 60 2L/min (15.9 2gal/min)]
Overload relief valve set pressure
39.7 (5760) [at 30L/min (8gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
Overload relief valve set pressure
37.8 (5480) [at 30L/min (8gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
T3-3-4
CONTROL VALVE E215B-E245B
PBa2 PAo
PBp1 PBp2
PBp1 PBp2
(P3)
(P3) (P4)
(P4)
PAa2 PBo
A
B
273x10 T2
273x10 H
H P1 unload PCb PAL
(Travel priotity) Travel left
C C
USE FOR YN30V00101F1
PAr
PB1 Boom conflux
Travel right (P2 unload)
D D
PBs
Boom Swing
E PCc
PBb
Pss
E
PBa1
Bucket Arm 1
F F
PBa2 PAo
PA
Arm 2 MU Option
G G
K PBp1 PBp2 K
(P3)
B A SM0826
T3-3-5
E215B-E245B CONTROL VALVE
J
154 164 101
P2
T2 T1
PAL JJ PBL
YT1
YBG1
PB1 PCa
P2-20
PBs PAs
YS1
Pss
PBa1 PAa1
YA1
PAo PBo
YP1
SECTION A-A
(P4)
163 162 163 169 155 162
154 164
P1
102
973 973
PTb PCb
P1-20
973 973
PBr PAr
YT1
973
PAb PBb
YB1
973 973
PBc PCc
PAc
YK1
974
973
PAa2 PBa2
YAG
1
974
(P3)
SM0532 162 162 169 155 163 162 SECTION B-B
T3-3-6
CONTROL VALVE E215B-E245B
552
CMR2 551
562 164
562 162
CMR1
BL
552
163
522
512
307
261
331 264
PBL
327 205
329 SECTION C-C
336
331
333 Travel priority
202 PTb
201 Travel right Boom conflux
333 202
331 PAr PB1
333
336 331
324
323 339
326
331 325
261
331
306 261
511
161 521
CCb
163 Ar 551
164
511
305
521
CP1
551 551
164 164
163
Br
161 310
164
154
(T3)
261
264 331
PBr
327
205
329
SECTION D-D 336
331
333
PCa
SM0533 P2 unload 202
T3-3-7
E215B-E245B CONTROL VALVE
Swing 204
203 PBs
Boom 333
333
336 Pss 331
331
336
603 322
211 321 322
AbR
279 x 3 266 321
331
331
215 XAb 261 261
160 303
514 161
524
As 162
CRb
556 Ab
163
164 511
511 523
521 LCs
LCb 556
164
551
Bb 162
164 Bs
161
301
266
264
264
602 PAb
160 PAs
206
205 BbR
SECTION E-E
551 Bucket
164 201
209 333
216 PCc Arm 1 331
333 PBa1 336
331 322
PBc
336
322 321
321 BaR 603
602 BcR 171
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc
LCa
551 551
164 164
Ac
162 Aa
302
161
264 264
603 PAc PAa1 205
205 SECTION F-F 605
AcR AaR SM0534
T3-3-8
CONTROL VALVE E215B-E245B
331 324
261 AoR
323
604
308 MU 331
162
261
162
162 311
511
521 Ao
LCAT2 511
551
164 521
515
LCo
521 551
LCAP2
551 164
164
Bo
162
161
604
BoR
264 264
PAa2 PBo
205 205
SECTION G-G
T2
161
P1
511
T1
521 163
CT1 163
551
162
511
164 P2
521
CT2
551
164
T3-3-9
E215B-E245B CONTROL VALVE
207 266
160
278 x 5 264
264
528
527
T2 518
T1
517
SECTION J-J
PBp1 PBp2
606
606
163
SM0536
SECTION K-K
T3-3-10
CONTROL VALVE E215B-E245B
T3-3-11
E215B-E245B CONTROL VALVE
T3-3-12
CONTROL VALVE E215B-E245B
T3-3-13
E215B-E245B CONTROL VALVE
351 371 361 340 319 308 317 340 361 371 350
SM0829
Arm 2 spool
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
16~18 (33~35)
308 Spool 1 350 Plug 1
Loctite #638
16~18 (33~35)
317 Plunger 1 351 Plug 1
Loctite #638
319 Plunger 1 361 O-ring 2
340 Spring 2 371 Backup ring 2
SM0830
Boom spool
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
16~18 (12~13)
301 Spool 1 350 Plug 1
Loctite #638
317 Plunger 1 361 O-ring 1
340 Spring 1 371 Buckup ring 1
T3-3-14
CONTROL VALVE E215B-E245B
101
171 164
201
321
PLc A B Dr
SM0831
T3-3-15
E215B-E245B CONTROL VALVE
P Pi
T Dr
T3-3-16
CONTROL VALVE E215B-E245B
PBs
555
A
Pss
G1/4
A SECTION B-B
B B
Pss
554
202
PAs
SECTION A-A
SM0833
T3-3-17
E215B-E245B CONTROL VALVE
104
107
102
101
SM0834
T3-3-18
CONTROL VALVE E215B-E245B
2 12
3 11
10
9
6
7
SM0835
T3-3-19
E215B-E245B CONTROL VALVE
OPERATION
1. In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through
unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic
tank through tank port T1. And when the operation of unloading valve is impossible due to failure of electric
control system, because the by-pass cut valve (606) located on the downstream of center by-pass
passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through travel priority spool
(306), and then flows though the center by-pass passage (52) which passes through travel right, boom,
bucket and arm 2 and the by-pass cut valve (606) on P1 side, and flows into low pressure circuit (D) and
boost check valve (517), and then returns to the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure
circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to
the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is impossible,
because the by-pass cut valve (606) located on the downstream of center by-pass passage (55) opens,
the hydraulic oil through hydraulic pump P2 port passes through main passage, and then flows though the
center by-pass passage (55) which passes through travel left, swing, arm 1 and option and the by-pass
cut valve (606) on P2 side, and flows into low pressure circuit (D) and boost check valve (517), and then
returns to the hydraulic tank through tank port T1.
(D)
606
Pss
517 52
306
YA1 YBG1
T1
P2
P1
309
310 606
55
(*)
(D)
SM0836
In neutral position
(*) Connected to low pressure circuit of P2 side casing
T3-3-20
CONTROL VALVE E215B-E245B
A B
AL BL
CP2
324 323 306
PBL
PAL
SM0837
T3-3-21
E215B-E245B CONTROL VALVE
CMR2 CMR2
P2 P2
B B
CMR1 CMR1
P1 P1
A A
307 307
327 327
329 329
PTb PTb
P2 P1 P2 P1
PTb PTb
Dr Dr Dr Dr
A
B A
B
SM0838
A - to each actuator
B - to travel right
Movement of travel priority spool
T3-3-22
CONTROL VALVE E215B-E245B
216 53
PAc
PBc
PCc
Bc Ac
LCc
322 321 304 (D) 511
T3-3-23
E215B-E245B CONTROL VALVE
53 (D*)
216
PAc
PCc
PBc
Bc Ac
LCc
322 321 304 511
(R) (H)
SM0840
T3-3-24
CONTROL VALVE E215B-E245B
4. Boom
a) In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves
rightward against the force of springs (321) (322), and simultaneously the secondary pressure of
solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309).
And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of
springs (325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa
and switches unloading spools (310).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens
load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing
through U-shaped passage, and supplied to the both boom cylinders head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter
of boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517),
and returns to the hydraulic tank through tank port T1.
(R) (R)
(H) (H)
Bb LCb CRb
Ab
PAb PBb
SM0841
(A): BH chamber
In boom up operation (Boom spool)
T3-3-25
E215B-E245B CONTROL VALVE
PB1
326
325
511
CCb
(B)
305 56 SM0842
T3-3-26
CONTROL VALVE E215B-E245B
(R) (R)
(H) (H)
LCb CRb
Bb Ab
PAb PBb
(D) SM0843
(A): BH Chamber
In boom down operation
T3-3-27
E215B-E245B CONTROL VALVE
5. Arm operation
a) In arm out operation
On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302)
moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure
of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs
(321) (328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and
switches unloading spools (309).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens
load check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool
(302) and casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass
passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage,
and pushes and opens load check valve LCAP2 (515) provided with orifice, and flows into U-shaped
passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and
casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil
from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side
(R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of
arm 1 spool (302) and casing and passes though low pressure circuit (D’) and casing inside passage
(HH) and then flows into low pressure circuit (D’) through between the perimeter of arm 2 spool (308)
and casing.
The return oil in low pressure circuit (D’) returns to hydraulic tank through tank port T1 without passing
through boost check valve (517).
(R) (H)
322 321 211 (AR) 514 302
511
CRar Ba LCa Aa
56
PBa1 PAa1 P1 LCAT2
(D')
LCAP2
Arm 1 (D)
RH (D') P1
RR HH PAa2
52 PBa2
(D') Dr Dr
Arm 2
(F)
PBa2 PAa2 Ba
(ROD) Aa (HEAD)
53 (G)
MU
AP2
LCAT2 LCAP2
328 321 308 511 515 SM0844
T3-3-28
CONTROL VALVE E215B-E245B
T3-3-29
E215B-E245B CONTROL VALVE
(R) (H)
56
PBa1 PAa1
Arm 1
(D')
RR RH HH
(D) 52
Arm 2 (a)
PBa2 PAa2
[XR]
53
MU
LCAT2 LCAP2
328 321 308 319 (D) 511 515 317
P1
(D') LCAT2
LCAP2
(D)
P1
PAa2 PBa2
Dr Dr
(F)
Aa (Head)
Ba
Circuit (I) (Rod)
(G) SM0845
T3-3-30
CONTROL VALVE E215B-E245B
(R) (H)
322 321 211 (AR) 514 302
CRar 511 LCa
Ba Aa
Circuit (II)
56
PBa1 PAa1 P1 LCAT2
(D') LCAP2
Arm 1 (D') (D)
P1
(D) RR 52 RH HH PAa2 PBa2
Dr Dr
Arm 2 (a) (F)
PBa2 PAa2 Aa(Head)
Ba
[XR] (Rod)
MU 53
(G)
LCAT2 LCAP2
T3-3-31
E215B-E245B CONTROL VALVE
6. Swing operation
On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves
leftward or rightward against the force of springs (321) (322), and simultaneously the secondary pressure
of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through
shuttle valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot
pressure acts on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and
then is led to port Pss.
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load
check valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through
U-shaped passage and is supplied to swing motor A side or B side through port (As) or (Bs).
In the meantime, the return oil from swing motor A side or B side passes through between the perimeter
of swing spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and
boost check valve (517), and then returns to the hydraulic tank through tank port T1.
204
PAs
PBs
Pss
Bs As
LCs
B A
Swing motor
SM0847
Swing operation
T3-3-32
CONTROL VALVE E215B-E245B
Ao LCo Bo
(O)
AoR
BoR
56
PAo PBo
(D) SM0848
T3-3-33
E215B-E245B CONTROL VALVE
CRb
Ab
(a) (b)
321
PLc Sa Sb Dr
A A
SECTION A-A
Sa
321 322
PBb
T3-3-34
CONTROL VALVE E215B-E245B
CRb
(a) (b)
Ab
321
PLc Sa Sb Dr
A A SECTION A-A
Sa
321 322
PBb
T3-3-35
E215B-E245B CONTROL VALVE
[X1]
PBp1
301 302
(C) (b)
Dr 101
201 (a)
(D)
52
SM0969
T3-3-36
CONTROL VALVE E215B-E245B
PBp1
301 302
(C) (b)
Dr 101
201 (a)
(D) 202
52
SM0970
T3-3-37
E215B-E245B CONTROL VALVE
527
528
(D') T2
518
T1
102
1
517 (D) 528
527
T2 518
102
T1
517
(D) 2
SM0971
1. In normal operation
2. In make up operation
Boost check valve operation
T3-3-38
CONTROL VALVE E215B-E245B
527
528
(D')
T2
518
T1
102
517 (D)
SM0992
T3-3-39
E215B-E245B CONTROL VALVE
T3-3-40
CONTROL VALVE E215B-E245B
(R)
1
(H)
2
Ab
XAb 5
9
SM0993
T3-3-41
E215B-E245B CONTROL VALVE
NOTE:
T3-3-42
SWING DEVICE E215B-E245B
OUTLINE
General view
THREAD FOR
M L EYE BOLT 2-M10
PB DEPTH 18
B RELIEF VALVE
(B PORT SIDE)
(SH)
IP
PG
RELIEF VALVE
A (A PORT SIDE)
DB
PA
SM0570
Tightening torque
Symbol Port name Port size
Nm (lbf•ft)
A, B Main port PF 3/4 167 (123)
T3-4-1
E215B-E245B SWING DEVICE
ANTI-REACTION
PB PA VALVE BLOCK
M DB
A,(B)
PG
IP
FILLING PORT
PT3/4
Grease
fitting
SM0571
PG
DB
PA PB
A B
Hydraulic diagram SM0572
T3-4-2
SWING DEVICE E215B-E245B
Specification
Model M5X130CHB–10A–41C/295
Swash-plate type, fixed-displacement plunger
Type
motor
Displacement cm3 129.2
Hydraulic motor
Working pressure MPa 32.4
Max. flow L/min 220
Braking torque Nm 655
Release pressure MPa 2.5~5.0
Relief set pressure MPa 29
Mass kg 49
T3-4-3
E215B-E245B SWING DEVICE
CONSTRUCTION
Swing motor
993
702 712
ANTI
CAVITATION
PLUNGER
351 Arrangement of brake spring
355
051 RELIEF VALVE
469
051-1
488 ANTI-REACTION
VALVE BLOCK 401
052 151
303 162 171 161
985
163 985 444 984 131 451
712 A A
472 390 391
VIEW I
702
707
706
100
980
743
742
400-1
111
400-2 052
121
400
123 994 SECTION A-A
122
114 301
124 443 491 101
SM0573
T3-4-4
SWING DEVICE E215B-E245B
Tightening Tightening
torque torque
No. Parts Q.ty No. Parts Q.ty
Nm Nm
(lbf•ft) (lbf•ft)
051 Relief valve; M33-P1,5 2 177 (130) 400 Anti-reaction valve; M22-P1.5 2 69 (51)
391 Rivet 2
T3-4-5
E215B-E245B SWING DEVICE
31
Install the filling port 27 Apply seal tape or
of this fitting toward Loctite #577.
motor side. 24
13
32
Fill up this space
with grease.
11
30
21
1
SM0574
Tightening Tightening
torque torque
No. Parts Q.ty No. Parts Q.ty
Nm Nm
(lbf•ft) (lbf•ft)
1 Pinion shaft 1 17 Needle bearing 4
2 #1 sungear 1 18 Washer 8
3 #1 pinion 3 19 Retaining ring 1
4 #2 sungear 1 20 Retaining ring 1
5 #2 pinion 4 21 Sleeve 1
6 Ring gear 1 22 Spring pin 4
7 Spider assy 1 23 Capscrew; M14X135 11 181 (134)
8 Spider 1 24 Cap 2
9 Shaft 4 25 Tube L=112 1
10 Spherical bearing 1 26 Elbow 1
11 Spherical bearing 1 27 Plug 1 69.1 (51)
12 Oil seal 1 28 Retaining ring 3
13 Housing 1 30 Oil seal 1
15 Thrust washer 6 31 Grease fitting 1
16 Needle bearing 3 32 Relief fitting 1
T3-4-6
SWING DEVICE E215B-E245B
HYDRAULIC MOTOR
Operation
If the high pressure oil flows into the cylinder
through the inlet port (a) of valve plate (131), as
shown on the figure on the right, the hydraulic
Cylinder block (111)
pressure acts upon piston (121) and creates force F
in the axial direction.
The force F may be divided into force F1 vertical to F2
shoe plate (124) via shoe (122) and force F2 at right F1
angles with the shaft. F
The force F2 is transmitted to cylinder block (111)
via pistons (121) and causes drive shaft to turn so
as to produce a rotating moment. Drive shaft (101)
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to drive
shaft by turns by pistons connected to inlet port of
high pressure oil.
If the oil supply and discharge directions are Valve
reversed, the drive shaft rotates in the opposite plate
direction. Shoe Shoe Piston (131)
Theoretical output torque T can be given by the plate (122) (121)
(122)
following equation. SM0575
PXq
T=
2X Low pressure oil High pressure oil
SM0576
T3-4-7
E215B-E245B SWING DEVICE
M port
Operation of relief valve
(Make-up port)
1. Consider where the relief valve is pressurized.
The pressure at the P, R ports is equal to the
tank pressure at the beginning, as shown in Fig.
SM0578.
The relief valve begins to operates when the DIRECTIONAL VALVE
hydraulic pressure that is determined by the SM0577
product of the pressure-receiving area A1 of
plunger (301) and the pressure P balances the
hydraulic pressure that is determined by the
Chamber h
product of the pressure-receiving area A2 of
Orifice m Spring (321) Piston 1 (302)
the plunger (301) and the pressure Pg of
chamber g.
Thereafter, the pressure of chamber g rises and
the piston 1 (302) begins to stroke. The load to P
spring (321) increases by this movement of the
piston. R
Pressure Chamber g
As the result, the relief pressure P is raised and receiving A3 A2
area A1 Plunger (301) A4
controlled in the pressure boost time t1 from P1 Orifice n
till Ps. SM0578
This process is explained in the following in the
relationships between the movements of the
components and the relief pressure:
a) Condition shown in Fig.SM0579. Chamber h
Orifice m Spring (321)
If the P port of the relief valve is pressurized, Pin (303) Piston 1 (302)
pressure is built up in chamber g via the
restrictor m of plunger (301).
The hydraulic pressure acting on plunger P
(301) increases and when it balances the
load Fsp of spring (321), the relief valve R
performs relieving action by the pressure Orifice n
Chamber g
Plunger (301)
P1.
This relationship is expressed as: SM0579
P1×A1=Fsp1+Pg1×A2
where Fsp1:
primary set load value of spring (321).
T3-4-8
SWING DEVICE E215B-E245B
T3-4-9
E215B-E245B SWING DEVICE
c) At anti-reaction action
When inertia load stops moving (point Y Fig.
k
SM0587), brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward 322 313 321 311 SM0584
the right return side by the action of spring
(321). Seat (313) tries to move to the right by
m n
the action of spring (322), but since
chamber p provides damping action by
orifice g, the return of the seat makes a time
P=PS
delay with regard to the return of the
plunger. L
Consequently, seat t opens. This makes a
passage connecting the AM port and BM
ports or both ports of the hydraulic motor by 322 313 321 311
SM0585
way of t r k. The result is that the
pressures at the AM and BM ports become
equal (Pb), falling into the condition at point p t
Z in Fig.SM0582. This prevents the
hydraulic motor from swing shock by the
closing pressure of the AM port. P<PS
k
322 313 g r 321 311
SM0586
P Y
PS
PB
X
Z
T
SM0587
T3-4-10
SWING DEVICE E215B-E245B
BRAKE SECTION
Operation
The cylinder (111) is jointed by drive shaft (101) and
a spline. Separator plate (743) is fixed in its
712
circumferential direction by circular grooves
provided in casing (301).
Now, if the friction plate (742) splined to the outer
circumference of the cylinder is pressed against 702
casing (301) via separator plate (743) and brake
712 743
piston (702) by the action of brake spring (712),
frictional force is created between friction plate (742) 742
and casing (301) and between separator plate (743) 702
and brake piston (702). The frictional force bounds
111 301
the drive shaft to brake the motor.
In the meantime, when brake release pressure 743 742 101
301
applied to the oil chamber formed between brake SM0588
piston (702) and casing (301) overcomes the spring
force, the brake is released as brake piston (702)
moves till friction plate (742) is separated from
casing (301).
T3-4-11
E215B-E245B SWING DEVICE
Operation
The swing reduction unit is used to reduce the
rotating speed which is transmitted by the hydraulic Ring gear (Fixed) Planetary shaft
motor and to convert it to the strong turning force
(torque).
This swing speed reduction unit is equipped with
planetary speed reducing mechanism. Spider
The planetary mechanism is made up of sun gear,
planetary pinion, planetary shaft, spider and ring Sun
gear, as shown in in Fig.SM0589. gear
For the operation of the 1st stage planetary, the
hydraulic motor rotates #1 sun gear (2). Sun gear
(2) is engaged with planetary pinion (3) and rotates,
but since ring gear (6) is fixed, planetary pinion (3)
revolves about sun gear (2) with the planetary shaft
and spider (7).
Planetary pinion
SM0589
The role of spider is to hold the planetary pinion and
planetary shaft and transmits the power from the
planetary pinion to the spider through the planetary
shaft.
The #1 spider (7) is linked with #2 sun gear (4) by Swing motor
the involute spline, and transmits the power to the
2nd stage planetary mechanism. 3 2
For the operation of the 2nd stage planetary, the 6
power is transmitted to sun gear (4) planetary
pinion (5) spider (8) similarly to the 1st stage.
7
The #2 spider (8) is linked with pinion shaft (1) by the
involute spline, and pinion shaft (1) is engaged with 4
the swing gear fixed on the undercarriage (lower
frame) and rotates. 8
13
5
10
11 1
SM0590
T3-4-12
TRAVEL DEVICE E215B-E245B
OUTLINE
Characteristics
Model 710 C3 K
T3-5-1
E215B-E245B TRAVEL DEVICE
Ports E215B
SM0551
T3-5-2
TRAVEL DEVICE E215B-E245B
Ports E245B
P1
T
Ps Pm1
Tin
Pm2 P2
Pp
1 A
2 SM0552
T3-5-3
E215B-E245B TRAVEL DEVICE
Ps Pm2
T
P2
P1
Pp
Pm1 SM0553
Ps Pm2
P2
R/G
P1
Pp
T3-5-4
TRAVEL DEVICE E215B-E245B
Direction of rotation
When assembling the track drive on the machine and connecting the hoses, follow instructions shown in below
sketch for proper direction of rotation
SM0555
COSTRUCTION
Track drive E215B
SM0556
1- Hydraulic motor
2- Reduction stages
T3-5-5
E215B-E245B TRAVEL DEVICE
3
7 4
6
5
SM0557
Brake
The track drive is supplied with a safety negative
disc brake fitted into the hydraulic motor (parking
brake).
Parking brake release is automatically operated
when high pressure oil is supplied to one of the two
ports of the hydraulic motor. For this reason, there is
no need of brake external pilot.
The brake technical data are shown on the track
drive installation drwing.
T3-5-6
TRAVEL DEVICE E215B-E245B
SM0558
T3-5-7
E215B-E245B TRAVEL DEVICE
SM0559
T3-5-8
TRAVEL DEVICE E215B-E245B
T3-5-9
E215B-E245B TRAVEL DEVICE
NOTE:
T3-5-10
SWIVEL JOINT E215B-E245B
OUTLINE
General view
E
A
F B
D
VIEW Y
VIEW Z
Z
SM0568
Specifications
Working pressure 34.3 MPa
High pressure ports A,B,C,D Max. impact pressure 51.5 MPa
Rated flow 255 L/min
Working pressure 0.49 MPa
Low pressure ports E
Rated flow 50 L/min
Working pressure 5 MPa
Low pressure ports F
Rated flow 30 L/min
Revolution 15 min-1
A,B,C,D (body) PF 1
A,B,C,D (stem) PF 3/4
Ports size
E PF 1/2
F PF 1/4
Length (height) 368 mm
Weight 24.5 kg
T3-6-1
E215B-E245B SWIVEL JOINT
CONSTRUCTION
E
2
H
C
13
D
H
6 E
A
1
B
D
VIEW Y
C
B 12
F
A
5
7
9 SECTION HH
3
E E 8
SM0569
1- Body 7- O-Ring
2- Stem 8- Capscrew; M8x20 (Q.ty 2) 30.4 Nm
3- Thrust plate 9- Capscrew; M8x30 (Q.ty 3) 30.4 Nm
4- Cover 12- Plug
5- Seal (Q.ty 5) 13- O-Ring (Q.ty 2)
6- Seal
T3-6-2
SWIVEL JOINT E215B-E245B
OPERATION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both
components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and
seal assy (6) and O-ring (7) that prevent external leaks.
Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves
are arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove.
The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2) keeps on flowing to
stem (2) or body (1) past the circumferential groove between body (1) and stem (2); the oil flow is never shut
off because of rotation. Further, an oil groove for lubrication that connects with the drain port is provided, in
order to prevent the body (1) from seizure with the stem (2).
This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.
T3-6-3
E215B-E245B SWIVEL JOINT
NOTE:
T3-6-4
CYLINDERS E215B-E245B
OUTLINE
General view
B
gth
l en
ed A
nd gth
e xte l en
lly te d
Fu ac
retr
ll y
Fu
SM0560
Specifications
Center
distance of
Cylinder bore Dry
Stroke pins
Use Rod Dia. Cushion weight
Full extend B /
Full retract A
(mm) (mm) (mm) (kg)
With cushion
Boom Ø 120 / Ø 85 1345 3200 / 1855 176
on rod side
With cushion
Arm Ø 135 / Ø 95 1558 3637 / 2079 255
on both sides
With cushion
Bucket Ø 120 / Ø 80 1080 2684 / 1604 153
on rod side
T3-7-1
E215B-E245B CYLINDERS
CONSTRUCTION
Boom cylinder
27 26 12 24 25
B
105 -0.5
105 -0.5
0
0
PT 1/4 28
28
SLIT
With hole
GREEN BLACK (1 place)
DETAIL 6 DETAIL B DETAIL C
9 8 7 6 4 5 3 11 10 2 1 13 14 15 17 16 18 19 20 21 22 23
SLIT
C Orientation of cut off part
of cushion bearing (13)
SM0561
T3-7-2
CYLINDERS E215B-E245B
Arm cylinder
27 26 12 26 27
B
120 -0.5
120 -0.5
0
0
PT 1/4
PS 1/8
SLIT
With hole
GREEN BLACK (1 place)
DETAIL 6 DETAIL B DETAIL C
9 8 7 6 3 4 5 11 10 2 1 13 14 15 16 17 18 19 20, 21 25
22
23 24
C SLIT
SM0562
T3-7-3
E215B-E245B CYLINDERS
Bucket cylinder
25 24 12 24 25
107 -0.5
107 -0.5
0
0
27
26
SLIT
With hole
GREEN BLACK (1 place)
DETAIL 6 DETAIL B DETAIL C
9 8 7 6 3 4 5 10 11 2 1 13 14 15 16 17 18 19 20 21 22 23
C SLIT
SM0563
T3-7-4
CYLINDERS E215B-E245B
Positioning
23 22 12 22 23
B
123 -0.5
128 -0.5
0
0
PT 1/4
24
SLIT
With hole
GREEN BLACK (1 place)
DETAIL 6 DETAIL B DETAIL C
9 8 7 6 3 4 5 10 11 2 1 13 14 15 16 17 18 19 20 21
SM0564
T3-7-5
E215B-E245B CYLINDERS
Operation
SM0566
T3-7-6
CYLINDERS E215B-E245B
CLEARANCE “D”
CHAMBER “A”
SM0567
T3-7-7
E215B-E245B CYLINDERS
NOTE:
T3-7-8
AIR CONDITIONER SYSTEM E215B-E245B
Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and an
inside /outside air switching unit. And this unit changes hot air to cool air.
AIR CYCLE
• Heater
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange
is performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from
grille through duct.
• Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange
is performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled
air blows off from grille through duct.
• Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine
flows in the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the
operation is controlled by air mixing damper on the air-con unit.
T3-8-1
E215B-E245B AIR CONDITIONER SYSTEM
25.0℃ COMPRESSOR
REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH
EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL
SM0024
T3-8-2
AIR CONDITIONER SYSTEM E215B-E245B
COMPONENT
27
33 30
27-1
40
32
39
27-6
27-3 27-5
27-2
35
35-7 35-6
35-1
35-2 35-5
34 35-8
35-10 35-9
SM0025
T3-8-3
E215B-E245B AIR CONDITIONER SYSTEM
CONSTRUCTION
(1) Air conditioner unit
49
48
6
47
46
44
31
42 31
41
50 F
3 1
45 1
43
32 G
1
1
28 1
39
37
38
B
36
27
H
9
40
A I
2
33
SM0022
T3-8-4
AIR CONDITIONER SYSTEM E215B-E245B
14
1 1 31 16
1 5
15
31
1
3
1 61
F 1
C 1
D
4
7
G
1 1
1
26 20 13
59
29
11
21 23
22
H
24 1
B
1
8 60
D
17
18 A
I
C
10
31
19
12
1
3
31 25
52
SM0021
T3-8-5
E215B-E245B AIR CONDITIONER SYSTEM
Receiver dryer
1 - Pressure switch
2 - Sight glass
A 2 B
3 - Desiccant
4 - Suction pipe
5 - Filter
6 - Receiver tank
A - Refrigerant INLET
B - Refrigerant OUTLET
2 -M6
1
3
4
SM0037
T3-8-6
AIR CONDITIONER SYSTEM E215B-E245B
FUNCTION
Mechanism of cooling circuit
MECHANISM OF COOLING
In the cooling process, the refrigerant that flows HFC-134a (R134a)
through the cooling circuit changes its phases from CH2FCF3
Chemical formula
liquid to gas and vice versa during which process
heat is transferred from the low temperature part Molecular weight 102.03
(compartment) to the high temperature part (outside Boiling point –26.19 °C
of the vehicle). Critical temperature 101.14 °C
Critical pressure 4.065 MPa
Kind of Refrigerant Critical density 511 kg/m3
Many kinds of refrigerants that change in that way Density of saturated liquid (25 °C) 1206 kg/m3
are available, but the following requirements are
Specific volume of saturated
needed for use in such applications: vapor (25 °C) 0.0310 m3/kg
• Latent heat of vaporization (heat of vaporization)
Latent heat of vaporization (0 °C) 197.5 kJ/kg
is large.
Flammability Non flammable
• It is easy to liquefy (condense). (It does not
require very high pressure for condensation.) Ozone destruction coefficient 0
• It is easy to gasify (evaporate). (It evaporates
sufficiently at not too low pressure, i.e. cools
down an object.)
• It has small specific heat. (Since the refrigerant
itself is cooled by the expansion valve, the loss
resulting from it must be held down to a
minimum.)
• It has a high critical temperature and a low
solidification point.
• It is stable chemically and does not corrode and
permeate into the circuit parts.
• It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
• It has small specific volume.
• It is easy to find out leakage.
Out of refrigerants meeting the above-mentioned
requirements, ones having characteristics that suit
the intended cooling unit are chosen and used. If a
refrigerant other that those designated is used,
sufficient refrigeration will not be performed or the
equipment in which the refrigerant is used may be
broken. Therefore, always use a designated
refrigerant for the cooling unit.
Table shows the principal characteristics of the P (MPa)
R134a refrigerant that is used in this machine. 4 R134a
CHARACTERISTICS OF REFRIGERANT
3
In general, the fluid (general term of gas and liquid)
has the following qualities:
2 LIQUID
1. As a gas under certain pressure is cooled down,
it begins to condensate at a certain temperature GAS
to take a liquid state. The temperature at which 1
condensation begins is unique to each
substance (fluid) at a given pressure. The
temperature determined by a given pressure is 0 15 18 35 50 T (°C)
called saturation temperature. SM0038
T3-8-7
E215B-E245B AIR CONDITIONER SYSTEM
Cooling circuit
The figure illustrates the cooling circuit of the car air-
conditioner.
In this circuit diagram, the portion that cools the air
of the compartment is the evaporator. The object air
is cooled off by utilizing the fact that the refrigerant
takes heat off the surrounding area as evaporation
heat as it evaporates in the cooling circuit. Since the
part at which vaporization of the refrigerant takes
place is the evaporator, cooled air is constantly
delivered to the circumference of the evaporator by
the blower fan. In the meantime, liquid refrigerant
(slightly wet vaporized refrigerant) is fed into the
evaporator, when "cooling" effect is attained. For
instance, in order to cool the air to 15 °C, the
refrigerant can not absorb evaporation heat from the
air unless it evaporates at a temperature lower that Furthermore, the cooling effect deteriorates unless
15 °C. For that purpose, it can be seen from the the feed rate of the refrigerant is controlled so that
figure that the pressure of the refrigerant in the all of the refrigerant supplied to the evaporator
evaporator must be less than 0.51 MPa. vaporizes and turns into dry vapor.
T3-8-8
AIR CONDITIONER SYSTEM E215B-E245B
Component parts
EVAPORATOR
The evaporator is an important heat exchanger that
absorbs the heat of the compartment air (object) by 1
the utilization of the latent vaporization heat of the
low-temperature, low-pressure liquid-state
refrigerant. Therefore, it is necessary that
satisfactory heat transfer between the object and
the refrigerant take place in the evaporator.
To that end, the evaporator is equipped with fins on
the air side in order to increase the heat transfer
area of the air side and thereby perform excellent
thermal transfer between the refrigerant and the air. 2
The humidity in the air condenses as the air cools
down and adheres to the outside of the evaporator
as water drops. The cooling effect deteriorates if the
water drops freeze. Therefore, how to discharge
water is an important point. 3
The amount of refrigerant supplied to the evaporator
is controlled by the expansion valve which is
described in the following. In order to attain proper
control, it is necessary to reduce the pressure drop 4
of the refrigerant of the evaporator. Accordingly, SM0026
reducing the pressure drop is one element that 1 - Evaporator
makes the evaporator attain its full performances. 2 - O-ring
3 - Expansion valve
EXPANSION VALVE 4 - Socket bolt M5 x 40
T3-8-9
E215B-E245B AIR CONDITIONER SYSTEM
T3-8-10
AIR CONDITIONER SYSTEM E215B-E245B
COMPRESSOR
The compressor performs the following three
functions in the cooling circuit: 1
1. Suction action
2. Pumping action
3. Compressive action
2
1. The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling effect.
2. The pumping action serves to cause all the
refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling. 3
3. The compressive action, as combined with the
action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as the SM0042
CONDENSER
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure by
the use of outer air and condenses the refrigerant.
The direction in which heat moves is from the
refrigerant to air, the opposite to the case of the
evaporator. Fins are equipped on the outer air side
to improve thermal transfer. If the refrigerant is not
cooled well by the condenser, the air in the
compartment can not be cooled sufficiently by the
evaporator. For that purpose, it is necessary to
secure ventilation required for the cooling of the
refrigerant.
SM0023
T3-8-11
E215B-E245B AIR CONDITIONER SYSTEM
RECEIVER DRYER
1. Receiver Tank
On the air-conditioner, the revolution of the 1 2
compressor varies greatly which causes the
proper flow of refrigerant in the cooling circuit to 3
vary. It is the receiver tank that receives the
variations. When the cooling circuit does not
need much refrigerant, the receiver tank stores
extra refrigerant temporarily and supplies it
when the cooling circuit needs much
refrigerant. The receiver tank also stores an
4
extra amount of refrigerant to be used for filling
balance and supplement small amounts of
leakage of the refrigerant through penetration
into rubber hoses.
2. Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil,
corrodes the metallic parts of the circuit or clogs 5
the circuit as the water freezes in the expansion
valve. It is desirable that the amount of water 6
mixed in the refrigerant should be held below a
concentration of 30ppm. The air-conditioner
uses a molecular sieve as desiccant suited for
7
the circuit, in order to absorb water content that
intrudes into the circuit when the dryer is
installed or when refrigerant is charged.
3. Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the 8
only means of confirming the inside of the
circuit visually.
4. Filter
5. Pressure Switch
This machine employs pressure switches of
high/low pressure type. SM0043
The pressure switch protects the circuit by 1 - Refrigerant inlet
cutting off the power supply to the compressor 2 - Sight glass
when high pressure increases abnormally high 3 - Refrigerant outlet
(more than 3.14 MPa). 4 - Pressure switch
The pressure switch also detects the leakage of 5 - Desiccant
refrigerant by cutting the power supply to the 6 - Suction pipe
7 - Filter
compressor when the pressure of the circuit
8 - Receiver tank
falls below 0.196 MPa.
T3-8-12
AIR CONDITIONER SYSTEM E215B-E245B
PRECAUTIONS TO BE EXERCISED IN
OPERATION
1. Special Refrigerator Oil
Unit: N·m (lbf·ft)
This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils TIGHTENING
PIPE FASTENING PART
TORQUE
other than SP20 may not be used. Since SP20
tends to absorb moisture and may corrode D hose and compressor (M8 bolt) 19.6~24.5 (14~18)
paint and resin, the following points must be D hose and condenser 19.6~24.5 (14~18)
noted:
L hose and condenser 11.8~14.7 (8.7~11)
1) Do not keep open all pipe connections on a
new compressor and the component parts L hose and receiver dyer (M6 bolt) 7.8~11.8 (5.8~8.7)
of the installed refrigeration circuit L hose and air-conditioner unit 11.8~14.7 (8.7~11)
(Remove valves and caps at the pipe
openings of the compressor, just before S hose and air-conditioner unit 29.4~34.3 (22~25)
connecting pipes. If you have removed a Expansion valve 1.96~2.45 (1.4~1.8)
pipe joint for repair, put a cap to both ports
immediately.)
2) Use care so SP20 does not adhere to the
painted surface and resin parts. In case Unit: N·m (lbf·ft)
SP20 has adhered to such surfaces, wipe it TIGHTENING
off immediately. SCREW SIZE
TORQUE
2. The receiver dryer is filled with desiccant to N4, T4 machine screw, M4 0.78~1.18 (0.58~0.87
absorb moisture in the circuit. Therefore,
remove the valve at the pipe port immediately N5, T5 machine screw, M5 1.96~2.45 (1.4~1.8)
before connecting pipes. M6 (mounting part of L hose
7.85~11.8 (5.8~8.7)
joint)
3. Tightening Torque
M6 (except mounting part of L
1) Pipe Joints 9.8~11.8 (7.2~8.7)
hose joint)
When connecting pipe joints, coat the O-ring
M8 (mounting part of S,D hose
with special oil (SP20) and fasten to the 19.6~24.5 (14~18)
joints)
tightening torque indicated in the table,
using a double spanner. M8 (mounting part of A/C unit) 9.8~11.8 (7.2~8.7)
2) Screws and Bolts M8 (other than those mentioned
11.8~15.7 (8.7~12)
Fasten to the tightening torque indicated in above)
the table M10 39.2~53.9 (29~40)
4. Amount of Oil for Compressor
The compressor SD7H (HD type) is filled with
135cc (8.2cu•in) of oil. If the oil volume is small,
seizure at high revolution and shortening of REPLACED PARTS AMOUNT TO BE FILLED IN
service life will occur. If the oil volume is large, EVAPORATOR 40 cc (2.4cu·in)
the cooling ability will be deteriorated.
Once the air-conditioner is operated, part of the CONDENSER 40 cc (2.4cu·in)
oil is dispersed in the refrigeration circuit.
Therefore, when replacing the parts in right Drain out the volume of oil left in
Table, adjust the oil level to that of table. COMPRESSOR the compressor to be replaced,
from the new compressor.
5. Before performing operation, stop the engine
and turn off all power supplies to the equipment
related to the air-conditioner. RECEIVER DRYER 20 cc (1.2cu·in)
6. After the operation is over, confirm that all faults HOSES 20 cc (1.2cu·in)
have been repaired completely, by operating
the air-conditioner.
T3-8-13
E215B-E245B AIR CONDITIONER SYSTEM
SM0027
2b
10
2a
SM0029
T3-8-14
AIR CONDITIONER SYSTEM E215B-E245B
14 15
SM0030
SM0032
T3-8-15
E215B-E245B AIR CONDITIONER SYSTEM
34
35 SM0035
T3-8-16
AIR CONDITIONER SYSTEM E215B-E245B
38
SM0036
T3-8-17
E215B-E245B AIR CONDITIONER SYSTEM
CHARGING REFRIGERANT
WARNING
• Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
• The refrigerant in liquid state is at very low temperature [approx. -26°C (-15°F)]. Therefore, handle
it with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
CAUTION
• Be careful about overcharge of gas
• Fasten pipes to a specified torque
T3-8-18
AIR CONDITIONER SYSTEM E215B-E245B
OPERATING PROCEDURE
The change of refrigerant in the air conditioner - The "gas charging procedure" consists in the filing
requires a "vacuum generation procedure" and a the circuit with refrigerant, after applying a
"gas charging procedure". vacuum. the filling of the gas is not only depending
upon the cooling performance of the air
- The "vacuum generation procedure" consists in conditioner, but it influences also the useful
removing moisture from the air conditioner circuit. working life of the circuit components. An
In the event even a small quantity of moisture excessive overloading increases considerably the
remains in the system, it would freeze in the small pressure of the system and damages the cooling
orifices of the expansion valve when in operation. performance. On the contrary, a too low charging,
This causes a clogging of the circuit or the results in an insufficient circulation of lubricant oil
formation of rust, with a series of operational in the compressor, causing the wear of the moving
troubles. prior to filling the circuit with refrigerant, parts of the compressor.
apply the vacuum and cause the boiling and
vaporisation of the moisture. In this manner, WARNING
moisture is eliminated from the system.
The gas filling operation involves the handling of
highly compressed gases; it is dangerous to handle
the gas without complying strictly with the relevant
procedures. The procedures and the protections
described in this manual for the filling of refrigerant
gas must be strictly adhered to.
Lower than
-750m mHg Gauge indicates
abnormality
Charge refrigerant gas to a gauge
Check and correct joints pressure of 0.1 MPa
SM0194
T3-8-19
E215B-E245B AIR CONDITIONER SYSTEM
6 5
WARNING
Never exchange by mistake the high pressure pipe 4
with the low pressure pipe when connecting them.
Install the pipe firmly until a click noise is heard. D
Connect the quick release joint of the charging pipe
with the service valve of the compressor. If the
charging pipe is connected in the opposite direction, S
mini-valve (9) of the compressor fails to open.
8 7
3. Connect the central valve of the gauge manifold
SM0016
with charging pipe (4) of the vacuum pump (7).
T3-8-20
AIR CONDITIONER SYSTEM E215B-E245B
WARNING D
Never start operating the compressor during this
work. The starting of the compressor causes the
blowing of the service can. 10
S
4. Check that there are no leakages of gas in the
cycle, using a gas leakage tester. Retighten
and eliminate all points of leakage. SM0019
T3-8-21
E215B-E245B AIR CONDITIONER SYSTEM
CAUTION
Do not open the high pressure valve of the manifold
under any circumstance nor place the service can
upside down.
R0115
T3-8-22
AIR CONDITIONER SYSTEM E215B-E245B
ELECTRIC CIRCUIT
(A)(B)
2
(C)
12 3
(N)
(R) (D)
155(BR) 150(BP)
4
FUSE 20A 15 85E(WB)
18(RG) (E)
25(WG)
FUSE 5A
13 26(RL)
FUSE 15A
E24(B) 5
FUSE 5A
(Q) (M)
FUSE BOX
(L) (F)
6
(P) 11
(K)
10 (G)
14
7
9
(J) (H)
8
SM0044
(I)
T3-8-23
E215B-E245B AIR CONDITIONER SYSTEM
Connectors
(I) MAKER : YAZAKI CORP. (J) MAKER : YAZAKI CORP. (K) MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249 HOUSING No. : 7123-2237 HOUSING No. : 7123-6020
TERMINAL : 17111 TERMINAL : 17111 TERMINAL : 7116-2871
26 25 85E
150 E24 18
150 155
SM0045
P W B R Y G L Br Lg O
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE
T3-8-24
AIR CONDITIONER SYSTEM E215B-E245B
T3-8-25
E215B-E245B AIR CONDITIONER SYSTEM
3. Relay
Four-electrode relay is used for the blower OFF
relay and compressor relay.
1) Blower OFF relay
The blower OFF relay turns on after
receiving the signal from the control
amplifier. A
When the blower OFF relay turns on, the A
source voltage is supplied to the blower
motor and the blower motor starts running.
2) Compressor relay
The relay ON—OFF is tripped by the control
amplifier and electronic thermostat control.
SM0049
3) Relay inspecting items
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay
because this relay has polarity.
5. Inspection: Inspect the continuity
between 3 and 4 according to the
conditions mentioned below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-
2:
Not continued
4. Air mix actuator
Air mix actuator is installed at the center of air-
con unit, and opens and closes air mix damper
through the link.
The air mix actuator contains potentiometer
which is switched by being coupled to the shaft
of actuator.
When the target air mix door position is CONTROL AMPLIFIER MOTOR ACTUATOR
T3-8-26
AIR CONDITIONER SYSTEM E215B-E245B
SM0052
7. Dual pressure switch
This dual pressure switch is attached on L-hose
and is used to turn OFF the compressor, and
employs dual type (for high and low pressure
control) to protect the cooler cycle from
possible failure at the time when abnormal
pressure was generated on the high pressure
side.
SPECIFICATION OF DUAL PRESSURE SWITCH
0.02MPa(2.9psi) 0.59MPa(86psi)
SM0053
ON
OFF
0.20MPa 3.14MPa
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
SM0054
T3-8-27
E215B-E245B AIR CONDITIONER SYSTEM
TROUBLESHOOTING
Note : M/A is motor
Air temperature does not fall. actuator
* is any of the
numbers 0 ~ 9
If AUTO switch or A/C switch is pushed, "HL.E" is indicated on the set
temp. display of the panel.
NO YES
"HL.*" is shown on the set temp. display • Connector for air mix M/A is disconnected or in
of the panel poor contact.
• Air mix M/A is failed.
NO YES • Main harness shows poor continuity.
NO YES
• Inner air sensor or harness is disconnected or shorted • Both inner air sensor and evaporation
• Inner air sensor connector is disconnected or in poor sensor are disconnected or shorted.
contact. • Controller failed.
See section monitor mode. See section monitor mode.
NO YES
NO YES
If M/A is at stop halfway, Turn compressor clutch on
eliminate cause, correct and and off. Inspect and correct Controller is faulty Inspect duct or
measure operating force. electric circuits. or inner air sensor eliminate cause for
(less than 14.7N: OK) is faulty. cool air intrusion.
Refer to Troubleshooting for
refrigeration cycle.
Inspect and replace.
NO YES
Replace.
T3-8-28
AIR CONDITIONER SYSTEM E215B-E245B
NO YES
"HL.*" is shown on the set temp. display • Connector for air mix M/A is disconnected or in
of the panel. poor contact.
• Air mix M/A is failed.
NO YES • Main harness shows poor continuity.
NO YES
Inspect and correct or replace parts.
NO YES
Blowout temp. rises at blowout
mode if temp. is set at HOT MAX
32.0 °C (64.4 °F)
NO YES
NO YES
NO YES
If M/A action is at stop, Inspect warm water piping.
eliminate cause, correct and Controller or inner Inspect duct or
measure operating force. air sensor is out of eliminate causes
(less than 14.7N: OK) order. for warm air entry.
NO YES
Replace.
T3-8-29
E215B-E245B AIR CONDITIONER SYSTEM
NO YES
NO YES Replace.
Note 2) Inspect blower motor relay. Blower Approx. 10V acts across light green wire
motor rotates if white / red wire and and grounding of blower amplifier.
red wire of blower motor relay are
direct connected.
NO YES
NO YES
Controller is out of order. Remove blower amplifier and check
Replace. for continuity across light green wire
Wire harness is faulty. and black wires; you get continuity.
Inspect and correct or
replace. NO YES
NO YES
Inspect and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES
T3-8-30
AIR CONDITIONER SYSTEM E215B-E245B
CASE (1)
"HL.*" is shown on the set temp. display of Note) * is any of the
the panel. numbers 0 ~ 9.
NO YES
CASE (2)
Does not blower motor speed change
because the setting mode is other face
NO YES
NO YES
T3-8-31
E215B-E245B AIR CONDITIONER SYSTEM
NO YES
NO YES
Voltage acts across white / green wire Pressure switch is faulty or refrigerant
and Ground (Black) connector gas is under charged or overcharged.
connected to excavator.
NO YES
NO YES
T3-8-32
AIR CONDITIONER SYSTEM E215B-E245B
NO YES
NO YES
NO YES
T3-8-33
E215B-E245B AIR CONDITIONER SYSTEM
NO YES
Cooling does not work if run at high speed. Oil comes out from piping and parts.
NO YES NO YES
Expansion valve is Expansion valve is frozen Natural leak from hose. Gas leaks from pipe
clogged or maladjusted. or intruded by water. joints and parts.
NO YES
Air bubbles are seen in sight glass. High pressure is lower.
Compressor cylinder does not get hot. Compressor cylinder gets very hot.
Expansion valve is maladjusted. (too much open) Compressor does not discharge well.
NO YES
YES NO
High pressure circuit before receiver is Clean condenser. Air bubbles are hard to go out even if
clogged up. water is poured on condenser.
T3-8-34
AIR CONDITIONER SYSTEM E215B-E245B
The failure of motor actuator and each sensor can be identified on the display of panel.
SM0055
SM0056
2. MODE is flickering.
SM0057
3. R/F is flickering.
Check harness or connector to motor actuator for the
inner and outer air damper for disconnection.
Note: The above indication and flickering does not
function if the harness and connector were
disconnected under the condition the panel ON/
OFF switch is ON.
After the failure was occured, if the panel ON/
OFF switch is turned ON, it functions.
After correction of failure, if the starter switch is
SM0058 not switched from OFF to ON the error indication
and flickering are not released.
T3-8-35
E215B-E245B AIR CONDITIONER SYSTEM
Failures of sensors
1. HL.* is indicated on 3 digits segment.
SM0059
SM0060
Note: The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the condition
the panel ON/OFF switch is ON.
And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is
released.
SM0061
T3-8-36
AIR CONDITIONER SYSTEM E215B-E245B
SM0062
SM0063
C D
1. Press inner and outer air flow select switch (A) and ON/OFF switch (D) simultaneously for 1 second.
2. Press AUTO switch (E).
(After all segments are lit on for 1 second, the mode is switched into monitor mode.)
3. Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit
and 2nd digit of segment in three digits. The 1st digit is indicated by "H".
4. Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by
pressing UP or DOWN of blower switch (B) or (C), and the required sensor is selected from the list
below.
SM0064
(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)
5. The monitor display is terminated by pressing the inner and outer air flow select switch (A) and ON/OFF
switch (D) for 1 second again, or turning off the main switch of excavator.
Notes:
- The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.
- Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch (D) again, and the error display is disappeared.
T3-8-37
E215B-E245B AIR CONDITIONER SYSTEM
2. Example 2
3. Example 3
When the segment exclusively used for monitor
indicates 2 (displays the solar radiation sensor
condition), since the segment indicates FF,the sensor is
in short-circuiting condition according to the list of 3
segments.
-->The solar radiation sensor is in short-circuiting
SM0067 condition.
4. List of 3 segments
SECOND SEGMENT
T3-8-38
OPERATIONAL PERFORMANCE TEST
M0103
OPERATIONAL PERFORMANCE TEST E215B-E245B
OPERATIONAL PERFORMANCE
TEST
CONTENTS
Group 1 - Introduction
How to Use the Maintenance Standard
and Cautions to Be Exercised ........... T4-1-1
Preparation for Performance Tests......... T4-1-2
T4-1-1
E215B-E245B INTRODUCTION
The machine
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
Test area
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m, and to make a full
swing with the front attachment extended. SM1231
Precautions
1. Before starting to test, agree upon the signals
to be employed for communication among
coworkers. Once the test is started, be sure to
communicate with each other using these
signals, and to follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid
accidents due to landslides or contact with SM1232
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground
with leaking oil. Use oil pans to catch escaping
oil. Pay special attention to this when removing
hydraulic pipings.
T4-1-2
STANDARD PERFORMANCES E215B-E245B
-0,5
P2 a2
Power P1 a1
boost 37.8 +1.0 MR1
-0.5
P2 a2
H 39.7 +0
-5.9
OR3 Boom up
Boom a1
R 37.8 +0 OR4 Boom down
-4.0
High pressure circuit
Main pump
Forward
RH a1 34.3 +0,7
Reverse -0,5 Simultaneous
Travel
Operation of travel RH
Forward and LH
LH a2 34.3 +0,7
Reverse -0,5
T4-2-1
E215B-E245B STANDARD PERFORMANCES
Measuring
Inspection Item Standard value Unit
condition
Sprocket revolution 1st speed 32~28
(RH, LH) min-1
nd 50~45
E215B 2 speed
Sprocket revolution 1st speed 28~24
(RH, LH) min-1
nd 45~40
E245B 2 speed
In 3.0~3.6
Arm
Out 2.3~2.9
Operating speeds
In 2.9~3.5
Positioner
Out 4.1~4.7
Boom cylinder 7
ATT amount of drift mm / 5 min (At no load)
Arm cylinder 6
- -
NOTE: over load relief valves OR1~OR8 described in advance (8) (4)
correspond to the following operations.
(5) (6) (1) (2)
1. Bucket digging 5. Swing left
2. Bucket dump 6. Swing right (7) (3)
3. Boom up 7. Arm in
4. Boom down 8. Arm out
T4-2-2
TEST PROCEDURES E215B-E245B
Warming up of engine
WIPER
SWITCH
SCREEN CHANGE SWITCH SM0851
NO.2 ENG
G-3 SPEED SET 1000
MEAS 1000
G-5 ENG PRS. LIVE
WATER TEMP 20 °C OFF
MODE H
H-1 ACCEL VOLT. 0.3 V
POS. 0%
G-1 MOTOR STEP 30
POS. 0%
COIL A 1.5 A
COIL B 1.5 A
G-2 LIMIT SW. OFF
SM0852
T4-3-1
E215B-E245B TEST PROCEDURES
MEASUREMENT OF HYDRAULIC
PRESSURE
HYDRAULIC EQUIPMENT
6.9 MPa (1000psi) pressure gauge: 1unit a5
49 MPa (7100psi) pressure gauge: 2 units
Pressure measuring equipment and instrument for B3
analysis: 1 set
Dr3 A3
PILOT CIRCUIT
Replace pilot gauge plug (a5) with plug PF1/4 for
pressure measurement, and attach pressure gauge
6.9 MPa (1000 psi).
T4-3-2
TEST PROCEDURES E215B-E245B
PLUG FOR
ARM (R) OPTIONAL RELIEF
OR8
FRONT
MACHINE
MACHINE
FRONT
T4-3-3
E215B-E245B TEST PROCEDURES
B3
A3
a5
PR1 Dr3 SM0856
PB
PA
SM0857
a5
B3
Dr3 A3
A2
PSV2 (A1)
(PSV1)
a1 a2 SM0853
T4-3-4
TEST PROCEDURES E215B-E245B
311
No. of turns of adjust Pressure change MPa
screw (psi) LOCK NUT HEX24
SM0858
1 turn Approx. 2.1 (305)
: 22 mm
: 27.4~31.4 N•m (20~23 lbf•ft)
: 19 mm Adjust screw
: 6 mm
T4-3-5
E215B-E245B TEST PROCEDURES
SM0862
T4-3-6
TEST PROCEDURES E215B-E245B
Travel speed
PURPOSES
Measure the travel sprocket revolution and confirm
the performances between the hydraulic pump and
the travel motor of the travel drive system.
CONDITIONS
Hydraulic oil temperature ;45~55°C (113~131°F)
Crawler on the right and left sides are tensioned
evenly.
PREPARATION
Attach the reflection panel with a magnet to the
travel motor cover. SM0863
Swing the swing frame through 90° as shown in
Figure and make the crawler on one side take off the
ground, using the attachment.
MEASUREMENT REFLECTION
PANEL
Engine revolution: Hi idle
2-speed travel switch: 1st speed and 2nd
speed
Measuring points: Right and left
Method, example 1:
Measure revolution with a stroboscope
Method, example 2:
Measure the revolutions per minute visually.
SM0864
E215B
Sprocket revolution Unit: min-1
Reference
Measurement Standard Service
value for
item value limit
remedy
H mode 1st 32~28 25.2~22.8
20.4 or
RH& speed less
LH H mode 32.5 or
50~45 39~35.3
2nd speed less
E245B
Sprocket revolution Unit: min-1
Reference
Measurement Standard Service
value for
item value limit
remedy
H mode 1st 28~24 22~19 17 or less
RH& speed
LH H mode
45~40 34~31 29 or less
2nd speed
T4-3-7
E215B-E245B TEST PROCEDURES
Deviation of travel
PURPOSE
Measure the amount of deviation at 20m (66ft) travel
and confirm the horizontal balance between the
hydraulic pump and the travel motor of the travel
drive system.
CONDITION
Hydraulic oil temperature: 45~55 °C
(113~131°F)
RH and LH crawler are tensioned evenly.
Firm, level ground Approx. 30~40 cm
Engine revolution: Hi idle.
PREPARATION SM0865
MEASUREMENT
1. Measure the max. deviation distance of the
circular arc in the 20m (66ft) length, excluding A
the preliminary run of 3~5m (10~16ft).
20m
2. Operate the travel lever at the same time.
T4-3-8
TEST PROCEDURES E215B-E245B
PURPOSE
Confirm that the parking brake holds a stopped
condition of the machine in a no-load travel position
and on a 15 degree slope.
CONDITION
BOOM FOOT PIN
A slope with (Approx. 15 deg) gradient and a
stopped condition in a no-load travel position.
ARM TOP PIN
PREPARATION
Place an angle meter on the shoe plate and confirm 15 degree slope
that it makes an angle more than 15 degree.
Hang a perpendicular in parallel with the guide SM0867
frame rib on the track frame and put a mark
(matching mark) on the shoe plate.
MEASUREMENT
Five minutes after the engine stops, measure the
movement distance of the matching mark.
SM0868
T4-3-9
E215B-E245B TEST PROCEDURES
PURPOSE
To measure the drain rate of the travel motor and to
confirm the performances of the travel motor.
CONDITIONS
Hydraulic oil temperature: 45~55°C
(113~131°F)
Engine revolution: Hi idle
PREPARATION
1. Place a stopper under the RH and LH travel FORWARD 90 o 10
sprockets. (3.54") (0.394")
o 80
(3.15")
MEASUREMENT AT TRAVEL LOCK ROTARY DIRECTION
SM0869
WARNING
Unless you observe the rotary force direction at
travel lock, rib "A" may be broken by stopper "B" in
some cases.
E215B
Unit: (gal)
Drain rate of travel motor
L/30 s
Measuring Standard Reference value
Service limit SM0870
position value for remedy
Drain rate 9 (2.4) 16 (4.2) 23 (6.1)
E245B
Unit: (gal)
Drain rate of travel motor
L/30 s
Measuring Standard Reference value
Service limit
position value for remedy
Drain rate 7 (1.6) 14 (3.5 21 (4.6)
T4-3-10
TEST PROCEDURES E215B-E245B
Swing speed
PURPOSE
Measure the swing time and confirm the
performances between the hydraulic pump and the
swing motor of the swing drive system.
CONDITIONS
Hydraulic oil temperature: 45~55°C
(113~131°F)
Firm, level ground
Engine revolution: Hi idle
PREPARATION
Put the bucket empty and extend the boom, arm and
bucket cylinder fully.
And the machine becomes a position of minimum
reach.
T4-3-11
E215B-E245B TEST PROCEDURES
PURPOSE
Confirm the braking torque performances by the
swing relief valve.
ARM TOP BOOM FOOT
PIN PIN
CONDITIONS
Hydraulic oil temperature: 45~55°C
(113~131°F)
Firm, level ground
Engine revolution: Hi idle
SM0872
PREPARATION
1. Put the bucket empty, retract the arm cylinder
fully and extend the bucket cylinders fully. And
move the boom so that the arm top pin is
positioned at same height with boom foot pin.
2. Put a matching mark on the outer
circumference of the swing bearing of the upper
frame side and of the track frame side. Place
two poles (flags) on the front and back of the
extended line of the matching mark.
Amount of deflection of
MATCHING MARKS
matching marks [m (ft-in)] ON INNER RACE
Swing drift
= x 360°
angle (°) Circumferenzial lenght of
SM0873
swing race [m (ft-in)]
T4-3-12
TEST PROCEDURES E215B-E245B
PURPOSE
To confirm the mechanical performances of the
swing parking brake that is fitted to the inside of the
swing motor.
CONDITIONS
On a slope of 15 degree incline.
Stop the machine at right angles with the slope. Put
the bucket empty, retract the arm cylinder fully and
extend the bucket cylinder fully. And move the boom
so that the arm top pin is positioned at same height
with boom foot pin.
PREPARATION SM0874
MATCHING MARKS
Performance of swing ON INNER RACE
Unit : mm(in)/5min
parking brake
Measuring Standard Reference value SM0875
Service limit
position value for remedy
C 0 1 (0.04) 2 (0.08)
T4-3-13
E215B-E245B TEST PROCEDURES
PURPOSE
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.
CONDITIONS
Hydraulic oil temperature: 45~55°C
(113~131°F)
Firm, level ground
Engine revolution: Hi idle
PREPARATION
1. Stop the engine.
2. Release pressure from inside the hydraulic
circuit.
3. Disconnect the swing motor drain hose from its
end returning to the hydraulic oil tank and take
oil in a container. SM0876
4. Put a plug to the tank side.
T4-3-14
TEST PROCEDURES E215B-E245B
PURPOSE
Measure the operating time of the boom, arm,
positioning and bucket and confirm the
performances between the hydraulic pump and the
cylinder of the attachment drive system.
CONDITIONS
Hydraulic oil temperature: 45~55°C
(113~131°F)
Engine revolution: Hi idle
Operating time excluding the cushion stroke.
PREPARATION
Firm level ground with the bucket empty.
MEASUREMENT
Measurement 1 ; Boom up and down 30cm (1ft)
With the boom operating lever at full stroke,
measure the required operating time of the bucket
between the ground surface and its highest position.
WARNING
When lowering the boom, allow the bucket onto a
soft ground or cushioning such as rubber tires ;
never put the bucket against concrete or other solid
material.
5
SM0877
T4-3-15
E215B-E245B TEST PROCEDURES
PURPOSE
Confirm that the cylinder oil tight by checking the
moving length of the cylinder rods. B
BOOM FOOT PIN
C
CONDITIONS
A
Hydraulic oil temperature: 45~55°C
(113~131°F) D
Firm, level ground
After cylinders are replaced, bleed off air from the ARM TOP PIN
SM0878
cylinders, before checking for oil tightness.
Retract the arm cylinder rod 50mm (2in) from stroke
end so that the piston does not match a same range
of the cushioning mechanism.
PREPARATION
Put the bucket empty. Extend the arm cylinder rod
50mm (2in) from the most retracted position. And
extend the bucket cylinders fully. Then hold the
boom so that the arm top pin is positioned at same
height with boom foot pin.
MEASUREMENT
Measure the items five minutes after the engine is
turned off.
T4-3-16
TEST PROCEDURES E215B-E245B
PURPOSE
Measure the gap between the lower frame and the
bottom face of the swing bearing and estimate the
degree of wear of the swing bearing.
CONDITIONS
Firm, level ground
The swing bearing mounting bolts are not loosened.
The swing bearing is lubricated well, not making
abnormal sound during turning.
PREPARATION
1. Install a dial indicator to the magnetic base and LOCATION OF BEARING
MOUNTING BOLTS
fix it to the lower frame.
2. Direct the upper swing body and the lower
frame toward the travel direction, bring the SWING BEARING
probe of the dial indicator in contact with the A
bottom surface of the outer race on the swing
body side and set the reading at zero.
DIAL INDICATOR
LOWER FLAME
MEASUREMENT
Measuring position 1 and 2
Measure the displacement of the outer race in the SM0879
axial direction in position 1 [The arm at 90°~110°
and the crawler front is lifted by attachment about
30cm (1ft)] and in position 2, using a dial indicator.
30cm
SM0879
Position 1
SM0872
Position 2
T4-3-17
E215B-E245B TEST PROCEDURES
Measuring position 3
T4-3-18
MECHATRO CONTROLLER E215B-E245B
M-2:
GOVERNOR MOTOR
E-1:
C-2: FUSE&RELAY
GAUGE CLUSTER BOX
ENGINE
ENGINE SPEED
SENSOR
PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER
SM0881
T4-4-1
E215B-E245B MECHATRO CONTROLLER
ENGINE CONTROL
3
1
11 3
3
5
Section A-A
10
4
HIGH LOW
HIGH LOW
2
4
2
Section B-B
Detail aa
9 7 6 8
Section C-C 9
SM0882
1 - Governor motor
2 - Lever assy
3 - Sems-Bolt M8x25 (Q.ty 4) 23.5 Nm (17.3 lbf x ft)
4 - Bracket
5 - Capscrew (Q.ty 3) 19.6 Nm (14.5 lbf x ft) Apply Loctite #242
6 - Rod
7 - Nut M10 10.7 Nm (7.89 lbf x ft)
8 - Nut M10 10.7 Nm (7.89 lbf x ft)
9 - Nut M8 (Q.ty 2) 23.5 Nm (17.3 lbf x ft)
10 - Sems-Bolt M6x16 (Q.ty 2) 4.4 Nm (3.25 lbf x ft)
11 - Sems-Bolt M6x20 9.6 Nm (7.08 lbf x ft)
T4-4-2
MECHATRO CONTROLLER E215B-E245B
SM0883
Speed sensor
Installing place: engine flywheel housing.
CN-136F
Sensor attaching procedure: push it into place and
fix with partially self-sealing cylindrical screw
M6x12, tightening torque 8±2 Nm.
SM0884
WORK MODE
SELECT SWITCH
SM0885
T4-4-3
E215B-E245B MECHATRO CONTROLLER
ADJUSTMENT OF MECHATRO
CONTROLLER OUTPUT (A-B-C
ADJUSTMENT)
Preparation
T4-4-4
MECHATRO CONTROLLER E215B-E245B
Adjusting procedure
MULTI DISPLAY
WASHER SWITCH
WIPER SWITCH
SELECT SWITCH
SM0886
T4-4-5
E215B-E245B MECHATRO CONTROLLER
ADJUSTMENT OF PUMP
("B" ADJUSTMENT)
PROCEDURE
1. The adjustment automatically shifts from
engine to pump, the speed shifts from LOW
idling to HIGH idling. And "MEMORY PUMP" is
displayed.
And the unloading proportional valve and pump
proportional valve actuate, accordingly the
loading of pump is increased.The "ENGINE
SPEED", P1, P2 "PUMP PRESSURE" and P1,
P2 pump "PROPO-VALVE" current (command
value) are indicated.
2. After detection of the engine rated speed, the FINISH PUMP
adjustment of pump is automatically ENGINE SPEED
completed. And "FINISH PUMP" is displayed. 2000rpm
PUMP PRESSURE
C-1 35.0M C-2 35.0M
(Press the buzzer stop switch on gauge cluster PROPO-VALVE
E-1 300mA E-2 300mA
while this display is appeared and the
adjustment is completed. The unloading
adjustment required later is not performed, and SM0889
default value is written.).
T4-4-6
MECHATRO CONTROLLER E215B-E245B
T4-4-7
E215B-E245B MECHATRO CONTROLLER
Judging condition 2:
the adjustment does not complete although the
pump proportional valve current reaches to the
specified value.
The P1 and P2 pump pressures usually
increase to 33~38MPa. When the pressure
does not increase:
a. Identify the reason why the pressure does
not increase,
• Check that the relief valve operates
normally.
• Check that the hydraulic circuit is free from
leak of pressure.
• Check that the pressure sensor functions
normally. And so on.
b. Identify the reason why the actual flow rate
does not increase,
• Check that the pump proportional valve
operates normally.
• Check that the pump regulator operates
normally. And so on.
3. In cases where unloading valve can not be
performed; And "ERROR UNLOAD" is
displayed.
Judging condition 1:
the pump pressure does not increase up to the
pressure in the range of the specified
adjustment. Or the increased pressure is held
as it is.
SM0892
Judging condition 2:
pressure sensor of either P1 pump or P2 pump
is failed.
Normally the pump pressures of P1 and p2
pumps gradually increase to 10~25MPa.
(It may be affected by operating oil
temperature.)
When the pump pressure does not increase:
a. Identify the reason why the pressure does
not increase,
• Check that the relief valve operates
normally.
• Check that the hydraulic circuit is free from
leak of pressure.
• Check that the pressure sensor functions
normally. And so on.
T4-4-8
MECHATRO CONTROLLER E215B-E245B
OTHER PRECAUTIONS
1. In the event of a failure, there is case where the
adjustment may not be performed normally.
First serve the machine, and perform the
adjustment work.
2. In the condition where large load is constantly
applied to engine, the adjustment could not be
performed normally.
PROCEDURE
1. Turn starter switch ON keeping the work mode
selector switch on the gauge cluster pressed,
MULTI DISPLAY
and hold it for 5~10 seconds, and then release (EXAMPLE)
it.
(If the engine is started, the following indication
is not displayed. Therefore do not start the
engine.)
2. Keep buzzer stop switch on gauge cluster
pressed for 5 seconds and release it and the
screen for selection of adjustment type is
displayed. And "ADJUST" is displayed.
When adjustment data is not entered in
mechatro controller, "READY" is indicated. If
the adjustment operation is once performed,
"FIN" is indicated.And the lever lock solenoid is
automatically released, disabling all operations.
3. Change the adjusting items with washer switch
( ) and wiper switch ( ), and select "ADJUST
UNLOAD".
Like the output adjustment, when adjustment
data is not entered in mechatro controller,
"READY" is indicated. If the adjustment
operation is once performed, "FIN" is indicated.
4. Press selector switch on gauge cluster to
display "START ENG". SM0893
T4-4-9
E215B-E245B MECHATRO CONTROLLER
CAUTION
The emergency mode should be used in only case
of emergency. We recommend that the defective
section is repaired by troubleshooting as early as
possible.
T4-4-10
TROUBLESHOOTING
M0103
TROUBLESHOOTING E215B-E245B
Section 5 TROUBLESHOOTING
Group 1 Troubleshooting (by Error Codes)
Group 2 Troubleshooting (by trouble)
Group 3 Troubleshooting (Trouble diagnosis mode)
SECTION 5 E215B-E245B
TROUBLESHOOTING
CONTENTS
OUTLINE
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred.
This manual describes how to solve the specific
phenomenon systematically as early as possible.
For troubleshooting concerning the inside of
equipment, refer to troubleshooting for each manual
of equipment.
GET TO THE SITE AS QUICKLY AS POSSIBLE Attending the field to verify actual thing
Verify model, serial number, situation of trouble and
field, and notify person of arrival time.
VERIFY BACKGROUND
OF TROUBLE OCCURRED
1. Model name and serial number
2. Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3. Operating time by hour-meter
4. History of trouble occurred and additional works.
5. Recurrence of past trouble, or problems on the SM0101
additional works.
Verifying background of trouble occurred
SM0102
EXPLANATION OF THE CAUSE OF TROUBLE
Confirm the symptoms of the trouble
1. Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
flaws on the piston rod. And the method of using
the machines should be explained so that the
same kind of trouble does not reoccur.
2. Treatment of damaged parts
The damaged parts to be claimed and returned
are evidence so they should be handled with
care. Protect them from entry of water, soils, etc.
into port of hydraulic unit, etc. and return them.
And also use care not to flaw and damage those
surfaces. SM0103
T5-1-1
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Classify failures into the following 3 types and carry out the troubleshooting.
No. Classes of failure Troubleshooting
A When error code after self-diagnosis is displayed Carry out troubleshooting according to the error
on gauge cluster code.
B When no failure is detected currently but error When it is hard to recreate the failure situation,
code after self diagnosis is remained in trouble cancel the data in the history and reproduce the
history failed situation or suppose the cause according to
the troubleshooting by error code, and then repair
it.
C When error code after self diagnosis is not • Carry out troubleshooting according to
displayed or is not remained in the history instructions in Chapter T5-2
"TROUBLESHOOTING BY TROUBLE".
• Carry out troubleshooting according to
instructions in Chapter T5-3 "TROUBLE
DIAGNOSIS MODE".
If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
(1) The blown fuse of mechatro controller
a. Blown fuse 5A of mechatro controller :
"DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the
controller program is not executed.
b. Blown fuse 20A of mechatro controller
The controller functions normally but the power supply applied when the controller drives the
solenoid, etc. stops.
Many error codes are displayed on the gauge cluster.
D013, D023, D033, D063,
E013, E023, F021
When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out
the troubleshooting referring to applicable page in the contents of error codes.
T5-1-2
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
T5-1-3
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
T5-1-4
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 1
Error code A015
Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment)
Judging condition Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting range.
Symptom Deviated from the reqired value, but no problem in normal operations.
Control in the
Rotate with the default engine.
event of failure
Returned in
The engine adjustment is completed normally.
normal condition
Screen No. 2 G-3 SPEED SET
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Checking Carry out engine adjustment (A adjustment). When "ERROR ENG" was
displayed during adjustment, refer to the section "Adjustment procedure -
Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
Table 2
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within the
Judging condition
adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation.
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition
Screen No. 9 E-1 P1 PUMP
Service diagnosis
Screen No. 9 E-2 P2 PUMP
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
T5-1-5
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 3
Error code A035
Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting
Judging condition
range.
Symptom It is not normal output, but no problem in normal operation.
Control in the
Work with the aid of output by default proportional valve.
event of failure
Returned in
The adjustment of unload valve is completed normally.
normal condition
Screen
8 D-1 P1 UN-LOAD (BP-CUT)
No.
Service diagnosis Screen
8 D-2 P2 UN-LOAD (BP-CUT)
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Checking Carry out adjustment of unload valve (C adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
Table 4
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging condition Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Screen
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
T5-1-6
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 5
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging condition Check adjustment data, and judge the data is correct or not.
Symptom It is not normal output, but no problem in normal operation.
Control in the
Control can be done by default value.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Screen
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table 6
Error code A235
Trouble The data of ROM adjustment is written incorrectly.
Judging condition Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Screen
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
T5-1-7
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 7
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging condition Check hourmeter memory, and judge the data is incorrect.
Symptom The hourmeter data which was judged as error is taken as 0 Hr. No problem in normal operation.
Control in the
Normal control is available.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Screen
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table 8
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging condition Check proportional valve adjustment data, and judge the data is incorrect.
Symptom It is not normal output, but no problem in normal operation.
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Screen
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
T5-1-8
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 9
Error code B012
Trouble Boom up pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the sensor after
Judging condition
starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The boom up operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
5 B-1 BOOM RAISE
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor SE-3 When B012 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 10
Error code B013
Trouble Boom up pressure sensor’s wiring disconnects.
Judging condition The input voltage from boom up pressure sensor is less than 0.1 V.
Symptom The boom up speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-1 BOOM RAISE
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor SE-3 When B013 is cancelled and other error occurs after exchanging the connector
with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up
When B013 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller
Check wiring for possible failure according to the wiring checking procedure
CN-126F
and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-9
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 11
Error code B014
Trouble Boom up pressure sensor’s power source is shortcut.
Judging condition The input voltage from boom up pressure sensor is 4.7 V or more.
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-1 BOOM RAISE
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor SE-3 When B014 is cancelled and other error occurs after exchanging the connector
with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up
When B014 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller
Check wiring for possible failure according to the wiring checking procedure
CN-126F
and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 12
Error code B022
Trouble Boom down pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the sensor after
Judging condition
starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The boom down operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
5 B-2 BOOM LOWER
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on after
SE-4 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-10
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 13
Error code B023
Trouble Boom down pressure sensor’s wiring is disconnecting.
Judging condition The input voltage from boom down pressure sensor is 0.1 V or less.
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-2 BOOM LOWER
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the connector
SE-4 with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down
When B023 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller
Check wiring for possible failure according to the wiring checking procedure
CN-127F
and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 14
Error code B024
Trouble Boom down pressure sensor’s power source is shortcut.
Judging condition The input voltage from boom down pressure sensor is 4.7 V or more.
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-2 BOOM LOWER
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on after
SE-4 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-11
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 15
Error code B032
Trouble Arm-in pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the sensor after
Judging condition
starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The arm-out operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
5 B-3 ARM OUT
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor SE-8 When B032 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out pressure When B032 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 16
Error code B033
Trouble Arm-out pressure sensor’s wiring is disconnecting.
Judging condition The input voltage from arm-out pressure sensor is 0.1 V or less.
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-3 ARM OUT
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor SE-8 When B033 is cancelled and other error occurs after exchanging the connector
with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out pressure
When B033 is displayed after the connector is exchanged with other sensor.
sensor and controller
Check wiring for possible failure according to the wiring checking procedure
CN-131F
and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-12
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 17
Error code B034
Trouble Arm-out pressure sensor’s power source is shortcut.
Judging condition The input voltage from arm-out pressure sensor is 4.7 V or more.
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1, P2 unload proportional valves to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-3 ARM OUT
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor SE-8 When B034 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 18
Error code B042
Trouble Arm-in pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the arm-in pressure
Judging condition
sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
5 B-4 ARM IN
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch on after
SE-7 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in pressure When B042 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-13
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 19
Error code B043
Trouble Arm-in pressure sensor’s wiring is disconnecting.
Judging condition The input voltage from arm-in pressure sensor is 0.1 V or less.
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but
Symptom if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket
bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1 and P2 unload proportional valve to 0 mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200 mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-4 ARM IN
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the connector
SE-7 with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in pressure
When B043 is displayed after the connector is exchanged with other sensor.
sensor and controller
Check wiring for possible failure according to the wiring checking procedure
CN-130F
and repair it if necessary..
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-14
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 20
Error code B044
Trouble Arm-in pressure sensor’s power source is shortcut.
Judging condition The input voltage from arm-in pressure sensor is 4.7 V or more.
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if
Symptom attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket
bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1, P2 unload proportional valves to 0 mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200 mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-4 ARM IN
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in pressure When B044 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary..
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-15
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 21
Error code B052
Trouble Bucket digging pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the bucket digging
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
5 B-5 BUCKET DIG
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on after
SE-1 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B052 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 22
Error code B053
Trouble Bucket digging pressure sensor’s wiring is disconnected.
Judging condition The input voltage from bucket digging pressure sensor is 0.1 V or less.
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-5 BUCKET DIG
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch on after
SE-1 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B053 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-16
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 23
Error code B054
Trouble Bucket digging pressure sensor’s power source is shortcut.
Judging condition The input voltage from bucket digging pressure sensor is 4.7 V or more.
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-5 BUCKET DIG
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch on after
SE-1 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B054 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 24
Error code B062
Trouble Bucket dump pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The bucket dump operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
5 B-6 BUCKET DUMP
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B062 is cancelled and other error occurs by turning starter switch on after
SE-2 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B062 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-17
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 25
Error code B063
Trouble Bucket dump pressure sensor’s wiring is disconnected.
Judging condition The input voltage from bucket dump pressure sensor is 0.1 V or less.
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-6 BUCKET DUMP
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B063 is cancelled and other error occurs by turning starter switch on after
SE-2 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B063 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 26
Error code B064
Trouble Bucket dump pressure sensor’s power source is shortcut.
Judging condition The input voltage from bucket dump pressure sensor is 4.7 V or more.
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-6 BUCKET DUMP
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B064 is cancelled and other error occurs by turning starter switch on after
SE-2 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B064 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-18
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 27
Error code B072
Trouble Swing pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the swing pressure
Judging condition
sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The swing operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
6 B-7 SWING
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on after
SE-5 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing pressure When B072 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 28
Error code B073
Trouble Swing pressure sensor’s wiring is disconnected.
Judging condition The input voltage from swing pressure sensor is 0.1 V or less.
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
6 B-7 SWING
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B073 is cancelled and other error occurs by turning starter switch on after
SE-5 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing pressure When B073 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-19
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 29
Error code B074
Trouble Swing pressure sensor’s power source is shortcut.
Judging condition The input voltage from swing pressure sensor is 4.7 V or more.
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
6 B-7 SWING
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B074 is cancelled and other error occurs by turning starter switch on after
SE-5 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing pressure When B074 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 30
Error code B092
Trouble Travel right pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the travel right
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The travel right operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
6 B-9 TRAVEL (R)
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch on after
SE-9 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B092 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-20
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 31
Error code B093
Trouble Travel right pressure sensor’s wiring is disconnected.
Judging condition The input voltage from Travel right pressure sensor is 0.1 V or less.
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen
6 B-9 TRAVEL (R)
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B093 is cancelled and other error occurs by turning starter switch on after
SE-9 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B093 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-21
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 32
Error code B094
Trouble Travel right pressure sensor’s power source is shortcut.
Judging condition The input voltage from Travel right pressure sensor is 4.7 V or more.
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen
6 B-9 TRAVEL (R)
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B094 is cancelled and other error occurs by turning starter switch on after
SE-9 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B094 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-22
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 33
Error code B102
Trouble Travel left pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the travel left
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The travel left operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
6 B-10 TRAVEL (L)
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on after
SE-10 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B102 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 34
Error code B103
Trouble Travel left pressure sensor’s wiring is disconnected.
Judging condition The input voltage from Travel left pressure sensor is 0.1 V or less.
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
6 B-10 TRAVEL (L)
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B103 is cancelled and other error occurs by turning starter switch on after
SE-10 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B103 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-23
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 35
Error code B104
Trouble Travel left pressure sensor’s power source is shortcut.
Judging condition The input voltage from Travel left pressure sensor is 4.7 V or more.
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
6 B-10 TRAVEL (L)
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B104 is cancelled and other error occurs by turning starter switch on after
SE-10 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B104 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-24
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 36
Error code B113
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging condition The input voltage from option selector position detect pressure sensor is 0.1 V or less.
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
16 B-11
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Option selector position detect When B113 is cancelled and other error occurs by turning starter switch on after
pressure sensor exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option selector
When B113 is displayed after turning the starter switch on after the connector
position detect pressure sensor
is exchanged with other sensor.
and controller
Check wiring for possible failure according to the wiring checking procedure
CN-162F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-25
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 37
Error code B114
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging condition The input voltage from selector position detect pressure sensor is 4.7 V or more.
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
16 B-11
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Option selector position detect When B114 is cancelled and other error occurs by turning starter switch on after
pressure sensor exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option selector
When B114 is displayed after turning the starter switch on after the connector
position detect pressure sensor
is exchanged with other sensor.
and controller
Check wiring for possible failure according to the wiring checking procedure
CN-162F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 38
Error code B162
Trouble P1 side option pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P1 side option
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The P1 side option operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
6 B-16 P1 OPT.
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on after
SE-20 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-26
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 39
Error code B163
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging condition The input voltage from P1 side option pressure sensor is 0.1 V or less.
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Screen
6 B-16 P1 OPT.
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B163 is cancelled and other error occurs by turning starter switch on after
SE-20 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B163 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-27
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 40
Error code B164
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging condition The input voltage from P1 side option pressure sensor is 4.7 or more.
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Screen
6 B-16 P1 OPT.
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B164 is cancelled and other error occurs by turning starter switch on after
SE-20 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B164 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 41
Error code B172
Trouble P2 side option pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P2 side option
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The P2 side option operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
6 B-17 P2 OPT.
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B172 is cancelled and other error occurs by turning starter switch on after
SE-11 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B172 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-28
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 42
Error code B173
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging condition The input voltage from P2 side option pressure sensor is 0.1 V or less.
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen
6 B-17 P2 OPT.
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B173 is cancelled and other error occurs by turning starter switch on after
SE-11 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B173 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 43
Error code B174
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging condition The input voltage from P2 side option pressure sensor is 4.7 V or more.
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen
6 B-17 P2 OPT.
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B174 is cancelled and other error occurs by turning starter switch on after
SE-11 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B174 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-29
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 44
Error code C012
Trouble P1 pump pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The P1 pump operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
7 C-1 PUMP P1
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on after
SE-22 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 45
Error code C013
Trouble P1 pump pressure sensor’s wiring is disconnected.
Judging condition The input voltage from P1 pump pressure sensor is 0.1 V or less.
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
7 C-1 PUMP P1
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C013 is cancelled and other error occurs by turning starter switch on after
SE-22 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C013 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-30
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 46
Error code C014
Trouble P1 pump pressure sensor’s power source is shortcut.
Judging condition The input voltage from P1 pump pressure sensor is 4.7 V or more.
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
7 C-1 PUMP P1
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C014 is cancelled and other error occurs by turning starter switch on after
SE-22 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C014 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 47
Error code C022
Trouble P2 pump pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The P2 pump operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
7 C-2 PUMP P2
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C022 is cancelled and other error occurs by turning starter switch on after
SE-23 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-31
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 48
Error code C023
Trouble P2 pump pressure sensor’s wiring is disconnected.
Judging condition The input voltage from P2 pump pressure sensor is 0.1 V or less.
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
7 C-2 PUMP P2
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C023 is cancelled and other error occurs by turning starter switch on after
SE-23 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C023 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 49
Error code C024
Trouble P2 pump pressure sensor’s power source is shortcut.
Judging condition The input voltage from P2 pump pressure sensor is 4.7 V or more.
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen
7 C-2 PUMP P2
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C024 is cancelled and other error occurs by turning starter switch on after
SE-23 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-32
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 50
Error code C033
Trouble Boom head pressure sensor’s wiring is disconnected.
Judging condition The input voltage from boom head pressure sensor is 0.1 V or less.
Symptom Overload detection is not available.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
7 C-3 BOOM-HEAD
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on after
SE-24 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C033 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 51
Error code C034
Trouble Boom head pressure sensor’s power source is shortcut.
Judging condition The input voltage from boom head pressure sensor is 4.7 V or more.
Symptom Then overload detection switch is ON, overload alarm sounds constantly.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
7 C-3 BOOM-HEAD
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on after
SE-24 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-33
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 52
Error code D012
Trouble P1 unload proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 1000 mA or more.
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
8 D-1 P1 UN-LOAD (BP-CUT)
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch on after
PSV-D exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 unload When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 53
Error code D013
Trouble P1 unload proportional valve’s wiring is disconnected.
The feed-back value from proportional valve is 100 mA or less.
Judging condition
(If output is 100 mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode).
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
8 D-1 P1 UN-LOAD (BP-CUT)
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D013 is cancelled and other error occurs by turning starter switch on after
PSV-D exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 unload When D013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-34
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 54
Error code D022
Trouble P2 unload proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 1000 mA or more.
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
8 D-2 P2 UN-LOAD (BP-CUT)
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D022 is cancelled and other error occurs by turning starter switch on after
PSV-B exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 unload When D022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-35
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 55
Error code D023
Trouble P2 unload proportional valve’s wiring is disconnected.
The feed-back value from proportional valve is 100 mA or less.
Judging condition
(If output is 100 mA or less, judging is not done.)
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
8 D-2 P2 UN-LOAD (BP-CUT)
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D023 is cancelled and other error occurs by turning starter switch on after
PSV-B exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 unload When D023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 56
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 1000 mA or more
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0 mA
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
8 D-3 S-TRAVEL
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Travel straight proportional When D032 is cancelled and other error occurs by turning starter switch on after
valve exchanging the connector with other sensor.
PSV-C Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-36
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 57
Error code D033
Trouble Travel straight proportional valve’s wiring is disconnected.
The feed-back value from proportional valve is 100 mA or less.
Judging condition
(If output is 100 mA or less, judging is not done.)
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0 mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
8 D-3 S-TRAVEL
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Travel straight proportional When D033 is cancelled and other error occurs by turning starter switch on after
valve exchanging the connector with other sensor.
PSV-C Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-37
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 58
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 1000 mA or more
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0 mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
8 D-4 ARM IN-2-SPEED
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional When D062 is cancelled and other error occurs by turning starter switch on after
valve exchanging the connector with other sensor.
PSV-A Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-38
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 59
Error code D063
Trouble Arm-in spool 2 proportional valve’s wiring is disconnected.
The feed-back value from proportional valve is 100 mA or less.
Judging condition
(If output is 100 mA or less, judging is not done.)
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0 mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
8 D-4 ARM IN-2-SPEED
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional When D063 is cancelled and other error occurs by turning starter switch on after
valve exchanging the connector with other sensor.
PSV-A Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 60
Error code D152
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1
2
3 •
T5-1-39
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 61
Error code D153
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1
2
3 •
Table 62
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 1000 mA or more.
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
9 E-1 PUMP P1
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on after
PSV-P1 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-40
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 63
Error code E013
Trouble P1 pump proportional valve’s wiring is disconnected.
The feed-back value from proportional valve is 100 mA or less.
Judging condition
(If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
9 E-1 PUMP P1
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E013 is cancelled and other error occurs by turning starter switch on after
PSV-P1 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-41
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 64
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 1000 mA or more.
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
9 E-2 PUMP P2
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E022 is cancelled and other error occurs by turning starter switch on after
PSV-P2 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 65
Error code E023
Trouble P2 pump proportional valve’s wiring is disconnected.
The feed-back value from proportional valve is 100 mA or less.
Judging condition
(If output is 100 mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
9 E-2 PUMP P2
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E023 is cancelled and other error occurs by turning starter switch on after
PSV-P2 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-42
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 66
Error code F011
Trouble ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition The feed-back signal is grounding level while exciting command is output.
Symptom ATT boost is not available.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Screen
3 F-1 POWER BOOST
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • ATT boost solenoid valve When F011 is cancelled and other error occurs by exchanging the connector for
SV-2 other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F011 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-43
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 67
Error code F013
Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feed-back signal is 24 V level while exciting command is not output.
Symptom ATT boost is not available or is leaving available.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Screen
3 F-1 POWER BOOST
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • ATT boost solenoid valve When F013 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F013 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-44
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 68
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition The feed-back signal is grounding level while exciting command is output.
Symptom Swing parking is not available.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is 24 V level while exciting command is output.
normal condition
Screen
3 F-2 SWING-BRAKE
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If failure
found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 69
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feed-back signal is 24 V level while exciting command is not output.
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is grounding level while exciting command is output.
normal condition
Screen
3 F-1 POWER BOOST
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-45
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 70
Error code F031
Trouble Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition The feed-back signal is grounding level while exciting command is output.
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is 24 V level while exciting command is output.
normal condition
Screen
3 F-3 1/2-TRAVEL
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Travel 1, 2 speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2
When F031 is displayed after the connector is exchanged with other solenoid
speed solenoid valve and
valve.
controller
Check wiring for possible failure according to the wiring checking procedure
CN-123F and repair it if necessary.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-46
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 71
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feed-back signal is 24 V level while exciting command is not output.
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Screen
3 F-3 1/2-TRAVEL
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Travel 1, 2 speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2
When F033 is displayed after the connector is exchanged with other solenoid
speed solenoid valve and
valve.
controller
Check wiring for possible failure according to the wiring checking procedure
CN-122F and repair it if necessary..
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 72
Error code F041
Trouble Option selector solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition The feed-back signal is grounding level while exciting command is output.
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition
Screen
11 F-4 OPT SELECT
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-47
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 73
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feed-back signal is 24 V level while exciting command is not output.
Symptom Option selector valve does not change to breaker side or it does not change from breaker to nibbler.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition
Screen
11 F-4 OPT SELECT
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 74
Error code G011
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1
2
3 •
T5-1-48
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 75
Error code G013
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1
2
3 •
Table 76
Error code G023
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1
2
3 •
T5-1-49
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 77
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging condition Engine rpm input is 3000 rpm or more. (Only trouble history).
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
2 G-3 MEAS 1 (for mechatro controller)
No.
Service diagnosis Screen
2 G-3 MEAS 2 (receive from engine controller)
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SV-13 Normal value: 1.6~2.0k .
2 • Wiring between option selector
Check wiring for possible failure according to the wiring checking
solenoid valve and controller
procedure and repair it if necessary.
CN-251F
Especially check wiring for false disconnection and noise included.
CN-105F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 78
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection.
Judging condition Voltage of alternator is 12 V or more, and speed sensor indicates excess low engine rpm.
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
2 G-3 MEAS 1 (for mechatro controller)
No.
Service diagnosis Screen
2 G-3 MEAS 2 (receive from engine controller)
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k .
2 • Wiring between engine speed
sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-136F and repair it if necessary.
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.).
T5-1-50
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 79
Error code H013
Trouble Accel potentiometer is disconnected.
Judging condition The input voltage from accel potentiometer is 0.1 V or less.
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
2 H-1 ACCEL VOLT.
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6~2.4k
SE-16 Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
CN-402F and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 80
Error code H014
Trouble Accel potentiometer’s power source is shortcut.
Judging condition The input voltage from accel potentiometer is 4.7 V or more.
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
2 H-1 ACCEL VOLT.
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6~2.0k .
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
CN-402F and repair it if necessary.
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-51
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 81
Error code H023
Trouble Boom angle potentiometer’s wiring is disconnected.
Judging condition The input voltage from boom angle potentiometer is 0.1 V or less.
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
12 H-2 BOOM
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k .
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
CN-702F and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-52
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 82
Error code H024
Trouble Boom angle potentiometer’s power source is shortcut.
Judging condition The input voltage from boom angle potentiometer is 0.1 V or less.
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
12 H-2 BOOM
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k .
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
CN-702F and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-53
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 83
Error code H033
Trouble Arm angle potentiometer’s wiring is disconnected.
Judging condition The input voltage from arm angle potentiometer is 0.1 V or less.
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
12 H-3 ARM
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-18 4.0~6.0k .
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between arm angle
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
CN-703F and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-54
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 84
Error code H034
Trouble Arm angle potentiometer’s power source is shortcut.
Judging condition The input voltage from arm angle potentiometer is 0.1 V or less.
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
12 H-3 ARM
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-18 4.0~6.0k .
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between arm angle
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
CN-703F and repair it if necessary.
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-55
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 85
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging condition The input voltage from fuel sensor is 0.1 V or less.
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
10 H-9 FUEL LEVEL
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15 EMPTY 95 .~ FULL 5
2 • Wiring between fuel sensor and
controller Check wiring for possible failure according to the wiring checking procedure
CN-152F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table 86
Error code H093
Trouble Fuel sensor’s wiring is disconnection.
Judging condition The input voltage from fuel sensor is 4.7 V or more.
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
10 H-9 FUEL LEVEL
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15 EMPTY 95 .~ FULL 5
2 • Wiring between fuel sensor and
controller Check wiring for possible failure according to the wiring checking procedure
CN-152F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-56
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 87
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging condition Reception from gauge cluster can not receive correctly.
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Wiring between gauge cluster
and controller Check wiring for possible failure according to the wiring checking procedure
CN-600F and repair it if necessary.
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-57
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 88
Error code K014
Trouble Battery relay contact welded.
The power 24 V is continuously supplied to controller for 40 seconds or more while the key switch ON
Judging condition
signal turned OFF.
Symptom The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF.
Control in the
Normal control with key switch OFF.
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24 V to mechatro controller is stopped.
Screen
4 K-1 AIS RELAY 2
No.
Service diagnosis Screen
4 K-3 KEY SWITCH OFF
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
R-1 relay coil. If 24 V power lives on battery relay secondary side, check on battery
CN-256F relay for failure and replace it if failed.
2 • Auto idle stop relay 2 Turn off the key switch, and remove the connector (CN-256F) on the battery
R-24 relay coil side. If power of battery relay on secondary side falls, remove either
• Alternator relay auto idling stop relay 2 or alternator relay.
The failure may be occurred in case where the power falls after the relay was
R-28
removed, and therefore check on the relay unit and replace it with new one if
failed.
3 • Wiring between auto idle stop
relay/alternator relay and When K014 is left displayed with the relay removed.
controller Check that no power 24 V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
CN-109F, CN2-1
When no failure found after checking on wiring and K014 is left displayed
• Fuse& relay box
Replace fuse/relay box.
E-1
4 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-58
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 89
Error code R014
Trouble Wiper motor arc prevention relay error.
The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
Judging condition
power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
25 PREVENT ARC
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Wiper motor arc prevention When error is cancelled after removing wiper motor arc prevention relay, check
relay relay unit for failure, replace it with new one if failed.
R-31 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor arc When R014 is left displayed with the relay removed.
prevention relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 checking procedure and replace it if necessary.
• Fuse& relay box When no failure found after checking on wiring and R014 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-59
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 90
Error code R024
Trouble Wiper motor forward rotation relay error.
The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
Judging condition
power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
25 CW MOTOR RLY
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
T5-1-60
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 91
Error code R034
Trouble Wiper motor reverse rotation relay error.
The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
Judging condition
power source.
Symptom Wiper does not move after forward rotation.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
25 CCW MOTOR RLY
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
T5-1-61
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 92
Error code R044
Trouble Washer motor relay error.
Judging condition The mechatro controller output line to washer motor relay is short-circuited with the power source.
Symptom Washer motor does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
25 MOTOR RELAY
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Washer motor relay When error is cancelled after removing washer motor relay, check relay unit for
R-32 failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
CN-112F, CN2-1 checking procedure and replace it if necessary.
• Fuse& relay box When no failure found after checking on wiring and R044 is left displayed
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-62
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 93
Error code R134
Trouble Swing flasher relay error.
Judging condition The mechatro controller output line to swing flasher relay is short-circuited with the power source.
Symptom Right swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
22 D13
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher
R-19 relay, check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal
condition.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-63
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 94
Error code R144
Trouble Swing flasher relay error.
Judging condition The mechatro controller output line to swing flasher relay is short-circuited with the power source.
Symptom Left swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
22 D14
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher
R-19 relay, check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal
condition.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-64
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 95
Error code R154
Trouble Travel alarm relay error.
Judging condition The mechatro controller output line to travel alarm relay is short-circuited with the power source.
Symptom Travel alarm does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
23 D15
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit for
R-8 failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between travel alarm When R154 is left displayed with the relay removed
relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R154 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-65
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 96
Error code R164
Trouble Auto idle stop relay 2 relay error.
Judging condition The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
4 K-1 AIS RELAY 2
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay unit
R-24 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between auto idle stop When R164 is left displayed with the relay removed
relay 2 and controller Check that no power 24 V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R164 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-66
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 97
Error code R174
Trouble Engine forcibly stop relay error.
Judging condition The mechatro controller output line to engine forcibly stop is short-circuited with the power source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate..
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
4 K-3 ENG STOP
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check relay
R-25 unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between engine forcibly When R174 is left displayed with the relay removed
stop relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R174 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-67
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
Table 98
Error code R184
Trouble Safety lock lever relay error.
Judging condition The mechatro controller output line to safety lock lever relay is short-circuited with the power source.
Symptom Safety lock lever timer does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
4 K-4 LOCK LEVER
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R184 is cancelled after removing of safety lock lever relay, check
R-26 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is , it is in abnormal condition.
2 • Wiring between safety lock lever When R184 is left displayed with the relay removed
relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R184 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-68
TROUBLESHOOTING (BY ERROR CODES) E215B-E245B
Table 99
Error code R214
Trouble Safety relay error.
Judging condition The mechatro controller output line to safety relay is short-circuited with the power source.
Symptom Safety relay does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
4 K-2 SAFETY RLY
No.
Service diagnosis Screen
checking screen No.
Screen
No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R214 is cancelled after removing of safety relay, check relay unit for
R-26 failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between safety lock lever When R214 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R214 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
T5-1-69
E215B-E245B TROUBLESHOOTING (BY ERROR CODES)
[MEMO]
T5-1-70
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
TROUBLESHOOTING BY TROUBLE
1. HYDRAULIC SYSTEM
Preface:
The troubleshooting for the failures shown below is explained here.
Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.
T5-2-1
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch by
switch diagnosis Push down the lever and it turns on, push tester, or check that the power
up and it turns off. voltage is lowered by pushing
the lever down.
3 Safety lever lock Check that the Measure both terminals of solenoid Check solenoid unit for
switching solenoid is switched connector. 24 V by pushing the lever possible failure.
correctly down, 0 V by pushing it up Check harness for possible
failure.
4 Safety lever lock Carry out service No.4 K-4 lock lever: Check action of relay by tester
relay diagnosis Push down the lever and it turns off, push
up and it turns on.
5 Pilot pressure sensor • Stop engine stop and key is on Check 5 V power for controller
position.
All pilot low pressure sensors are 0
MPa to 0.1 MPa.
6 Solenoid valve for Measure pressure About 0 MPa by pushing the lever up, Replace solenoid valve
safety lock lever of solenoid A1 port and 4 MPa or more by push it down.
7 Pilot line filter Disassemble and Check filter for clogging Clean filter
check it visually
8 Pilot gear pump Measure pilot Check that it is 4 MPa or more in high Check gear pump and the
primary pressure at idling relief valve for possible failure
gear pump
9 Multi control valve (in Change position Since all are blocked due to poor
case that travel is switching performance, check that the
operable) lever select pattern is set to the proper
position.
10 Actual measuring Carry out service • No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/ diagnosis D-1 P2 unload valve (cut valve) largely differed from the
P2 unload • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.3 Boom up full lever & check proportional valve and
relief controller for possible failure.
11 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2 MPa in boom up full lever and high
directly at the ports idling operation
A7 and A5 of 8
sections solenoid
block
12 Actual measuring Carry out service • No.9 E-1 P1 pump In case where the reading is
current value of P1/ diagnosis. E-2 P2 pump largely differed from the
P2 pump • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.18 Travel right full lever check proportional valve and
& idling controller for possible failure.
Operation No.19 Travel left full lever &
idling
T5-2-2
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
13 Secondary pressure Measure the pump Check that pump proportional valve Replace proportional valve
of pump proportional proportional valve secondary pressure is 2.7 MPa or more
valve secondary pressure in right (left) travel full lever and high
directly in idling idling operation
operation. (Ports a3, Right travel: P1 pump proportional valve
a4) Left travel: P2 pump proportional valve
14 Main relief pressure Carry out service • See Service Diagnosis Data List Measure the relief pressure
diagnosis Operation No.3 Boom up full lever & relief actually
15 Check set pressure Check that P1 and P2 pump pressures Reset or replace
are 32 MPa in boom up full lever, high
idling and H mode operation.
16 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding.
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage, etc.
2. Engine down/stalled
1 Actual measuring Carry out service • No.9 E-1 P1 pump In case where the reading is
current value of P1/ diagnosis E-2 P2 pump largely differed from the
P2 pump • See Service Diagnosis Data List actually measured value,
proportional valve Operation No. 1 Operation is nil check proportional valve and
controller for possible failure.
2 Secondary pressure Measure the pump Check that P1/P2 pump proportional Replace proportional valve
of P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 0.5 to 1.0 MPa in control lever neutral
directly (Ports a3, and high idling operation.
a4)
3 Pressure sensor of Check pressure • See Service Diagnosis Data List Check pressure sensor and
P1, P2 pump Operation No. 1 Operation is nil replace it if necessary
Operation No.3 Boom up full lever &
relief
4 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding
Free from abnormal damage, etc on outside
surface
Spring free from breakage, damage, etc.
T5-2-3
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
1 Pilot pressure Carry out service Check that targeted pilot pressure of Check remote control valve
sensor diagnosis sensor is 0MPa in high idling
2 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
3 Main spool Check targeted Check that spool is free from abnormal Replace
spool visually damage and spring is free from
breakage
4 Over load relief Check targeted Free from dust entered in port relief Replace
valve spool visually valve. Seat is free from abnormality
5 Lock valve poppet Check targeted Seat is free from abnormality Replace
(in case of boom and poppet visually
arm)
6 Lock valve selector Exchange lock Check that the trouble is reversed Replace
(in case of boom and valve selector of
arm) boom/arm and
boom/arm
7 Holding valve spool Check that smooth Free from abnormal resistance against Replace
for boom sliding of spool in sliding Do not pull spool out of sleeve
(in case of boom) sleeve forcibly.
8 Holding valve relief Check targeted Filter free from abnormal contamination Replace
valve for boom spool visually
(in case of boom)
9 Cylinder Check targeted Make sure of no problem of seals by Replace cylinder or seals
cylinder visually disassembling and investigation
1 Pressure sensor Carry out service • See Service Diagnosis Data List Replace pressure sensor
diagnosis Operation No. 1 Operation is nil
• All low pressure sensors are 0MPa to
0.1 MPa
2 Actual measuring Carry out service • No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/ diagnosis D-1 P2 unload valve (cut valve) largely differed from the
P2 unload • See Service Diagnosis Data List actually measured value,
proportional valve Operation No. 1 Operation is nil check proportional valve and
controller for possible failure.
3 Secondary pressure Measure the Check that P1/P2 unloads secondary Replace proportional valve
of unload proportional valve pressures is within the range of 2.7 MPa
proportional valve secondary pressure or more in control lever neutral and high
directly at the ports idling operation
A7 and A8 of 8
sections solenoid
block
T5-2-4
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
4 Actual measuring Carry out service • No.9 E-1 P1 pump In case where the reading is
current value of P1/ diagnosis E-2 P2 pump largely differed from the
P2 pump • See Service Diagnosis Data List actually measured value,
proportional valve Operation No. 1 Operation is nil check proportional valve and
controller for possible failure.
5 Secondary pressure Measure the pump Check that P1/P2 pump proportional Replace proportional valve
of P1, P2 pump proportional valve valve pressures are within the range of Check regulator
proportional valve secondary pressure 0.5 to 1.0 MPa in control lever neutral
directly. (Ports a3, and high idling operation
a4)
6 Command current Carry out service • No.15 D-15 In case where the reading is
value of short-circuit diagnosis. • See Service Diagnosis Data List largely differed from the
Operation No. 1 Operation is nil. actually measured value,
check proportional valve and
controller for possible failure.
7 Secondary pressure Measure the Control lever is neutral, high idling and Replace proportional valve.
of proportional valve secondary pressure secondary pressure is within the range
in short-circuit valve. of proportional of 0.5 -1.0 MPa.
valve in short-circuit
valve directly. (G
Port)
8 Slow return check Visual check Check that slow return check valve Clean and replace
valve of pilot line installed on pilot line is free from dust
(in case of boom up entered
or arm out)
9 Short-circuit valve Visual check When removing, free from abnormal Replace (Check on the casing
spool. resistance against free from abnormal site for damage).
damage, etc on outside surface Spring
is free from breakage, damage, etc.
1 Boom up pressure Carry out service • See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.3 boom up full lever and sensor
relief Check remote control valve
2 Remote control Measure directly Check that pressure is 3.0 MPa or more Check remote control valve
valve remote control in boom up full lever and high idling When equipped with multi
pressure of boom operation control valve, check it while
up changing lever pattern
3 Pump pressure Carry out service • See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, P2 Operation No.4 boom up full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high
operation. pressure sensor.
4 Actual measuring Carry out service • No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/ diagnosis D-1 P2 unload valve (cut valve) largely differed from the
P2 unload • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.3 Boom up full lever & check proportional valve and
relief controller for possible failure.
T5-2-5
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2 MPa in boom up full lever and
directly at the ports high idling operation
A7 and A5 of 8
sections solenoid
block
6 Actual measuring Carry out service • No.9 E-1 P1 pump In case where the reading is
current value of P1/ diagnosis E-2 P2 pump largely differed from the
P2 pump • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.4 boom up full lever & in check proportional valve and
operation controller for possible failure.
7 Secondary pressure Measure the pump Check that P1/P2 pump proportional Replace proportional valve
of P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 1.8 to 3.0 MPa in boom up full lever and
directly (Ports a3, high idling operation
a4)
8 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is No problem for sliding ability of internal
low. piston (Check it through PBp2 port.)
9 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1 and P2 Free from abnormal damage, etc on damage)
pressures are low. outside surface
11 Conflux check valve Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Only P2 pressure is Free from abnormal damage, etc on damage)
high. outside surface
12 Holding valve for Visual check When removing, free from abnormal Replace
boom (poppet) resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
Both P1 and P2 outside surface
pressures are high.
13 Boom spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Only P1 pressure is Spring is free from breakage. damage)
high.
14 Check boom spool Disassembly and Free from abnormal resistance against Replace spool assembly
and recirculation investigation sliding
<Trouble> Spring is free from breakage.
Only P1 pressure is
low.
15 Conflux spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Only P2 pressure is Spring is free from breakage. damage)
high. Free from abnormal damage, etc on
outside surface
T5-2-6
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
16 Main relief valve Check set pressure • See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is relief
low.
17 Over load relief Visual check (Head Pressure is 32 MPa or more in boom up When only relief pressure of
valve side) full lever and high idling. Free from dust boom up is low, replace valve
<Trouble> entered in over load relief valve. Seat is
Relief pressure is free from abnormality
low.
1 Boom down Carry out service • See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.5 boom down full lever sensor.
& in operation Check remote control valve.
2 Remote control Measure remote Check that pressure is 3.0 MPa or more Check remote control valve
valve control pressure of in boom down full lever and high idling When equipped with multi
boom down directly operation control valve, check it while
changing lever pattern.
3 Actual measuring Carry out service P1 unload valve (cut valve) In case where the reading is
current value of P1 diagnosis • See Service Diagnosis Data List largely differed from the
unload proportional Operation No.5 boom down full lever actually measured value,
valve & in operation check proportional valve and
controller for possible failure.
4 Secondary pressure Measure the Check that P1 unload secondary Replace proportional valve
of P1 unload proportional valve pressures are within the range of 0.8 to
proportional valve secondary pressure 1.2 MPa in boom down full lever and
directly at the ports high idling operation
A7 of 8 sections
solenoid block.
5 Actual measuring Carry out service • No.9 E-1 P1 pump In case where the reading is
current value of P1 diagnosis • See Service Diagnosis Data List largely differed from the
pump proportional Operation No.5 boom down full lever actually measured value,
valve & in operation check proportional valve and
controller for possible failure.
6 Secondary pressure Measure the pump Check that P1 pump proportional valve Replace proportional valve
of P1 pump proportional valve pressures are within the range of 2.0 to
proportional valve secondary pressure 2.5 MPa in boom down full lever and
directly (Ports a3, high idling operation
a4)
7 Actual measuring Carry out service Check that the value is not change • Check pressure sensor of
current value of diagnosis regardless of operation travel
travel straight • See Service Diagnosis Data List • In case where the reading is
proportional valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value,
& idling check proportional valve
Operation No.19 Travel left full lever & and controller for possible
idling failure.
T5-2-7
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
8 Travel straight Measure directly High idling pressure is 0.8 MPa or less Replace proportional valve
proportional valve the travel straight regardless neutral/operation
secondary pressure proportional valve
secondary
pressure.
9 Actual measuring Carry out service Check that the value is not change • Check pressure sensor of
current value of diagnosis regardless of operation No 15 D-15 travel.
short-circuit valve. • See Service Diagnosis Data List • In case where the reading is
Operation No. 1 Operation is nil. largely differed from the
Operation No.18 travel right full lever actually measured value,
& idling. Operation No.19 travel left full check proportional valve
lever & idling and controller for possible
failure.
10 Secondary pressure Measure directly High idling pressure is 0.8 MPa or less Replace proportional valve
of proportional valve the travel straight regardless neutral/operation
in short-circuit valve proportional valve
secondary
pressure. (G Port)
11 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
12 Lock valve poppet Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Boom down is low. Free from abnormal damage, etc on damage)
outside surface
13 Holding valve Visual check When removing, free from abnormal Replace
(poppet) resistance against sliding Free from (Check on the casing side for
<Trouble> abnormal damage, etc on outside damage)
Boom down is slow. surface
14 Boom spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Boom down is slow. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
15 Check boom spool Disassembly and Free from abnormal resistance against Replace spool assembly
and recirculation investigation sliding
<Trouble> Spring is free from breakage.
Machine can not be
lifted by supporting
with boom.
16 short-circuit valve Visual check. When removing, free from abnormal Replace (Check on the casing
spool. resistance against free from abnormal site for damage).
damage, etc on outside surface Spring
is free from breakage.
T5-2-8
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
17 Main relief valve Check set pressure • See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is relief
low.
18 Over load relief Visual check Free from dust entered in port relief Replace
valve valve.
<Trouble> Seat is free from abnormality
Machine can not be
lifted by supporting
with boom.
1 Arm in pressure Carry out service • See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.6 arm in full lever and sensor
relief Check remote control valve
2 Remote control Measure directly Check that pressure is 3.0 MPa or more Check remote control valve
valve pressure remote control in arm in full lever and high idling When equipped with multi
pressure of arm in operation control valve, check it while
changing lever pattern
3 Pump pressure Carry out service • See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, P2 Operation No.7 arm in full lever and in between P1 and P2 pump
pump pressures in operation pressures, check high
operation. pressure sensor
4 Actual measuring Carry out service • No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/ diagnosis D-1 P2 unload valve (cut valve) largely differed from the
P2 unload • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.6 Arm in full lever & check proportional valve and
relief controller for possible failure.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2 MPa in arm in full lever and high
directly at the ports idling operation.
A7 and A5 of 8
sections solenoid
block.
6 Actual measuring Carry out service • No.9 E-1 P1 pump In case where the reading is
current value of P1/ diagnosis E-2 P2 pump largely differed from the
P2 pump • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.7 Arm in full lever & in check proportional valve and
operation controller for possible failure.
T5-2-9
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
7 Secondary pressure Measure the pump Check that P1/P2 pump proportional Replace proportional valve
of P1, P2 pump proportional valve valve pressures are 2.0 MPa or more in
proportional valve secondary pressure arm in full lever and high idling
directly. (Ports a3, operation. (Secondary pressure is
a4) affected by oil temperature and
attachment weight)
8 Actual measuring Carry out service • See Service Diagnosis Data List In case where the reading is
current value of arm diagnosis Operation No. 1 Operation is nil largely differed from the
in spool 2 Operation No.6 Arm in full lever & actually measured value,
proportional valve relief check proportional valve and
Operation No.7 Arm in full lever & in controller for possible failure.
operation
9 Secondary pressure Measure directly Check that secondary pressure of Replace proportional valve
of arm in spool 2 the proportional proportional valve secondary pressures
proportional valve valve secondary are within the range of following
pressure at the Lever neutral: 0 MPa
ports A8 (arm 2 Motion in the air: 1.7 to 2.2 MPa
spool) of 8 sections Arm in relief: 2.5 MPa or more
solenoid block.
10 Actual measuring Carry out service Check that the value is not change • Check pressure sensor of
current value of diagnosis regardless of operation travel
travel straight • See Service Diagnosis Data List • In case where the reading is
proportional valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value,
& idling check proportional valve
Operation No.19 Travel left full lever & and controller for possible
idling failure.
11 Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve
of travel straight the proportional regardless of neutral/operation
proportional valve valve secondary
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block
12 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
13 Main relief valve Check set pressure • See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is relief
low.
14 Over load relief Visual check (Head Pressure is 32 MPa or more in arm in When only relief pressure of
valve side) and relief. arm in is low, replace valve
<Trouble> Free from dust entered in over load relief
P1, P2 pressure is valve.
low. Seat is free from abnormality
T5-2-10
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
15 Over load relief Visual check (Rod Pressure is 32 MPa or more in arm out When only relief pressure of
valve side) and relief. arm out is low, replace valve
<Trouble> Free from dust entered in over load relief
P1, P2 pressure is valve.
low. Seat is free from abnormality.
16 Arm 1 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1, P2 pressure is Free from abnormal damage, etc on damage)
high. outside surface
Spring is free from breakage.
17 Arm 2 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1, P2 pressure is Free from abnormal damage, etc on damage)
high or low. outside surface
Spring is free from breakage.
18 Check arm 2 spool Disassembly and Free from abnormal resistance against Replace spool assembly
and recirculation investigation sliding
<Trouble> Spring is free from breakage.
Arm in power is
poor.
19 Check lock valve Visual check Free from abnormal resistance against Replace
poppet sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
Both P1, P2 outside surface
pressures are high.
No
Sections Contents/normal value Corrective action, others
.
1 Arm out pressure Carry out service • See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.8 arm out full lever and sensor
relief Check remote control valve
2 Remote control Measure directly Check that pressure is 3.0 MPa or more Check remote control valve
valve remote control in arm out full lever and high idling When equipped with multi
pressure of arm out operation control valve, check it while
changing lever pattern
3 Pump pressure Carry out service • See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, P2 Operation No.9 arm out full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high
operation. pressure sensor
4 Actual measuring Carry out service • No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/ diagnosis D-1 P2 unload valve (cut valve) largely differed from the
P2 unload • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.8 Arm out full lever & check proportional valve and
relief controller for possible failure.
T5-2-11
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
No
Sections Contents/normal value Corrective action, others
.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2 MPa in arm out full lever and high
directly at the ports idling operation
A7 and A5 of 8
sections solenoid
block
6 Actual measuring Carry out service • No.9 E-1 P1 pump In case where the reading is
current value of P1/ diagnosis E-2 P2 pump largely differed from the
P2 pump • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.9 Arm out full lever & in check proportional valve and
operation controller for possible failure.
7 Secondary pressure Measure the pump Check that P1/P2 pump proportional Replace proportional valve
of P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 1.5 to 2.7 MPa in arm out full lever and
directly (Ports a3, high idling operation
a4) (Secondary pressure is affected by oil
temperature and attachment weight)
8 Actual measuring Carry out service Check that the value is not change • Check pressure sensor of
current value of diagnosis regardless of operation travel
travel straight • See Service Diagnosis Data List • In case where the reading is
proportional valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value,
& idling check proportional valve
Operation No.19 Travel left full lever & and controller for possible
idling failure.
9 Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve
of travel straight the proportional regardless of neutral/operation
proportional valve valve secondary
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block
10 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
11 Main relief valve Check set pressure • See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is relief
low.
12 Over load relief Visual check (Rod Pressure is 32 MPa or more in arm out When only relief pressure of
valve side) and relief. arm out is low, replace valve
<Trouble> Free from dust entered in over load relief
P1, P2 pressure is valve. Seat is free from abnormality
low.
13 Arm 1 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
T5-2-12
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
No
Sections Contents/normal value Corrective action, others
.
14 Arm 2 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
15 Check arm 2 spool Disassembly and Free from abnormal resistance against Replace spool assembly
and recirculation investigation sliding
<Trouble> (spring side) Spring is free from breakage.
Both P1, P2
pressures are low.
16 Check lock valve Visual check Free from abnormal resistance against Replace
poppet sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
Both P1, P2 outside surface
pressures are high.
1 Bucket digging Carry out service • See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.12 bucket digging full sensor
lever and relief Check remote control valve
2 Remote control Measure directly Check that pressure is 3.0M Pa or more Check remote control valve
valve remote control in bucket digging full lever and high When equipped with multi
pressure of bucket idling operation control valve, check it while
digging changing lever pattern
3 Pump pressure Carry out service • See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, P2 Operation No.13 Bucket digging full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high
operation. pressure sensor
4 Actual measuring Carry out service • No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/ diagnosis D-1 P2 unload valve (cut valve) largely differed from the
P2 unload • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.12 Bucket digging full check proportional valve and
lever & relief controller for possible failure.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2 MPa in bucket digging full lever and
directly at the ports high idling operation
A7 and A5 of 8
sections solenoid
block
6 Actual measuring Carry out service • No.9 E-1 P1 pump In case where the reading is
current value of P1/ diagnosis E-2 P2 pump largely differed from the
P2 pump • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.13 Bucket digging full check proportional valve and
lever & in operation controller for possible failure.
7 Secondary pressure Measure the pump Check that P1 pump proportional valve Replace proportional valve
of P1, P2 pump proportional valve pressures is 2.7 MPa or more and P2
proportional valve secondary pressure pump proportional valve pressure is 1.6
directly (Ports a3, to 2.2 MPa in bucket digging full lever
a4) and high idling operation.
T5-2-13
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
8 Attachment boost Carry out service No.3 POWER BOOST Check harness
solenoid command diagnosis Bucket digging COMP OFF, MEAS OFF Replace solenoid valve
9 Attachment boost Measure switching Check that pressure is 0 MPa in bucket Replace solenoid valve
solenoid secondary valve secondary digging full lever and high idling
pressure pressure operation
10 Actual measuring Carry out service • See Service Diagnosis Data List In case where the reading is
current value of diagnosis Operation No.12 Bucket digging full largely differed from the
travel straight lever & relief actually measured value,
proportional valve check proportional valve and
controller for possible failure.
11 Secondary pressure Measure directly Check that travel straight secondary Replace proportional valve
of travel straight the proportional pressure is 2.7 MPa or more in bucket
proportional valve valve secondary digging full lever and high idling
pressure at the operation
ports A6 (travel
straight) of 8
sections solenoid
block
12 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is No problem for sliding ability of internal
low. piston (Check it through PBp2 port.)
13 Check stroke limiter Visual check When piston is removed from cover, it is Replace
<Trouble> free from abnormal resistance against (Check on the casing side for
Both P1, P2 sliding damage.)
pressures are high. Free from abnormal damage, etc on
outside surface
14 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
15 Main relief valve Check set pressure • See Service Diagnosis Data List Reset or replace
Operation No.3 Boom up full lever and
relief
16 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
17 Bucket spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1, P2 Free from abnormal damage, etc on damage)
pressures are high. outside surface
Spring is free from breakage.
18 Over load relief Check targeted Free from dust entered in over load relief Replace
valve spool visually valve.
Seat is free from abnormality.
T5-2-14
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
1 Bucket dump Carry out service • See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.14 Bucket dump full sensor
lever and relief Check remote control valve
2 Remote control Measure directly Check that pressure is 3.0 MPa or more Check remote control valve
valve remote control in bucket dump full lever and high idling When equipped with multi
pressure of bucket operation control valve, check it while
dump changing lever pattern
3 Pump pressure Carry out service • See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, P2 Operation No.15 Bucket dump full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high
operation. pressure sensor
4 Actual measuring Carry out service • No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/ diagnosis D-1 P2 unload valve (cut valve) largely differed from the
P2 unload • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.14 Bucket dump full check proportional valve and
lever & relief controller for possible failure.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2 MPa in bucket dump full lever
directly at the ports and high idling operation. Replace
A7 and A5 of 8 proportional valve
sections solenoid
block
6 Actual measuring Carry out service • No.9 E-1 P1 pump In case where the reading is
current value of P1/ diagnosis E-2 P2 pump largely differed from the
P2 pump • See Service Diagnosis Data List actually measured value,
proportional valve. Operation No.15 Bucket dump full check proportional valve and
lever & in operation controller for possible failure.
7 Secondary pressure Measure the pump Check that P1 pump proportional valve Replace proportional valve
of P1, P2 pump proportional valve pressures is 2.7 MPa or more and P2
proportional valve secondary pressure pump proportional valve pressure is 0.9
directly (Ports a3, to 1.4 MPa in bucket dump full lever and
a4) high idling operation.
8 Actual measuring Carry out service • See Service Diagnosis Data List In case where the reading is
current value of diagnosis Operation No.14 Bucket dump full largely differed from the
travel straight lever & relief actually measured value,
proportional valve check proportional valve and
controller for possible failure.
9 Secondary pressure Measure directly Check that travel straight secondary Replace proportional valve
of travel straight the proportional pressure is 2.7 MPa or more in bucket
proportional valve valve secondary dump full lever and high idling operation
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block
T5-2-15
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
10 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is No problem for sliding ability of internal
low. piston (Check it through PBP2 port.)
11 Check stroke limiter Visual check Free from abnormal damage and wear Replace
<Trouble> on outside of piston inside cover (Check on the casing side for
Pilot pressure is low. damage.)
12 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
13 Main relief valve Check set pressure • See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 Boom up full lever and
Relief pressure is relief
low.
14 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
15 Bucket spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1, P2 Free from abnormal damage, etc on damage)
pressures are high. outside surface
Spring is free from breakage.
16 Over load relief Check targeted Free from dust entered in over load relief Replace
valve spool visually valve.
Seat is free from abnormality.
1 Swing pressure Carry out service • See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.11 Swing full lever and sensor
in operation Check remote control valve
2 Remote control Measure directly Check that pressure is 3.0 MPa or more Check remote control valve
valve remote control in boom up full lever and high idling When equipped with multi
pressure of swing operation control valve, check it while
changing lever pattern
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP ON, MEAS ON Check harness
Swing: COMP OFF, MEAS OFF
4 Swing parking brake Measurement of Lever neutral: 0 MPa Replace solenoid valve
solenoid solenoid valve A2 In operation: 4 MPa or more
port
T5-2-16
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
5 Shuttle valve Visual check No contamination on spool cover (short Clean or replace
<Trouble> side) and orifice
Pilot pressure is low. No damage on spool cover (long side)
and shuttle
6 Pump pressure Carry out service • See Service Diagnosis Data List Check high pressure sensor
sensor diagnosis for P2 Operation No.11 Swing full lever and
pump pressures in in operation
operation
7 Actual measuring Carry out service • No.8 D-2 P2 unload valve (cut valve) In case where the reading is
current value of P2 diagnosis • See Service Diagnosis Data List largely differed from the
unload proportional Operation No.11 Swing full lever & in actually measured value,
valve operation check proportional valve and
controller for possible failure.
8 Secondary pressure Measure the Check that P2 unload secondary Replace proportional valve
of P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2 MPa in swing full lever and high
directly at the ports idling operation
A5 of 8 sections
solenoid block
9 Actual measuring Carry out service • No.9 E-2 P2 pump In case where the reading is
current value of P2 diagnosis • See Service Diagnosis Data List largely differed from the
pump proportional Operation No.11 Swing full lever & in actually measured value,
valve operation check proportional valve and
controller for possible failure.
10 Secondary pressure Measure the pump Check that P2 pump proportional valve Replace proportional valve
of P2 pump proportional valve pressure is 2.7 MPa or more in swing full
proportional valve secondary pressure lever and high idling operation
directly (Ports a3,
a4)
11 Actual measuring Carry out service Check that the value is not change • Check pressure sensor of
current value of diagnosis regardless of operation travel
travel straight • See Service Diagnosis Data List • In case where the reading is
proportional valve Operation No. 1 Operation is nil largely differed from the
(Check this trouble Operation No.18 Travel right full lever actually measured value,
by only swing & idling check proportional valve
operation) Operation No.19 Travel left full lever & and controller for possible
idling failure.
12 Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve
of travel straight the proportional regardless of neutral/operation
proportional valve valve secondary
(Check this trouble pressure at the
by only swing ports A6 (travel
operation) straight) of 8
sections solenoid
block
T5-2-17
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
13 Command current Carry out service Check that the value is not change • Check pressure sensor of
value of short-circuit. diagnosis regardless of operation No 15 D-15 travel.
• See Service Diagnosis Data List • In case where the reading is
Operation No. 1 Operation is nil. largely differed from the
Operation No.18 travel right full lever actually measured value,
& idling. Operation No.19 travel left full check proportional valve
lever & idling and controller for possible
failure.
14 Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve.
of proportional valve the secondary regardless of neutral/operation.
in short-circuit valve. pressure of the
proportional valve
in short-circuit
valve. (G Port)
15 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
16 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is low. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
17 Swing spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
18 Short-circuit valve Visual check. • When removing, free from abnormal Replace (Check on the casing
spool. resistance against free from abnormal site for damage).
damage, etc on outside surface
Spring is free from breakage.
19 Swing relief valve Check set pressure • See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever and
Relief pressure is relief
low.
20 Swing motor Visual check Inner parts (cylinder block, piston, valve Replace
brake etc) are to be free from abnormal
resistance against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
21 Swing reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
gear oil from swing metal powder. reduction gear
reduction gear drain
22 Swing reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
T5-2-18
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
1 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure
brake solenoid diagnosis Lever neutral: COMP ON, MEAS sensor
ON Check harness
Swing: COMP OFF, MEAS OFF
3 Boost check valve Visual check When removing, free from abnormal Replace
(Sound of resistance against sliding
cavitation at Spring is free from breakage.
stopping)
4 By-pass check Visual check When removing, free from abnormal Replace
valve resistance against sliding
(Sound of Spring is free from breakage.
cavitation at
stopping)
6 Swing motor Visual check When removing, free from abnormal Replace
piston resistance against sliding
Spring is free from breakage.
7 Swing reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
gear oil from swing metal powder. reduction gear
reduction gear
drain.
1 Swing pressure Carry out service • •Engine stop & starter key ON Check and replace pressure
sensor diagnosis All pilot low pressure sensors are sensor
within range of 0 to 0.1 MPa.
2 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP ON, MEAS ON Check harness
Swing: COMP OFF, MEAS OFF Check parking brake release
switch
T5-2-19
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
6 Parking brake Visual check Piston and friction plate do not have Replace
abnormal resistance against sliding
Free from spring damage
No
Sections Contents/normal value Corrective action, others
.
2 Swing pressure Carry out service • Engine stop & starter key ON Replace pressure sensor
sensor diagnosis All pilot low pressure sensors are
within range of 0 to 0.1 MPa.
3 Swing relief valve Check set • See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.10 Swing full lever
Relief pressure is and relief
low.
4 Anti-reaction valve Visual check Free from dirt entering Clean or replace
Sliding part should be free from
foreign matter entering, abnormal
damage and wear.
5 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is free
valve from breakage
6 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
1 Travel right and left Carry out service • See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
2 Remote control Measure directly Check that pressure is 2.1 MPa or more Check remote control valve
valve remote control in travel right (left), forward (reverse) full
pressure of travel lever and high idling operation
right and left
T5-2-20
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
3 Actual measuring Carry out service • No.9 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/ diagnosis D-1 P2 unload valve (cut valve) largely differed from the
P2 unload • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.18 Travel right full lever check proportional valve and
& idling controller for possible failure.
Operation No.19 Travel left full lever &
idling
4 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly at the ports (reverse) full lever and high idling
A7 and A5 of 8 operation
sections solenoid Travel right (P1 unload): 0.5 to 1.0 MPa
block Travel left (P2 unload): 0.5 to 1.0 MPa
5 Actual measuring Carry out service • No.9 E-1 P1 pump In case where the reading is
current value of P1/ diagnosis E-2 P2 pump largely differed from the
P2 pump • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.18 Travel right full lever check proportional valve and
& idling controller for possible failure.
Operation No.19 Travel left full lever &
idling
6 Secondary pressure Measure the pump Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 pump proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly (Ports a3, (reverse) full lever and high idling
a4) operation
Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more
7 Actual measuring Carry out service Check that the value is not change • Check voltage of low
current value of diagnosis regardless of operation pressure sensor other than
travel straight • See Service Diagnosis Data List sensor for travel
proportional valve Operation No. 1 Operation is nil • In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value,
Operation No.19 Travel left full lever & check proportional valve
idling and controller for possible
failure
8 Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve
of travel straight the proportional regardless of neutral/operation
proportional valve valve secondary
pressure
9 Command current Carry out service Check that the value is not change • Check pressure sensor of
value of short-circuit diagnosis regardless of operation No 15 D-15 travel.
• See Service Diagnosis Data List • In case where the reading is
Operation No. 1 Operation is nil. largely differed from the
Operation No.18 travel right full lever actually measured value,
& idling. Operation No.19 travel left full check proportional valve
lever & idling and controller for possible
failure.
10 Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve.
of proportional valve the secondary regardless of neutral/operation.
in short-circuit valve. pressure of the
proportional valve
in short-circuit
valve. (G Port)
T5-2-21
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
11 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
Check sealing ability of shuttle valve and
entry of dust in orifice
12 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
13 Travel spool Visual check of When removing, free from abnormal Replace
<Trouble> targeted spool resistance against sliding (Check on the casing side for
Pump pressure is Free from abnormal damage, etc on damage)
high. outside surface
Spring is free from breakage.
14 short-circuit valve Visual check. When removing, free from abnormal Replace (Check on the casing
spool. resistance against free from abnormal site for damage).
damage, etc on outside surface Spring
is free from breakage
15 Travel motor relief Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel
valve 32 MPa or more in right and left travel motorÅfs relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel
locked crawler belt) and high idling motorÅfs relief valve is failed.
16 Travel motor Visual check Inner parts (piston, cylinder block, valve Replace
plate, brake valve spool) are to be free
from abnormal resistance against
sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
17 Parking brake in Visual check When removing, free from abnormal Replace
travel motor resistance against sliding
No sticking on friction plate and
separator plate
18 Travel reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
gear oil from travel metal powder. reduction gear
reduction gear drain
19 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
T5-2-22
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
1 Travel right and left Carry out service • See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
2 Remote control Measure directly Check that pressure is 2.1 MPa or more Check remote control valve
valve remote control in travel right (left), forward (reverse) full
pressure of travel lever and high idling operation
right and left
3 Actual measuring Carry out service Check that the value is not change • Check voltage of low
current value of diagnosis regardless of operation pressure sensor other than
travel straight • See Service Diagnosis Data List sensor for travel
proportional valve Operation No. 1 Operation is nil • In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value,
Operation No.19 Travel left full lever & check proportional valve
idling and controller for possible
failure.
4 Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve
of travel straight the proportional regardless of neutral/operation
proportional valve valve secondary
pressure
5 Actual measuring Carry out service • No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/ diagnosis D-1 P2 unload valve (cut valve) largely differed from the
P2 unload • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.18 Travel right full lever check proportional valve and
& idling controller for possible failure.
Operation No.19 Travel left full lever &
idling
6 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly at the ports (reverse) full lever and high idling
A7 and A5 of 8 operation
sections solenoid Travel right (P1 unload): 0.5 to 1.0 MPa
block Travel left (P2 unload): 0.5 to 1.0 MPa
7 Actual measuring Carry out service • No.9 E-1 P1 pump In case where the reading is
current value of P1/ diagnosis E-2 P2 pump largely differed from the
P2 pump • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.18 Travel right full lever check proportional valve and
& idling controller for possible failure.
Operation No.19 Travel left full lever &
idling
8 Secondary pressure Measure the pump Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 pump proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly (Ports a3, (reverse) full lever and high idling
a4) operation
Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more
T5-2-23
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
9 Exchange P1 for P2 Exchange delivery Check the direction of deviation If the direction is changed,
pipe of P1 for P2 inspect a pump. If the
direction is not changed,
inspect a valve and travel unit.
10 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
Check sealing ability of shuttle valve and
entry of dust in orifice
11 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage
12 Travel spool Visual check of When removing, free from abnormal Replace
<Trouble> targeted spool resistance against sliding (Check on the casing side for
Pump pressure is Free from abnormal damage, etc on damage)
high. outside surface
Spring is free from breakage
13 Travel motor relief Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel
valve 32 MPa or more in right and left travel motorÅfs relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel
locked crawler belt) and high idling motorÅfs relief valve is failed.
Replace as necessary
14 Travel motor Visual check Inner parts (piston, cylinder block, valve Replace
plate, brake valve spool) are to be free
from abnormal resistance against
sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
15 Travel reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
gear oil from travel metal powder. reduction gear
reduction gear drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
17 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage, etc.
T5-2-24
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
1 Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed Check pressure sensor
switching solenoid diagnosis No.3 F-3 1/2-TRAVEL Check harness
Lever neutral COMP OFF, MEAS OFF Check travel 1/2 speed switch
Travel operation COMP ON, MEAS ON on gauge cluster
2 Travel 1/2 speed Measure A3 port Lever neutral: 0 MPa Replace solenoid valve
switching solenoid pressure on In operation: 4 MPa or more
solenoid valve
3 1/2 speed switching Visual check Check that spool is free from abnormal Replace
spool in travel motor damage and spring is free from (Check on the casing side for
breakage damage)
4 1/2 speed switching Visual check Free from entry of dust Remove dust or replace
orifice in travel motor
5 Tilting piston in Visual check Free from abnormal wear on piston and Replace
travel motor seal (Check on the casing side for
damage)
1 Pilot pressure Carry out service • Engine stop & starter key switch is ON Check pressure sensor and
sensor diagnosis Targeted pilot low pressure sensor is replace as necessary
in range of 0 to 0.1 MPa Check remote control valve
2 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
3 Parking brake in Visual check When removing, free from abnormal Replace
travel motor resistance against sliding
Spring free from breakage, damage, etc.
4 Orifice of passage Visual check Free from entry of dust Remove dust or replace
for parking brake in
travel motor
19. Travel does not run straightly when both crawlers and attachment operated simultaneously .
1 Actual measuring Carry out service No. 8 D-3 S-TRAVEL is should be • Check voltage of low
current value of diagnosis COMP 557 mA and MEAS 557±30 mA pressure sensor other than
travel straight in both travel full lever and in boom-up travel sensor
proportional valve full lever at high idling (Command value • In case where the reading is
is changed according to operation. largely differed from the
Above mentioned values indicate while actually measured value,
boom-up and full lever operation are check proportional valve
performed). and controller for possible
failure.
T5-2-25
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
2 Secondary pressure Measure directly Check secondary pressure is within Replace proportional valve
of travel straight the proportional range of 1.7 to 2.1 MPa in both travel full
proportional valve valve secondary lever and in boom-up full lever at high
pressure idling. (Command value is changed
according to operation. Above
mentioned values indicate while boom-
up and full lever operation are
performed).
3 Command current Carry out service No 15 D-15 is should be COMP 530 mA • Check voltage of low
value short-circuit diagnosis. and MEAS 530±30 mA in both travel full pressure sensor other than
valve lever and in boom-up full lever at high travel sensor.
idling • In case where the reading is
largely differed from the
actually measured value,
check proportional valve
and controller for possible
failure.
4 Secondary pressure Measure directly Check secondary pressure is within Replace proportional valve.
of proportional valve the secondary range of 1.5 to 1.9 MPa in both travel full
in short-circuit valve. pressure of the lever and in boom-up full lever at high
proportional valve idling.
in short-circuit
valve. (G Port)
5 Travel straight spool Visual check When removing, free from abnormal Replace
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
6 Short-circuit valve Visual check. When removing, free from abnormal Replace (Check on the casing
spool. resistance against free from abnormal site for damage).
damage, etc on outside surface Spring
is free from breakage.
20. Slow breaker (crusher) operation, weak power (In case of conflux, check p1 unload/pump and travel
straight)
1 Pressure sensor for Carry out service • See Service Diagnosis Data List Check and replace pressure
optional attachment diagnosis Operation No.16 P2 side OPT full sensor
lever and relief Check remote control valve
2 Remote control Measure directly Check that pressure is 2.1 MPa or more Check remote control valve
valve remote control in optional attachment full lever and high
pressure of travel idling operation
right and left
3 Actual measuring Carry out service • See Service Diagnosis Data List •In case where the reading is
current value of P1/ diagnosis Operation No.16 P2 side OPT full largely differed from the
P2 unload lever and relief actually measured value,
proportional valve check proportional valve and
controller for possible failure.
T5-2-26
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
4 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2 MPa
directly at the ports
A7 and A5 of 8
sections solenoid
block
5 Actual measuring Carry out service • See Service Diagnosis Data List • Check voltage of low
current value of diagnosis Operation No.16 P2 side OPT full pressure sensor other than
travel straight lever & relief sensor for optional
proportional valve attachment
• In case where the reading is
largely differed from the
actually measured value,
check proportional valve
and controller for possible
failure.
6 Secondary pressure Measure directly Check that travel straight secondary Replace proportional valve
of travel straight the proportional pressure is 2.7 MPa or more in optional
proportional valve valve secondary attachment full lever and high idling
pressure at the operation
ports A6 (travel
straight) of 8
sections solenoid
block
7 P1 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
<Trouble> poppet and no contamination on orifice
Only P1 pressure is No problem for sliding ability of internal
low. piston (Check it through PBp2 port.)
8 Relief pressure Check set pressure • See Service Diagnosis Data List Reset or replace
Operation No.16 P2 side OPT full
lever and relief
(Set value of factory shipment is 24.5
MPa.)
9 Remote control Check targeted Check sealing ability of shuttle valve and Replace
valve remote control entry of dust in orifice.
valve
10 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
11 Spool for optional Visual check When removing, free from abnormal Replace
attachment resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
P1, P2 pressures outside surface
are high. Spring is free from breakage.
12 Over load relief Check targeted Free from dust entered in over load relief Replace
valve spool visually valve
Seat is free from abnormality.
T5-2-27
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
1 N&B selector spool Visual check When removing, free from abnormal Replace
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage
2 N&B selector Screw for Check that the error indication is Replace solenoid valve
solenoid emergency disappeared by turning emergency
screw
3 N&B selector Carry out service • No.11 F-4 Option selector is B mode Check solenoid valve
solenoid diagnosis COMP ON, MEAS ON Check harness
Spool position BRK
Selector switch BRK
4 N&B selector Carry out service • No.16 B-11 Check pressure sensor
pressure sensor diagnosis Data List Check harness
3.0 MPa at B mode and 0.0 MPa at A
mode
1 N&B selector spool Visual check When removing, free from abnormal Replace
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
2 N&B selector Carry out service • No.11 F-4 Option selector is A mode Check solenoid valve
solenoid diagnosis COMP OFF, MEAS OFF Check harness
Spool position NIB
Selector switch NIB
T5-2-28
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
T5-2-29
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
2. ELECTRIC SYSTEMS
T5-2-30
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
ATTENTION
Do not insert the male terminal the thickness differs.
It may cause loose connection.
T5-2-31
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
T5-2-32
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
2.2 TROUBLE
1. Engine does not stop.
2. "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
3. Auto accel does not actuate. (The engine speed does not automatically slow down.)
4. Auto accel does not actuate. (The engine speed does not automatically speed up.)
5. Wiper does not function.
T5-2-33
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
T5-2-34
TROUBLESHOOTING (BY TROUBLE) E215B-E245B
3. Auto accel does not actuate. (The engine speed does not automatically slow down.)
No
Sections Contents/normal value Corrective action, others
.
1 Engine coolant Check engine No.2 G-5 WATER TEMP Replace engine coolant
temperature coolant Auto accel does not work in the sensor
temperature by temperature -15 °C or less.
carrying out Warm up and raise the coolant
service diagnosis. temperature to – 15 °C or more
2 Gauge cluster Indication of auto Mark "Display/not display" for auto Replace gauge cluster
accel accel switches by auto accel switch
operation on gauge cluster.
3 Low pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
sensor No.6 is in the range of 0~0.1 MPa at
control lever neutral position.
4. Auto accel does not actuate. (The engine speed does not automatically speed up.)
No
Sections Contents/normal value Corrective action, others
.
1 Low pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
sensor No.6 is raised with control lever
operated.
T5-2-35
E215B-E245B TROUBLESHOOTING (BY TROUBLE)
Wiping range of
forward and
reverse movements
Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position
SM0111
Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF
relay Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
R-30: Check that the relay is worked as shown in the table. Check that the relay is excited.
* When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
Reverse rotation from the wiper startup, turn OFF all relay's outputs. if necessary.
relay
T5-2-36
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) E215B-E245B
The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not
be detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal
output.
1. Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not operated, both selector valve and proportional valve are
automatically actuated, the sensor detects the machine condition and the mechatro controller identifies
the normal condition or failed condition of the system.
T5-3-1
E215B-E245B TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
For
Forthe
tthediagnosing
diagnosingitems,
items,see
seeTable
Table 48-1.
1.
When
Whenrequired
requiredto
tostop
stopin indiagnosis
diagnosis
Turn engine on operation,press
operation, pressthe
thebuzzer
buzzerstop
stopswitch
switch
manually. BACK TO No.3 and
andthetheoperation
operationisisforcedly
forcedlystopped.
stopped.
When failed,
DIAG MODE 1 RESULT 1 1 P1 UNLOAD
ENGINE SPEED
P1 UN-LOAD PSV NG
NG
0000 rpm
PRESSURE
P1 UN-LOAD SPOOL NG C-1 00.0M C-2 00.0M
PROPO-VALVE
DATA END FEED DATA END FEED E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
SM0114
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground.
If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or
death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail
to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition.
2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select
valve for possible abnormality.
Check that the commands of proportional valve and select valve do not largely differ from the actually
measured values through the service diagnosis.
The preliminary investigation of electric system makes the time saving and high precision diagnosis
possible.
3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as
an example. When multiple troubles are occurred at the same time, there is a case no accordance of
diagnosis obtained. In this case, contact our dealer/distributor.
4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not
appear. If necessary, examine the presence or absence of trouble referring to the trouble history.
T5-3-2
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) E215B-E245B
Turn engine on
Example: Case of boom up
manually. AT CONTROL LEVER IS
NEUTRAL WHEN FINISHING OF
DIAGNOSIS IS REQUIRED.
BOOM UP BOOM UP
OK BACK TO No.3
PRESSURE 0.0 MPa PRESSURE 1.5 MPa PRESSURE 3.0 MPa
SM0115
SEARCHABLE OPERATION
Boom up
Boom down
Bucket digging
Bucket dump
Arm in
Arm out
Swing
Travel right
Travel left
P1 side option
P2 side option
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground.
If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or
death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail
to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. Place
the bucket on the ground between both crawlers.
2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate
attachment.
When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UN-
LOAD PSV NG" is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not
appear. If necessary, examine the presence or absence of trouble referring to the trouble history.
T5-3-3
E215B-E245B TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
T5-3-4
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) E215B-E245B
T5-3-5
E215B-E245B TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
[MEMO:]
T5-3-6
REPAIR INSTRUCTIONS
M0103
REPAIR INSTRUCTIONS E215B-E245B
Section 2 UPPERSTRUCTURE
Group 1 Upperstructure
Group 2 Pump device
Group 3 Control valve
Group 4 Swing device
Group 5 Pilot valve
Section 3 UNDERCARRIAGE
Group 1 Swing bearing
Group 2 Travel device
Group 3 Swivel joint
Group 4 Track adjuster
Group 5 Front idler
Group 6 Upper and lower roller
Group 7 Tracks
GENERAL INFORMATION
CONTENTS
W1-1-1
E215B-E245B PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
W1-1-2
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY E215B-E245B
SM0173
RIGHT WRONG
a
A a
b b
a=b a≠b
SM0174
W1-1-3
E215B-E245B PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
ELECTRICAL EQUIPMENT
- The disassembly of electrical equipment is not
allowed.
- Handle equipment with care so as not to drop it or
bump it.
- Connector should be removed by unlocking while
holding the connector.
Never stress in tension to the caulked section by
pulling wire.
- Check that connector is connected and locked
completely.
- Engine key off before removing and connecting
connector.
- Engine key off before touching terminals of starter
and alternator.
- Wash machine with care so as not to splash water
on electrical equipment and connector.
- When water has entered in the waterproofed
connector, the removing of water is not easy. So
check the removed waterproofed connector with
care to protect it from entry of water. If moisture
adheres on it, dry it completely before connecting.
- Remove battery grounding terminal before
beginning work close to battery and battery relay
with tools.
WARNING
Battery fluid is dangerous. The battery fluid is
dilute sulfuric acid, and causes scald and loss of
eyesight by adhering on eyes, skin and clothes.
When the fluid has adhered on them, take an
emergency measure immediately and see a
doctor for medical advice.
- When it has adhered on skin:
wash with soap and water.
- When it has got in eyes:
wash in water for 10 minutes or more
immediately.
- When it was swallowed:
drink milk or water.
W1-1-4
TIGHTENING TORQUE E215B-E245B
TORQUE CHART
WARNING
Use tools appropriate for the work to be done.
Makeshift tools and procedures can create safety
hazards. For loosening and tightening nuts and
bolts, use the correct tools. Avoid bodily injury
caused by slipping wrenches.
Bolt Types
Tighten nuts or bolts correctly to torque
specifications. Two kinds of bolts, hexagon bolts T
and socket bolt, each made of different material, are
used. Make sure to employ the correct bolts and
tighten them to specification when assembling the
machine or components.
SM0175
T Bolt,
Hexagon
Wrench Socket
Bolt Dia. Wrench
Size bolt
Size
(Nm)
M18 13 6 29.5
M10 17 8 64
M12 19 10 108
M14 22 12 175
M16 24 14 265
M18 27 14 390
M20 30 17 540
M22 32 17 740
M24 36 19 930
M27 41 19 1370
M30 46 22 1910
M33 50 24 2550
M36 55 27 3140
W1-2-1
E215B-E245B TIGHTENING TORQUE
IMPORTANT
1. Apply lubricant (i. e. white zinc B dissolved into
spindle oil) to nuts and bolts to stabilize their
friction coefficients.
2. Torque tolerance is ± 10%.
3. Be sure to use bolts of correct length. Bolts that
are too long cannot be tightened, as the bolt tip
comes into contact with the bottom of the bolt
hole. Bolts that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart are for general
use only.
Do not use these torques if a different torque is
given for a specific application.
5. Make sure that the nut and bolt threads are
clean before installing. Remove dirt or
corrosion, if any.
1.4 1 12 9 4 1 6 7 14
6 3
4 5
2.3
2 13 8 5 2 3 10 11
SM0176
W1-2-2
TIGHTENING TORQUE E215B-E245B
IMPORTANT
1. Be sure to clean and inspect sealing surfaces.
Scratches / roughness cause leaks and seal
wear. Unevenness causes seal extrusion. If SM0177
defects cannot be polished out, replace the
component.
2. Be sure to use only specified O-rings. Inspect
WRONG
O-rings for any damage. Take care not to file O-
ring surfaces. When installing an O-ring into a
groove, use grease to hold it in place.
3. Loosely assemble split flange halves. Make
sure that the split is centrally located and
perpendicular to the port. Hand-tighten the
bolts to hold the parts in place. Take care not to
pinch the O-ring.
4. Tighten bolts alternately and diagonally, as SM0178
shown, to ensure even tightening.
5. Do not use air wrenches. Using an air wrench
often causes tightening of one bolt fully before
tighten the others, resulting in damage to O-
rings or uneven tightening of bolts.
• Lock Plate
RIGHT WRONG
IMPORTANT: do not reuse lock plates. Do not try to
bend the same point twice.
• Cotter Pin
Do not bend it round
Bend along edge sharply
IMPORTANT: do not reuse cotter pins. Match the
holes in the bolt and nut while tightening, not while
loosening.
RIGHT RIGHT WRONG
• Lock Wire
IMPORTANT: apply wire to bolts in the bolt-
tightening direction, not in the bolt-loosening
direction.
Bend along edge sharply
SM0180
RIGHT WRONG
Loosen
Tighten
SM0181
W1-2-3
E215B-E245B TIGHTENING TORQUE
PIPING JOINT
Pipe Thread Connection / Union Joint
Tightening Torque Specifications 1 4 3 5 2
Union Joint
Metal sealing faces (4) and (5) of adaptor (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
Joint Body SM0182
IMPORTANT
1. Do not over-tighten union nut (3). Excessive
force will be applied to metal sealing surfaces
(4) and (5), possibly cracking adaptor (1). Be 37°
sure to tighten union nut (3) to specifications.
37°
2. Scratches or other damage to sealing surfaces
(4) or (5) will cause oil leakage at the joint.
Take care not to damage them when
connecting /disconnecting. Male Union Joint Female Union Joint
SM0183
NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.
W1-2-4
TIGHTENING TORQUE E215B-E245B
IMPORTANT
1. Be sure to replace O-Ring (6) with a new one
when reconnecting.
2. Before tightening union nut (9), confirm that O- 8 10 Joint body
SM0184
Ring (6) is seated correctly in O-Ring groove
(8). Tightening union nut (9) with O-Ring (6)
displaced will damage O-Ring, resulting in oil
leakage.
3. Take care not to damage O-Ring groove (8) or
sealing face (10). Damage to O-Ring (6) will
cause oil leakage.
4. If union nut (9) is found to be loose, causing oil
leakage, do not tighten it to stop the leak.
Instead, replace O-Ring (6) with a new one,
then tighten union nut (9) after confirming that
O-Ring (6) is securely seated in place.
W1-2-5
E215B-E245B TIGHTENING TORQUE
Screwed-In Connection
• Application Procedure
Leave one to two pitch threads uncovered
Confirm that the thread surface is clean, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap
seal tape in the same direction as the threads.
SM0188 SM0189
W1-2-6
TIGHTENING TORQUE E215B-E245B
Connecting Hose
WARNING
WRONG RIGHT
1. When replacing hoses, be sure to use only
genuine parts. Using hoses other than genuine
hoses may cause oil leakage, hose rupture or
separation of fitting, possibly resulting in a fire
on the machine.
2. Do not install hoses kinked. Application of high
oil pressure, vibration, or an impact to a kinked
hose may result in oil leakage, hose rupture or SM0190
separation of fitting.
Utilize print marks on hoses when installing
hoses to prevent hose from being installed WRONG RIGHT
kinked.
Rubbing Against Each Other
3. If hoses rub against each other, wear to the
hoses will result, leading to hose rupture. Take
necessary measures to protect hoses from
rubbing against each other.
Take care that hoses do not come into contact SM0191
with moving parts or sharp objects.
WRONG RIGHT
Clamp Clamp
Rubbing
SM0192
WRONG RIGHT
Rubbing
Clamp
SM0193
W1-2-7
E215B-E245B TIGHTENING TORQUE
NOTE:
W1-2-8
SECTION 2 E215B-E245B
UPPERSTRUCTURE
CONTENTS
WARNING
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear
and appropriate to hold the weight of load.
W2-1-1
E215B-E245B UPPERSTRUCTURE
14
13 SM0261
W2-1-2
UPPERSTRUCTURE E215B-E245B
17 15
installation of the cab
Install it in reverse order of removing according to
the Tightening Torque Table. 15
Tightening
Allen wrench
Tightening position torque
HEX
Nm (lbf·ft)
Nut M16 - (17) 24 191 (140) 16
Capscrew - (2), (9) 19 79.4 (60)
15
Sems bolt M6 - Torxdriver
8.5 (6.3) Smontaggio e rimontaggio
15 dei bulloni di fissaggio
(5), (6) T30
cabina
Sems bolt M6 - 15
Plus driver 5.0 (3.7) SM0262
(12), (13)
18
18
SM0263
W2-1-3
E215B-E245B UPPERSTRUCTURE
Removal of counterweight
1. Remove plugs (1) from the counterweight and
attach two M36 eye bolts to the counterweight.
1
5
6
7
4 SM0265
SM0266
W2-1-4
UPPERSTRUCTURE E215B-E245B
Installation of counterweight
4 SM0265
4 SM0267
W2-1-5
E215B-E245B UPPERSTRUCTURE
A B B
E
C D D
F F F
F F D
C
B
A
E E
SM0268
W2-1-6
UPPERSTRUCTURE E215B-E245B
4 2 3 5
A A
4 6 6 5
2 3
section A - A
SM0269
W2-1-7
E215B-E245B UPPERSTRUCTURE
1
3. Attach wire ropes (3) like illustrated in the figure
beside.
Use chain blocks (4) for easy adjustment of
wire rope lengths and to level the frame.
Wire ropes:
D 16 mm x 2.5 m, 2 pcs
D 16 mm x 1.5 m, 2 pcs
Chain blocks:
for 2,000 kg, 2 pcs
SM0271
W2-1-8
UPPERSTRUCTURE E215B-E245B
6
SM0272
CAUTION
OUTER (S) ZONE POSITION
Confirm the reamer bolt position (X) referring to Fig
SM0274.
(*) SM0274
W2-1-9
E215B-E245B UPPERSTRUCTURE
NOTE:
W2-1-10
PUMP DEVICE E215B-E245B
WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.Prevent these
dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear
and appropriate to hold the weight of load.
Removal Installation
1. Remove all protection panels and doors to give 1. Lift the hydraulic pump device by means of
access to the Hydraulic Pump Device. hoist and ropes.
2. Disconnect all electrical connectors. NOTE: hydraulic pump device weight: 143 kg.
3. Remove all hoses and collector from hydraulic 2. Install the hydraulic pump device to the engine
pump device. by means of related bolts.
: 19, 22, 30, 36 mm : 17 mm
: 8, 10 mm : 431 ± 43.1 Nm
4. Fasten the hydraulic pump device by means of 3. Install all hoses and collector to the hydraulic
hoist and lifting ropes. pump device.
: 19 mm
NOTE: hydraulic pump device weight: 143 kg. : 29,4 Nm
5. Remove the fixing bolts of hydraulic pump : 22 mm
device and draw it from engine. : 39,2 Nm
: 17 mm : 30 mm
: 137,2 Nm
: 36 mm
: 156,9 Nm
: 8 mm
: 64 Nm
: 10 mm
: 108 Nm
W2-2-1
E215B-E245B PUMP DEVICE
9
534
702 412 406
531 261
548 792 413
774
789 732 532 710
9
535 271
953
886
806
728
717 468 717
724
113 313
127 808 124
954 546
123 407 325
824 901
725
710
490
262 490
111
251 727 885
401
312
116 717 886 8
124
127 314 710
141
157
156 725 727
151 153 7
885 886 467 6
152
211 466 5
214
212 6 435
435
4
10 11
SM0275
NOTE: the number in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
4 - Pilot pump 407 - Socket bolt M6×55 (Q.ty 3)
5 - PTO gear casing 412 - Socket bolt (Q.ty 2)
6 - O-Ring (Q.ty 2) 413 - Socket bolt (Q.ty 2)
7 - Cover 435 - Socket bolt (Q.ty 2)
8 - Socket bolt (Q.ty 2) 466 - Plug VP PF 1/4 (Q.ty 2)
9 - Regulator 467 - Plug VP PF 3/8 (Q.ty 2)
10 - Short-circuit valve 468 - Plug VP PF 3/4 (Q.ty 4)
11 - Socket bolt 490 - Plug nptf 1/16 (Q.ty 27)
111 - Shaft (F) 531 - Tilt Pin m24×2 (Q.ty 2)
113 - Shaft (R) 532 - Servo piston M24×2 (Q.ty 2)
116 - 1st gear 534 - Stopper (Q.ty 2)
123 - Roller bearing (Q.ty 2) 535 - Stopper (Q.ty 2)
124 - Needle bearing (Q.ty 2) 546 - Spacer (Q.ty 2)
127 - Bearing spacer (Q.ty 4) 548 - Feed back Pin (Q.ty 2)
141 - Cylinder block (Q.ty 2) 702 - O-Ring (Q.ty 2)
151 - Piston (Q.ty 18) 710 - O-Ring (Q.ty 2)
152 - Shoe (Q.ty 18) 717 - O-Ring (Q.ty 2)
153 - Plate (Q.y 2) 724 - O-Ring (Q.ty 18)
156 - Spherical bushing (Q.ty 2) 725 - O-Ring (Q.ty 6)
157 - Cylinder spring (Q.ty 18) 727 - O-Ring (Q.ty 3)
211 - Shoe plate (Q.ty 2) 728 - O-Ring (Q.ty 4)
212 - Swash plate (Q.ty 2) 732 - O-Ring (Q.ty 2)
214 - Tilting bushing (Q.ty 2) 774 - Oil seal
251 - Swash plate support (Q.ty 2) 789 - Backup ring (Q.ty 2)
261 - Cover (front) 792 - Backup ring (Q.ty 2)
262 - Cover (rear) 806 - Hex. nut M16 (Q.ty 2)
271 - Pump casing (Q.ty 2) 808 - Hex. nut M20 (Q.ty 2)
312 - Valve block 824 - Snap ring (Q.ty 2)
313 - Valve plate (front) 885 - Valve plate pin (Q.ty 2)
314 - Valve plate (rear) 886 - Spring pin (Q.ty 4)
325 - Sensor Block 901 - Eye bolt M10 (Q.ty 2)
401 - Socket bolt M20×210 (Q.ty 8) 953 - Set screw M16×30 (Q.ty 2)
406 - Socket bolt M8×20 (Q.ty 4) 954 - Set screw M20 (Q.ty 2)
W2-2-2
PUMP DEVICE E215B-E245B
312
466 SM0276
5
2. Removing PTO gear casing. 435
Remove the socket bolts (435), then remove
PTO gear casing (5).
: 8 mm
SM0278
3. Removing regulator.
Remove the socket bolts (412) e (413), then
remove regulator (9). 9
: 6 mm
SM0277
W2-2-3
E215B-E245B PUMP DEVICE
SM0279
SM0281
W2-2-4
PUMP DEVICE E215B-E245B
261
SM0282
SM0283
271
212
(211)
SM0284
111
(113)
SM0285
W2-2-5
E215B-E245B PUMP DEVICE
NOTE: the valve plate may come off during the 312
separation of pump casing from valve block.
314
(313)
SM0286
SM0287
W2-2-6
PUMP DEVICE E215B-E245B
Assembly
1. Assembly is a reverse order of disassembly,
but notice the following:
- Repair scored parts at disassembly. Get
replacements ready beforehand
- Wash parts sufficiently in cleaning oil and dry
them with jet air.
- Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
- In principle, replace sealing parts such as O-
Rings and oil seals.
- Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
- Do not mix up front pump parts with rear
pump parts.
SM0288
3. Install swash plate placing the pump casing
with its mounting surface of the regulator facing
251
down. Insert the tilting bushing of the swash 271 (531)
plate into tilting pin (531), and fit swash plate
(212) to swash plate support (251) properly.
SM0289
W2-2-7
E215B-E245B PUMP DEVICE
251
NOTE: Do not knock on the shaft with a hammer or
somethings.
Fix the bearing by lightly tapping the outer race of it
by means of a plastic hammer and set it exactly to 123
the end by using a steel rod and others.
127,824
111
SM0290
NOTE: Coat the oil seal in seal cover with a thin film 406
of grease.
Handle the oil seal with sufficient care so it is not
scored.
SM0291
SM0292
W2-2-8
PUMP DEVICE E215B-E245B
312
NOTE: do not mistake the suction and delivery
sides of the valve plate.
314
(313)
SM0293
SM0295
W2-2-9
E215B-E245B PUMP DEVICE
5
435
SM0278
435
311
312
466 SM0276
W2-2-10
PUMP DEVICE E215B-E245B
MAINTENANCE STANDARD:
Unit: mm (poll.)
Recommended
Standard
Part name and inspection item value for Remedy
dimension (mm)
replacement (mm)
Clearance between piston and cylinder
0.039 0.067 Replace piston or cylinder.
bore (D-d)
SM0520
SM0521
t
SM0522
Free height of cylinder spring (L) 41.1 40.3 Replace cylinder spring.
L
SM0523
SM0524
Repair standards for cylinder, valve plate and swash plate (shoe plate face)
W2-2-11
E215B-E245B PUMP DEVICE
626
625
624
753
627
623
621 D 728
B 645
611
622 F
733 874 646
732 613
875 644
631
898 612
652 875
A 643
651
836 G E
897 C
655
654
653
814
630
438
629
763
802
628
756
801
924
412
656 413
438 757
Y
W
Z D
418 079 E
041 876
755 X 615
601 755
722 858
466 496 734
755 G
887
708 F
A 876
662 B 724 614
439 C
642 730 725 8-724 755
858
041 755
755 466
466 755
641 SM0296
NOTE: the number in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
W2-2-12
PUMP DEVICE E215B-E245B
W2-2-13
E215B-E245B PUMP DEVICE
Disassembly of regulator
624,625,626
627
801
629( 628 )
W2-2-14
PUMP DEVICE E215B-E245B
629
SM0299
439
641
SM0501
SM0502
615
614
SM0503
W2-2-15
E215B-E245B PUMP DEVICE
SM0504
613(875)
SM0505
SM0506
611
SM0507
W2-2-16
PUMP DEVICE E215B-E245B
662
15. Remove VP plug (466) from pilot cover (641) 642
and draw out spool (642) and spring (662).
466
641
SM0509
W2-2-17
E215B-E245B PUMP DEVICE
Assembly
814
NOTE: Make sure that the spool and the sleeve SM0511
652
SM0512
W2-2-18
PUMP DEVICE E215B-E245B
614(875,858)
858
615
614
SM0515
W2-2-19
E215B-E245B PUMP DEVICE
SM0516
662
13. Put spring seat (644), pilot spring (646) and 642
adjust stem (645) into the pilot hole. Then
assemble spring seat (624), inner spring (626)
and outer spring (625) into the compensating 466
hole.
641
SM0509
NOTE: do not mistake the direction of the spring
seat.
644,645,646
14. Attach cover (629) fitted with adjust screws 626
(628 and 925), adjust stem (627), lock nut
(630), nut (801) and socket bolt (924). Then 625(624)
fasten them with socket bolts (438).
: 5 mm
: 12 Nm
630 924
SM0518
W2-2-20
PUMP DEVICE E215B-E245B
126
886
826
128
885
728
886
115
468
326
435
125
118
825 125 SM0519
W2-2-21
E215B-E245B PUMP DEVICE
Disassembly
414
125
NOTE: ball bearing (125) can not be separated from
3rd gear (118).
118
SM0527
W2-2-22
PUMP DEVICE E215B-E245B
Assembly
Maintenance standard
SM1251
W2-2-23
E215B-E245B PUMP DEVICE
NOTE:
W2-2-24
CONTROL VALVE E215B-E245B
WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear
and appropriate to hold the weight of load.
W2-3-1
E215B-E245B CONTROL VALVE
2 SM0528
W2-3-2
CONTROL VALVE E215B-E245B
P1 P1 pump
P2 P2 pump
SM0529
W2-3-3
E215B-E245B CONTROL VALVE
Ba Arm 1 out
T1 Tank return
PAa2 Arm 2 in
SM0530
W2-3-4
CONTROL VALVE E215B-E245B
A
B
273x10 T2
H 273x10 H
P1 unload PCb PAL
(Travel priotity) Travel left
C C
D D
PBs
Boom Swing
E PCc
PBb E
PBa1 Pss
Bucket Arm 1
F F
PBa2 PAo
PA
Arm 2 MU Option
G G
K PBp1 PBp2 K
(P3)
B A
PBa2 PAo
PBp1 PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2 PBo
W2-3-5
E215B-E245B CONTROL VALVE
J
154 164 101
P2
T2 T1
PAL JJ PBL
YT1
YBG1
PB1 PCa
P2-20
PBs PAs
YS1
Pss
PBa1 PAa1
YA1
PAo PBo
YP1
SECTION A-A
(P4)
163 162 163 169 155 162
154 164
P1
102
973 973
PTb PCb
P1-20
973 973
PBr PAr
YT1
973
PAb PBb
YB1
973 973
PBc PCc
PAc
YK1
974
973
PAa2 PBa2
YAG
1
974
(P3)
SM0532 162 162 169 155 163 162 SECTION B-B
W2-3-6
CONTROL VALVE E215B-E245B
552
CMR2 551
562 164
562 162
CMR1
BL
552
163
522
512
307
261
331 264
PBL
327 205
329 SECTION C-C
336
331
333 Travel priority
202 PTb
201 Travel right Boom conflux
333 202
331 PAr PB1
333
336 331
324
323 339
326
331 325
261
331
306 261
511
161 521
CCb
163 Ar 551
164
511
305
521
CP1
551 551
164 164
163
Br
161 310
164
154
(T3)
261
264 331
PBr
327
205
329
SECTION D-D 336
331
333
PCa
SM0533 P2 unload 202
W2-3-7
E215B-E245B CONTROL VALVE
Swing 204
203 PBs
Boom 333
333
336 Pss 331
331
336
603 322
211 321 322
AbR
279 x 3 266 321
331
331
215 XAb 261 261
160 303
514 161
524
As 162
CRb
556 Ab
163
164 511
511 523
521 LCs
LCb 556
164
551
Bb 162
164 Bs
161
301
266
264
264
602 PAb
160 PAs
206
205 BbR
SECTION E-E
551 Bucket
164 201
209 333
216 PCc Arm 1 331
333 PBa1 336
331 322
PBc
336
322 321
321 BaR 603
602 BcR 171
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc
LCa
551 551
164 164
Ac
162 Aa
302
161
264 264
603 PAc PAa1 205
205 SECTION F-F 605
AcR AaR SM0534
W2-3-8
CONTROL VALVE E215B-E245B
331 324
261 AoR
323
604
308 MU 331
162
261
162
162 311
511
521 Ao
LCAT2 511
551
164 521
515
LCo
521 551
LCAP2
551 164
164
Bo
162
161
604
BoR
264 264
PAa2 PBo
205 205
SECTION G-G
T2
161
P1
511
T1
521 163
CT1 163
551
162
511
164 P2
521
CT2
551
164
W2-3-9
E215B-E245B CONTROL VALVE
207 266
160
278 x 5 264
264
528
527
T2 518
T1
517
SECTION J-J
PBp1 PBp2
606
606
163
SM0536
SECTION K-K
W2-3-10
CONTROL VALVE E215B-E245B
W2-3-11
E215B-E245B CONTROL VALVE
General precautions
• As all the hydraulic components are precisely
machined, it is essential to carry out disassembly
and reassembly in an especially clean location.
• When handling the control valve, take special
care to prevent the entry of foreign matter, such
as dust or sand.
• Cap each port of the control valve before
removing the valve from the machine. Before
disassembly, confirm that each cap is in place
and then clean the exterior of the assembly.
Use a workbench. Lay a clean sheet of paper or
rubber mat over the workbench.
• When carrying or moving the control valve, hold
the body, and never put pressure on a lever, an
exposed spool, or the end cover. Handle the
valve with care.
• Tests(for relief characteristics, leaks, overload
valve setting, flow resistance, etc.) that are
desired after disassembly and reassembly
require hydraulic testing apparatus.
• For this reason, do not disassemble hydraulic
units that you are capable of disassembling but
cannot test or adjust.
Prepare beforehand washing fluid, hydraulic oil,
grease, etc.
Tools
W2-3-12
CONTROL VALVE E215B-E245B
DISASSEMBLY
SM0537
SM0538
SM0504
SM0539
SM0540
W2-3-13
E215B-E245B CONTROL VALVE
SM0541
SM0542
SM0543
SM0544
W2-3-14
CONTROL VALVE E215B-E245B
SM0545
SM0546
W2-3-15
E215B-E245B CONTROL VALVE
SM0548
SM0550
W2-3-16
CONTROL VALVE E215B-E245B
SM0801
SM0802
SM0803
W2-3-17
E215B-E245B CONTROL VALVE
SM0804
SM0805
SM0807
W2-3-18
CONTROL VALVE E215B-E245B
SM0808
SM0809
SM0810
10.3 Fix the travel straight spool assy with vise
via a protective plate (aluminum plate,
etc.). Remove bolt (333) and separate
spring seat (331), springs (327, 329) and
stopper (336) from travel straight spool
(307).
W2-3-19
E215B-E245B CONTROL VALVE
SM0811
SM0812
12.2 Swing
Loosen socket bolts (273) and remove
spool cover (206) and O-ring (264), (266).
Do not disassemble spool cover (206)
further unless there is special reason.
SM0813
W2-3-20
CONTROL VALVE E215B-E245B
SM0815
SM0816
W2-3-21
E215B-E245B CONTROL VALVE
SM0817
SM0818
W2-3-22
CONTROL VALVE E215B-E245B
SM0819
SM0820
SM0821
W2-3-23
E215B-E245B CONTROL VALVE
W2-3-24
CONTROL VALVE E215B-E245B
Control valve
1. Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.
2. Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust.
3. If the check valve seat of the casing or the block has dents or damage on its surface, smooth it by lapping.
IMPORTANT: Take care not leave lapping compound behind in the casing or block.
4. Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from scratches,
dents, and the like. Remove any small defects with an oil stone or lapping compound.
5. Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages
are free from foreign matter.
6. Replace any broken or deformed spring with new one.
7. Replace all O-ring with new ones.
Relief valve
1. Make sure that the poppet and the seat surface at the tip of the seat are without fault and that the contact
surface is even all over.
2. Manually confirm that the main poppet slides smoothly onto and off the seat.
3. Confirm that the outer circumference of the main poppet and the inner circumference of its seat are free
from defects such as scratches.
4. Confirm that each spring is free from breakage, deformation, and excessive wear.
5. Confirm that the orifices of the main poppet and its seat are not clogged.
6. Replace all O-rings with new ones. (Between casing and seal)
REASSEMBLY
Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly
procedures.
For the tightenig torque of socket bolts and plugs refer to page W2-3-11.
W2-3-25
E215B-E245B CONTROL VALVE
IMPORTANT: take care to prevent misassembling of parts and assembling position error because the parts in
1. to 5. are similar in shape.
Assembling plate
1. Place O-rings (162), (163) in casing.
2. Attach plates (212), (213) and tighten socket bolts (274), (275) to the specified torque.
IMPORTANT: take care to prevent drop of poppet and spring when attaching by-pass cut valve.
W2-3-26
CONTROL VALVE E215B-E245B
IMPORTANT: Assemble it giving attention to the label attached when disassembling to prevent mistake
because the port relief valves (602), (603), (605) are similar in shape.
NOTE:
• apply Loctite #262 when tightening bolt (333).
• take care not to deform P2 unload spool (310) because of careless over clamping.
IMPORTANT: Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
3. Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and
tighten socket bolt (273) to the specified torque.
NOTE:
• apply Loctite #262 when tightening bolt (333).
• Take care not to deform travel priority spool (307) because of careless over clamping.
IMPORTANT: place travel priority spool assembly in casing B (102) carefully. Do not squeeze it into place.
3. Attach spring cover (202) with O-ring (261) attached to the spring side of travel priority spool assembly,
and tighten socket bolt (273) to the specified torque.
W2-3-27
E215B-E245B CONTROL VALVE
NOTE:
• apply Loctite #262 when tightening bolt (333).
• take care not to deform option spool (311) because of careless over clamping
IMPORTANT: place option spool assembly in casing A (101) carefully. Do not squeeze it into place.
3. Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and
tighten socket bolt (273) to the specified torque.
NOTE:
• apply Loctite #262 when tightening bolt (333).
• take care not to deform arm 2 spool (308) because of careless over clamping.
IMPORTANT: place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.
3. Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten
socket bolt (273) to the specified torque.
NOTE:
• apply Loctite #262 when tightening bolt (333).
• take care not to deform arm 1 spool (302) because of careless over clamping.
IMPORTANT: place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.
2. Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and
tighten socket bolt (273) to the specified torque.
W2-3-28
CONTROL VALVE E215B-E245B
NOTE:
• apply Loctite #262 when tightening bolt (333).
• take care not to deform bucket spool (304) because of careless over clamping.
IMPORTANTE: Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.
3. Attach spring cover (209) with O-ring (261) attached to the spring side of bucket spool assembly and
tighten socket bolt (273) to the specified torque.
4. Attach piston (216) to spring cover (209), place O-ring (164) in plug (551) and tighten to the specified
torque.
NOTE:
• apply Loctite #262 when tightening bolt (333).
• take care not to deform swing spool (303) because of careless over clamping.
IMPORTANT: place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.
3. Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly
and tighten socket bolt (273) to the specified torque.
W2-3-29
E215B-E245B CONTROL VALVE
NOTE:
• apply Loctite #262 when tightening bolt (333).
• take care not to deform boom spool (301) because of careless over clamping.
IMPORTANT: place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.
3. Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool assembly
and tighten socket bolt (273) to the specified torque.
NOTE:
• apply Loctite #262 when tightening bolt (333).
• take care not to deform boom conflux spool (305) because of careless over clamping.
IMPORTANT: place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.
3. Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool assembly
and tighten socket bolt (273) to the specified torque.
NOTE:
• apply Loctite #262 when tightening bolt (333)
• take care not to deform travel spool (306) because of careless over clamping.
IMPORTANT: place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into
place.
3. Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly and tighten
socket bolt (273) to the specified torque.
W2-3-30
CONTROL VALVE E215B-E245B
NOTE:
• apply Loctite #262 when tightening bolt (333).
• take care not to deform P1 unload spool (309) because of careless over clamping.
IMPORTANT: place P1 unload spool assembly in casing B (102) carefully. Do not squeeze it into place.
3. Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool assembly and
tighten socket bolt (273) to the specified torque.
2. Swing
- Place O-rings (264), (266) in spool cover (206) and tighten socket bolt (273) to the specified torque.
W2-3-31
E215B-E245B CONTROL VALVE
MAINTENANCE STANDARDS
Inspection of components
W2-3-32
SWING DEVICE E215B-E245B
WARNING
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear
and appropriate to hold the weight of load.
Preparation
1. Park the machine on a firm, level surface.
W2-4-1
E215B-E245B SWING DEVICE
Removal
: 36 mm 3
SM0701
W2-4-2
SWING DEVICE E215B-E245B
Installation
removed.
1
6. Install the hoses (4 and 5) on the elbows of port
A and B.
2
: 30 mm
: 108 Nm 3
SM0701
W2-4-3
E215B-E245B SWING DEVICE
33
27 44
20 1
21
31
2
15 3 17 13-14
16 43 29 42 12 30
19 A A
43 32
38
37
35
36
4
41
6
25 40
26 8
24 9
7
A-A
45
18
11 28 34 5 10
SM0703
W2-4-4
SWING DEVICE E215B-E245B
Preliminary operations
1. Hydraulic components are precision products 3. Study the structural drawing before the work
and have small clearance. Therefore, begins and prepare necessary parts according
assemble and disassemble in a less dusty to your purpose and the scope of work. Seals
clean place. Use clean tools and cleaning oil and O-Rings once removed can not be used
and handle components with full care. again.
2. If a component is removed from the main body, 4. The piston and the cylinder block are shop fitted
clean the area around the ports thoroughly and when new. If you intend to reuse them, put a
plug them up so no dust and water do not enter. matching mark on the piston and the cylinder
When fitting them back to the body, do not block.
remove the plugs till piping is completed.
Disassembly
31
SM0705
W2-4-5
E215B-E245B SWING DEVICE
10. Lay the motor on its side again and draw out
cylinder block (6) from drive shaft (5), draw out
piston (8), set spring (7), plate (10) and shoe
plate (11).
SM0706
Perform the following operations as required:
a. Drawing the inner race of roller bearing (28)
from drive shaft (5), using a press.
b. Drawing out the outer race of roller bearing 11 7 8
(28) from casing (18), by lightly tapping the
steel rod from the oil seal (34) housing side.
c. Separate the outer race of roller bearing (42)
from valve casing (19), using a slide hammer
bearing puller.
10 39 40 6
SM0707
34
28
18
SM0708
W2-4-6
SWING DEVICE E215B-E245B
Assembly
SM0709
3. Insert shoe plate (11).
4. Set the set plate (10) and spring (7), then set
piston sub (8, 9) assy. 8 6
9 7
5. Assemble piston sub assy (8, 9) fixed in
retainer plate (10) into cylinder (6), match it to
the spline of drive shaft (5) and insert it in place.
SM0710
39
40
SM0711
W2-4-7
E215B-E245B SWING DEVICE
20
21
31
SM0705
W2-4-8
SWING DEVICE E215B-E245B
8 7 4 19 2 28 16
6
20
3
10 15
12 18
17
5
9
23 22
31
32
25 26
13
24
27
21
11 1
30
SM0714
W2-4-9
E215B-E245B SWING DEVICE
Preliminary operations:
Disassembly
7 2
1. Place the reduction unit assy on a stable work
bench as shown in figure, remove plug (27),
drain out oil put a matching mark on the
matching surface of the figure on the right side.
: 12 mm
SM0718
W2-4-10
SWING DEVICE E215B-E245B
xxxxxxxxx SM0720
xxxxxxxxx
21
30
11 xxxxxxxxx
SM0721
W2-4-11
E215B-E245B SWING DEVICE
SM0723
8 9
18
5
24
18
22
SM0724
W2-4-12
SWING DEVICE E215B-E245B
Assembly
21 30
SM0726
xxxxxxxxx
1 11
SM0727
W2-4-13
E215B-E245B SWING DEVICE
SM0729
xxxxxxxxx
12
13
SM0730
W2-4-14
SWING DEVICE E215B-E245B
SM0731
20
SM0732
3 16 28 15
15
SM0733
W2-4-15
E215B-E245B SWING DEVICE
17
22
SM0734
SM0735
SM0736
W2-4-16
SWING DEVICE E215B-E245B
17. Mesh the #1 spider assy (7) with ring gear (6) 13
and set them in place.
x
18. Mesh #1 sun gear (2) with #1 pinions (3) and
set them in place.
: 181 Nm
23
x 25
x
27
SM0739
W2-4-17
E215B-E245B SWING DEVICE
MAINTENANCE STANDARDS
Swing motor
Unità: mm (poll.)
Recommended
Standard
Item value for Remedy
dimension (mm)
replacement (mm)
Clearance between piston and cylinder
bore (D-d)
NOTE: lap each sliding surface to a standard roughness level or finer. If the spherical sliding surface of the
spring (7) and cylinder (6) are roughened, replace parts in pairs.
W2-4-18
SWING DEVICE E215B-E245B
A D
C
D
C
B
SM0740
0 Replace entire
A Wear in #1 planetary shaft Ø 39 -0.011 spider assy
No flaking
0 Replace four shafts
B Wear in #2 planetary shaft Ø 29 -0.009 as a set
W2-4-19
E215B-E245B SWING DEVICE
NOTE:
W2-4-20
PILOT VALVE E215B-E245B
WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear
and appropriate to hold the weight of load.
Preparation
1. Park the machine on a firm, level surface. “Releasing the hydraulic pressure” at page. T2-
1-47.
3. Cut-off the engine. Press the valve located on
2. To drain the hydraulic pressure from the the hydraulic oil cap to release any residual
Hydraulic System, refer to procedure pressure present in the tank itself.
Removal
1. Free and lift rubber cap (5) complete with plate
(4) unlocking its hooks using a screwdriver.
60
W2-5-1
E215B-E245B PILOT VALVE
Installation
60
W2-5-2
PILOT VALVE E215B-E245B
WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear
and appropriate to hold the weight of load.
Preparation
1. Park the machine on a firm, level surface. “Releasing the hydraulic pressure” at page. T2-
1-47.
3. Cut-off the engine. Press the valve located on
2. To drain the hydraulic pressure from the the hydraulic oil cap to release any residual
Hydraulic System, refer to procedure pressure present in the tank itself.
.
Removal
1. Remove the cover under the cab
IMPORTANT: attach an identification tag on each
hose to aid in reassembly.
5. Disconnect pipes (from 3 through 6) of body
(8).
: 19, 22 mm
NOTE: attach a cap on each of disconnected hose
ends. 60
W2-5-3
E215B-E245B PILOT VALVE
Installation
: 19 mm
: 108 Nm (80.0 lbf·ft)
W2-5-4
PILOT VALVE E215B-E245B
60
W2-5-5
E215B-E245B PILOT VALVE
60
3. Remove adjusting nut (1) applying spanners to
circular plate (3).
: 22, 32 mm
60
WARNING
When the force of return springs (15) is high, never
loosen joint (4). If loosened, it might result in
jumping out of plate (5) plug (7) and push rod (9).
(
Remove joint (4) pressing plate (5) downward with
two fingers.
60
W2-5-6
PILOT VALVE E215B-E245B
NOTE: When the force of return spring (15) è is
high, press plate to let it come up slowly.
When the force of return spring (15) is low, plug (7)
is left in casing (22) due to sliding resistance of O-
Ring (8).
60
60
WARNING
To prevent personal injury, plug (7) must be
removed slowly and evenly until the return spring
(15) force is completely released
60
60
W2-5-7
E215B-E245B PILOT VALVE
IMPORTANT: Never push down spring seat (12) in
7 mm or more. (For port 1 and 3).
Never push down spring seat (14) in 9.4 mm or
more. (For port 2 and 4).
60
60
60
13. Remove inside seal (6) from plug (7) with small
driver
Cleaning parts
1. Clean parts with wash oil roughly and the parts
of pilot valve completely.
2. Dry parts by swabbing clean waste cloth.
3. Apply rust preventives on parts.
60
W2-5-8
PILOT VALVE E215B-E245B
60
W2-5-9
E215B-E245B PILOT VALVE
60
60
60
W2-5-10
PILOT VALVE E215B-E245B
60
60
60
60
60
W2-5-11
E215B-E245B PILOT VALVE
(
60
9. Screw adjusting nut (1), applying Loctite #277
to the thread of joint, until it touches circular
plate (3), and tighten it applying spanner to stop
circular plate returning.
60
: 22 mm
: 68.6±4.9 Nm (50±3.6 lbf·ft)
: 32 mm
60
60
W2-5-12
PILOT VALVE E215B-E245B
R
R
K
R
\
\
[ [
I
G
/RFWLWH
J
7
J
O
T
7 U
X
W 7
L 7
N 7
K X
W 7
M W
X
U
T
7
/RFWLWH
]
U
Z
7 aa
60
W2-5-13
E215B-E245B PILOT VALVE
1. Boot replacement
NOTE: the pilot control unit does not need to be
removed from the machine to perform this
operation.
60
W2-5-14
PILOT VALVE E215B-E245B
I O
4. Retaining plate removal (7-h)
1) Remove
• The pilot control unit from the machine
• Both rubber boots
• Both switch plates (6)
2) Unscrew simultaneously both screws (7-i)
holding the retaining plate using a 8 mm
socket wrench.
* Reassembly : 60
• Apply a droplet of Loctite #262 on the
screw thread.
• Torque: 30 Nm (22 lbf•ft)
L
K
60
W2-5-15
E215B-E245B PILOT VALVE
1) Remove:
• The pilot control unit from the machine.
• Both rubber boots.
• Both switch plates.
• The retaining plate.
2) Remove the wiper ring (12-y) Remove the
wiper ring (12-o).
* Reassembly: R
• Replace with a new wiper ring (12-y). \
$ %
60
CAUTION
Always place the damping plunger (12-o) prior to
the wiper ring (12-y), and make sure the wiper ring K
(12-y) is correctly positioned.
\
3) Remove the damping plunger (12-o).
4) Using a needle, remove the seal (12-x) [
placed inside the body (22)
* Reassembly: R
• Replace with a new seal and grease it.
60
[
$ %
60
W2-5-16
PILOT VALVE E215B-E245B
1) Remove
• The pilot control unit from the machine.
• Both rubber boots
• Both switch plates
• The retaining plate
2) Guide/plunger replacement:
• Insert the end of a thin screwdriver
between the guide and the body (22),
carefully lift the guide to remove it from the
body.
60
W2-5-17
E215B-E245B PILOT VALVE
60
60
(22).
W2-5-18
PILOT VALVE E215B-E245B
X
W
60
Z
60
W2-5-19
E215B-E245B PILOT VALVE
60
W
Z ]
60
T
U 60
W2-5-20
PILOT VALVE E215B-E245B
W2-5-21
E215B-E245B PILOT VALVE
NOTE:
W2-5-22
SECTION 3 E215B-E245B
UNDERCARRIAGE
CONTENTS
WARNING
Wear close-fitting clothing and safety equipment ap-
propriate to the job. Use tools appropriate for the job
to be performed. Always ensure that slings and
chains used for lifting are adequate to the load and
in good condition.
Removal
$
1. Put alignment marks on (A) swing bearing (1)
and track frame (2).
60
: 30 mm
60
60
W3-1-1
E215B-E245B SWING BEARING
Installation
Clean the matching surfaces of swing bearing and
the frame.
1. Apply THREEBOND 1102 to the matching sur-
faces of swing bearing and track frame.
60
%
NOTE - Apply Loctite #262 on the thread of the
screws (3) before assembling.
60
A: Front Side
B: Position of Plug
60
TOOL TABLE
W3-1-2
TRAVEL DEVICE E215B-E245B
WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear
and appropriate to hold the weight of load.
Preparation
1. Park the machine on a firm, level surface. 3. Cut-off the engine. Press the valve located on
2. To drain the hydraulic pressure from the Hy- the hydraulic oil cap to release any residual
draulic System, refer to procedure "Releasing pressure present in the tank itself. Remove hy-
the hydraulic pressure" at page. T2-1-47. draulic oil tank cap. Connect a vacuum pump to
maintain negative pressure in the hydraulic oil
tank.
Removal
The procedure starts on the premise that the track 2. Attach the travel device to a crane using a wire
link has already been removed. rope. Remove any slack from the wire rope so
1. Loosen bolts M12 (7) to remove cover (6). Dis- as to secure the travel device when the mount-
connect hoses (2), (3), (4) and (5). ing bolts are removed.
: 19 mm
NOTE: Travel device weight:
: 29.4 ±5 Nm (21.7 ± 3.7 lbf·ft)
Approx. 300 kg (661.5 lbs).
: 27 mm
: 78.5 ±5 Nm (57.9 ± 3.7 lbf·ft)
: 36 mm 3. Remove bolts M16 (1). Remove the travel de-
: 177 ±18 Nm (130.5 ± 13 lbf·ft) vice using the crane.
: 24 mm
: 279 ±29 Nm (206 ± 21 lbf·ft)
NOTE: Install caps on all disconnected hose and
line ends.
W3-2-1
E215B-E245B TRAVEL DEVICE
8
1
NOTE: Initial inspection of hydraulic motor and
7 6
gears, can be made without disassembling the track
drive from the machine.
9 SM0300
W3-2-2
TRAVEL DEVICE E215B
dz
dz
60
60
60
W3-2-3
E215B TRAVEL DEVICE
60
60
60
60
W3-2-4
TRAVEL DEVICE E215B
60
60
60
60
W3-2-5
E215B TRAVEL DEVICE
60
$
60
60
W3-2-6
TRAVEL DEVICE E215B
NOTE: tighten nos. 2 screws M20x100-8.8 ISO
4017 (15) at 180° with nos. 2 washers 22x60x4 ISO
7093 in the thread holes of the gearbox housing (17)
to avoid the housing comes out from the hydraulic
motor (16) during the movement of the unit. Remove
the screws when the unit is positioned.
60
60
60
W3-2-7
E215B TRAVEL DEVICE
60
60
60
W3-2-8
TRAVEL DEVICE E215B
60
60
60
60
W3-2-9
E215B TRAVEL DEVICE
60
60
60
60
W3-2-10
TRAVEL DEVICE E215B
60
60
11. Remove the O-ring seal (3) from its seat in the
fourth plug (10).
60
60
W3-2-11
E215B TRAVEL DEVICE
13. Take out the plunger assy (9) from the flushing
valve (2).
60
14. Take out the 1st spring seat (9) from the plunger
assy (12).
60
15. Take out the 2nd spring seat (12) from the flush-
ing valve (2).
60
60
W3-2-12
TRAVEL DEVICE E215B
60
60
60
60
W3-2-13
E215B TRAVEL DEVICE
21. Remove the O-ring seal (18) from its in the plug
(16).
60
22. Remove the spring seat (19) from its seat in the
base plate (17).
60
60
24. Unscrew the plug (21) from the base plate (17).
60
W3-2-14
TRAVEL DEVICE E215B
25. Remove the O-ring seal (18) from its seat in the
plug (21).
60
60
60
28. Take out the free piston (24) from the relief
valve (23).
60
W3-2-15
E215B TRAVEL DEVICE
60
60
60
32. Take out the first flanged plug assy (29) and the
spring seat.
60
W3-2-16
TRAVEL DEVICE E215B
33. Take out the spring seat (30) from the first
flanged plug (29).
60
60
35. Take out the first spring seat (32) from the
counterbalance valve spool (33).
60
60
W3-2-17
E215B TRAVEL DEVICE
60
60
60
40. Take out the second flanged plug assy (29) and
the spring seat.
60
W3-2-18
TRAVEL DEVICE E215B
41. Take out the spring seat (30) from the second
flanged plug (29).
60
60
43. Take out the second spring seat (32) from the
counterbalance valve spool (33).
60
60
W3-2-19
E215B TRAVEL DEVICE
60
60
47. Remove the O-ring seal (36) from the plug (35).
60
60
W3-2-20
TRAVEL DEVICE E215B
60
50. Unscrew the plug (40) from the base plate (17).
60
60
60
W3-2-21
E215B TRAVEL DEVICE
60
60
60
60
W3-2-22
TRAVEL DEVICE E215B
60
60
60
60
W3-2-23
E215B TRAVEL DEVICE
60
60
60
63. By using two screws M8, take out the brake pis-
ton (52).
60
W3-2-24
TRAVEL DEVICE E215B
60
60
60
60
W3-2-25
E215B TRAVEL DEVICE
60
69. Take out the nos. 3 pins (68) from their seats in
the cylinder block (56).
60
60
71. Take out the pistons (58) from the retainer plate
(59).
60
W3-2-26
TRAVEL DEVICE E215B
60
73. Take out the nos. 2 steel balls (61) from their
seats in the flanged hub (44).
60
74. Take out the nos. 2 pistons (62) from their seats
in the flanged hub (44).
60
75. Take out the nos. 2 springs (63) from their seats
in the flanged hub (44).
60
W3-2-27
E215B TRAVEL DEVICE
60
60
60
W3-2-28
TRAVEL DEVICE E215B
W3-2-29
E215B TRAVEL DEVICE
60
60
60
60
W3-2-30
TRAVEL DEVICE E215B
60
60
60
60
W3-2-31
E215B TRAVEL DEVICE
60
60
60
60
W3-2-32
TRAVEL DEVICE E215B
60
60
60
60
W3-2-33
E215B TRAVEL DEVICE
60
60
60
60
W3-2-34
TRAVEL DEVICE E215B
60
60
60
60
W3-2-35
E215B TRAVEL DEVICE
60
60
60
60
W3-2-36
TRAVEL DEVICE E215B
60
29. Fix the base plate (17) to flanged hub (44) using
nos. 10 socket head screws M14x40 (43),
grade 12.9, tightened by a torque wrench at
235 Nm torque.
: 12 mm
: 235 Nm (173 lbf·ft)
60
&
60
60
W3-2-37
E215B TRAVEL DEVICE
60
60
34. Insert the plugs (40) in the base plate (17) and
tighten by a torque wrench at 10 ±1 Nm torque.
: 10 ±1 Nm (7.35 ± 0.7 lbf·ft)
60
60
W3-2-38
TRAVEL DEVICE E215B
60
60
60
60
W3-2-39
E215B TRAVEL DEVICE
60
60
60
60
W3-2-40
TRAVEL DEVICE E215B
60
60
60
60
W3-2-41
E215B TRAVEL DEVICE
60
60
60
60
W3-2-42
TRAVEL DEVICE E215B
60
60
60
60
W3-2-43
E215B TRAVEL DEVICE
60
57. Insert the free piston (24) in the relief valve (23)
checking that the groove side is turned toward
the inside of the motor.
60
58. Insert the relief valve (23) inside the base plate
(17).
60
60
W3-2-44
TRAVEL DEVICE E215B
60
60
60
60
W3-2-45
E215B TRAVEL DEVICE
60
60
60
60
W3-2-46
TRAVEL DEVICE E215B
60
60
60
60
W3-2-47
E215B TRAVEL DEVICE
60
60
60
60
W3-2-48
TRAVEL DEVICE E215B
76. Insert the first plug (10) in the flushing valve (2)
and tighten by a torque wrench at 67 ±5 Nm
torque.
: 67 ±5 Nm (49.4 ± 3.7 lbf·ft)
60
60
60
60
W3-2-49
E215B TRAVEL DEVICE
60
60
60
60
W3-2-50
TRAVEL DEVICE E215B
84. Insert the third plug (4) in the flushing valve (2)
and tighten by a torque wrench at 67 ±5 Nm
torque.
: 67 ±5 Nm (49.4 ± 3.7 lbf·ft)
60
60
86. Insert the fourth plug (1) in the flushing valve (2)
and tighten by a torque wrench at 67 ±5 Nm
torque.
: 67 ±5 Nm (49.4 ± 3.7 lbf·ft)
60
60
W3-2-51
E215B TRAVEL DEVICE
60
Ɏ
3. Place the gearbox housing (4) on the bearing
inner ring (2).
60
60
W3-2-52
TRAVEL DEVICE E215B
W3-2-53
E215B TRAVEL DEVICE
+
60
60
60
W3-2-54
TRAVEL DEVICE E215B
60
60
W3-2-55
E215B TRAVEL DEVICE
60
60
60
60
W3-2-56
TRAVEL DEVICE E215B
12. Stake the ring nut (8) near 2 seats of the hy-
draulic motor.
60
60
60
60
W3-2-57
E215B TRAVEL DEVICE
60
60
60
60
W3-2-58
TRAVEL DEVICE E215B
60
60
60
60
W3-2-59
E215B TRAVEL DEVICE
60
60
W3-2-60
TRAVEL DEVICE E215B
MAINTENANCE STANDARD
Sprocket
%
&
'
(
$
60
IMPORTANT: Consult NEW HOLLAND KOBELCO S.p.A. for any inqueries concerning welding procedures.
W3-2-61
E215B TRAVEL DEVICE
NOTES
W3-2-62
TRAVEL DEVICE E245B
WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these
dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes. Hydraulic oil, at the end
of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior to beginning any
intervention, make sure that the oil and components are cooled-off. The hydraulic oil tank cap can be ejected,
if the pressure is not released from the tank. Press the valve located on the hydraulic oil tank to release any
residual pressure present in the tank itself. Check that the lifting devices (hooks, chains, etc.) are in perfect
conditions without any sign of excessive wear and appropriate to hold the weight of load.
Preparation
1. Park the machine on a firm, level surface.
2. To drain the hydraulic pressure from the Hydraulic System, refer to procedure "Releasing the hydraulic
pressure" at page T2-1-47.
3. Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure
present in the tank itself. Remove hydraulic oil tank cap. Connect a vacuum pump to maintain negative
pressure in the hydraulic oil tank.
APPLY
LOCTITE #262
OR EQUIVALENT
4
60
W3-2-63
E245B TRAVEL DEVICE
REMOVING
Preparation for removal
1. Remove crawler, lift up crawler frame using at-
tachment, and put it on square timbers to float
and stabilize.
Removing cover
2. Remove sems bolt (6) M12x25 and also re-
move covers (1). 6
: 19 mm 1
60
3. Preparation of oil pan.
: 27 mm
: 41 mm
60
W3-2-64
TRAVEL DEVICE E245B
Removing sprocket
5. Removing thirty (one side) capscrews (3)
M16x50.
: 24 mm
60
60
60
W3-2-65
E245B TRAVEL DEVICE
INSTALLING
Installing of the travel motor piping is performed in
the reverse order of removal.
1. Cleaning
Check that contact surface of travel motor and
crawler frame is free from burr and stain.
2. Tightening torque
Tighten capscrew and hydraulic pipes to the
torque specified in "Tightening Torque").
3. Fill inside from motor drain port to casing with
hydraulic oil before piping for drain. When start-
ing operation, operate motor in low idling and at
low speed for several minutes, and check it for
possible oil leakage and noise.
TIGHTENING TORQUE
NAME SIZE TOOLS No. REMARKS
(N/m)
Bolts M12 19 6 83.4 (61.5 lbf·ft)
Apply Loctite #262
Capscrew M16 24 3 279 (206 lbf·ft)
Ø 10X1.5 19 - 49 (36.1 lbf·ft)
Flareless nut for pipes,
Ø 18X2.5 32 - 147 (108 lbf·ft)
sleeve
Ø 28 41 - 275 (203 lbf·ft)
PF1/4 19 - 29.4 (21.7 lbf·ft)
Hose cap
PF1/2 27 - 78.5 (57.9 lbf·ft)
PF1/4 19 - 36.3 (26.8 lbf·ft)
Connector PF1/2 27 - 108 (79.7 lbf·ft)
PF1 41 - 255 (188 lbf·ft)
W3-2-66
TRAVEL DEVICE E245B
W3-2-67
E245B TRAVEL DEVICE
: 27 mm
17-3
60
W3-2-68
TRAVEL DEVICE E245B
are scored.
W3-2-69
E245B TRAVEL DEVICE
52
2
59
60
60
W3-2-70
TRAVEL DEVICE E245B
60
63
64
60
60
60
W3-2-71
E245B TRAVEL DEVICE
37
38
39
60
39
38 60
W3-2-72
TRAVEL DEVICE E245B
45
37
40 60
37
60
60
W3-2-73
E245B TRAVEL DEVICE
60
60
Removing shaft
1. Separate shaft (36) and ball bearing (49) from
flange (1).
60
W3-2-74
TRAVEL DEVICE E245B
Removing cover
1. Loosen bolts (96) and remove them.
2. Then remove cover (95).
: 8 mm
W3-2-75
E245B TRAVEL DEVICE
91
94
60
93
60
WARNING
Use care of the following when removing the 1st
stage holder assy. Take care so you do not pinch
your fingers at removing.
60
W3-2-76
TRAVEL DEVICE E245B
83
60
W3-2-77
E245B TRAVEL DEVICE
WARNING
Bolt (82) is coated with adhesive Loctite to prevent
it from loosening. Fix flange (1) securely for that rea-
son. 78
80 77
When loosening bolt (82), use a tool with a suffi- 81
ciently long extension such as iron pipe. If you do 82
60
not use it and try to loosen by force, you may injure
your waist or other parts.
Removing holder C
1. Fix flange (1) and loosen and remove bolt (76).
2. Holder C (74) is fixed to flange (1) with pin (99).
3. Attach the removing jig from the motor side and
separate holder C (74) by the use of a press.
74
: 17 mm
WARNING 76
99
When loosening bolt (76), use care of the followin:
Coat bolt (76) with screw locking agent to prevent it 60
from loosening. For that purpose, fix flange (1) se-
curely.
To loosen bolt (76), use a tool with a sufficiently long
extension such as an iron pipe. If you loosen it by
force, you may injure your waist or yourself in some
cases.
W3-2-78
TRAVEL DEVICE E245B
99
72
72
60
70
60
Storage of parts
This completes disassembly. Clean the disassem-
bled parts thoroughly, coat them with a thick film of
rust preventive oil, put them in plastic bags and
store them in a cool, dark, dry place.
W3-2-79
E245B TRAVEL DEVICE
1
70
'
60
72
71
( (
60
70
W3-2-80
TRAVEL DEVICE E245B
71
IMPORTANT: Do not reuse shims (73) that were
once used.
- Do this work without fail. If pre-load adjustment is
1
not done well, the reduction unit may be broken
during operation.
60
- Clean the measuring surface thoroughly.
W3-2-81
E245B TRAVEL DEVICE
Assembling holder C
1. Fix flange (1) and erect pins (99) [four places]
upright on flange (1).
2. Bring the shims selected under (5) in contact 74
with holder C (74), using grease, match the pin
holes in holder C (74) to the pins and press it in 73
by press.
3. Fit washer (75) to holder C (74), coat bolts (76)
with Loctite and tighten the bolts to a specified 99
torque.
: 17 mm
: 539 Nm (397.5 lbf·ft) 1
60
W3-2-82
TRAVEL DEVICE E245B
82 81 82
NOTE: Use care of the attaching direction of thrust
plate (81). If the neck of the bolt is damaged, it
breaks down.
Clean the screw threads of bolt (82) thoroughly, de-
grease it and coat it with Loctite.
Clean the screw threads in the tapped hole of holder
&
C (74) thoroughly and degrease it thoroughly.
60
W3-2-83
E245B TRAVEL DEVICE
84 83
60
Assembling holder B
1. Engage the inner gear teeth of holder B (85)
with the teeth of sun gear C (83) and assemble
holder B (85) into sun gear C (83).
83
85
60
W3-2-84
TRAVEL DEVICE E245B
W3-2-85
E245B TRAVEL DEVICE
94
72
91
94
60
Unit: mm (in)
Step dimension (T) Thrust plate code Shim thickness (t)
1.20 ~ 0.67
20941-62306 2.3
(0.0472 ~ 0.0264)
0.66 ~ 0.04
20941 - 62307 2.8
(0.0260 ~ 0.0016)
0.03 ~ -0.16
20941 - 62308 3.0
(0.00122 ~ -0.0063)
-0.174 ~ -0.41
20941 - 62309 3.2
(-0.00685 ~ -0.0161)
-0.42 ~ -0.80
B0841 - 23017 3.6
(-0.0165 ~ -0.0315)
W3-2-86
TRAVEL DEVICE E245B
Attaching cover
1. Remove foreign matter completely from the
matching surface between the end face of 72
housing (72) and cover (95).
2. Next, thoroughly degrease the matching sur- 95
face between the end face of housing (72) and 96
cover (95).
3. Further, apply liquid packing to the corner of the
spigot joint on the matching surface side of
housing (72) of cover (95).
4. Match the tapped holes in housing (72) with the
bolt holes in cover (95) and place cover (95) in
housing (72).
5. Finally, attach bolts (96) and tighten them to 60
specified torque.
: 8 mm
: 73.4 Nm (54.1 lbf·ft)
Fitting plugs
1. Take off O-ring (98) from plug (97), replace it
with a new one and place it in plug (97).
2. Then, attach plugs (97) to the oil inlet / outlet 95
and the level ports (3 in all) of cover (95), and
tighten them to specified torque.
: 12 mm
98
: 157 Nm (115.8 lbf·ft) 97
This completes the assy of the reduction unit.
Next comes the assemble of the motor. Assemble
it, referring to "Assembling the Motor".
60
W3-2-87
E245B TRAVEL DEVICE
MOTOR
Assembling piston 3
1. Place spring (61) in the hole where piston assy
(48) of flange (1) is located. 48
2. Then, mount piston assy (48) to flange (1). 61
60
W3-2-88
TRAVEL DEVICE E245B
60
Installing shaft
1. Press ball bearing (49) into shaft (36), using the
bearing fixing jig.
Then mount shaft (36) into the center of flange 36
(1).
49
60
60
W3-2-89
E245B TRAVEL DEVICE
WARNING
If snap ring (41) is tight, the snap ring pliers come off
from the snap ring and you are injured by it, in some
cases. When fixing the snap ring, always use a jig
60
(J) and make sure that the claw of the snap ring pli-
ers is engaged in the hole of the snap ring.
If it is difficult to narrow the snap ring, use snap ring
pliers one size larger. 41
To press in collar (44), align the center of the cylin-
der block with that of the press.
60
W3-2-90
TRAVEL DEVICE E245B
37
40
60
39
38
60
37
38
60
W3-2-91
E245B TRAVEL DEVICE
W3-2-92
TRAVEL DEVICE E245B
Fitting springs
1. Fit springs (59) into eight holes in brake piston
(56).
59
60
W3-2-93
E245B TRAVEL DEVICE
W3-2-94
TRAVEL DEVICE E245B
60
NOTE: Coat O-ring (64) with grease.
Do not coat O-ring (63) with grease.
Fix knock pin (60) with its taper part upward.
Coat the surface of valve plate (62) and the cylinder
block (37) with hydraulic oil and install them to base
plate (2).
Since the surface of the base plate (2) in contact
with base plate (2) faces downward, take care so
the valve plate does not fall.
When installing base plate (2) to flange (1), make
sure of the location of O-ring (63) and the location of
the oil passage hole in base plate (2).
Before assmble, make sure of the knock pin (60)
fixed in base plate (2), the hole in the base plate (2)
into which spring (59) enters, the knock pin hole on
the flange side (1), and the position of spring (59).
Tighten socket bolts (52) evenly all round on the cir-
cumference.
W3-2-95
E245B TRAVEL DEVICE
W3-2-96
TRAVEL DEVICE E245B
17-17,18 2
NOTE: Replace O-ring (17-7) with a new one, be- 17-3
fore assembly. 17-7
Make sure that O-ring (17-7) and backup ring (17-
18) are fitted to poppet seat (17-3). 17 60
Coat O-ring (17-17) and backup ring (17-18) with
grease, before assy.
3
60
W3-2-97
E245B TRAVEL DEVICE
Attaching cap
1. Attach spring seat (8) and spring (9), in that or-
der, to plunger (3).
2. Fit ball (33) and spring (34), O-ring (14), plug
(15), in that order, into the hole beside the hole
in base plate (2) in which cap (11) is placed.
33,34,14,15
3. Finally, fasten capscrew (13) to a specified
torque.
: 10 mm 17
8
: 108 Nm (79.7 lbf·ft)
9
10
TOOL TABLE
W3-2-98
TRAVEL DEVICE E245B
MAINTENANCE STANDARD
Sprocket
%
&
'
(
$
60
IMPORTANT: Consult NEW HOLLAND KOBELCO S.p.A. for any inqueries concerning welding procedures.
W3-2-99
E245B TRAVEL DEVICE
NOTES
W3-2-100
SWIVEL JOINT E215B-E245B
WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.
Preparation
1. Park the machine on a firm, level surface.
2. Cut-off the engine. Actuate the manual and pedal pilot valves to release any residual pressure from inside
the hydraulic system. Press the valve located on the hydraulic oil tank to release any residual pressure
present inside the tank itself.
3. Remove hydraulic oil tank cap. Connect a vacuum pump to maintain negative pressure in the hydraulic oil
tank.
Removal
NOTE: Attach labels or tags to hoses and adapters, 3. Remove tubes (2 and 8) (PF1).
to aid in assembly.
: 36 mm
: 177 ±18 Nm (130.5 ± 13 lbf·ft)
1. Remove tube (5 and 6) (PF1/2).
: 27 mm 4. Remove tubes (3 and 4) (PF1/4).
: 78.5 ±5 Nm (57.9 ± 3.7 lbf·ft) : 19 mm
: 29.4 ±5 Nm (21.7 ± 3.7 lbf·ft)
2. Remove tubes (1 and 7) (PF1).
: 36 mm
: 177 ±18 Nm (130.5 ± 13 lbf·ft)
60
W3-3-1
E215B-E245B SWIVEL JOINT
: 36 mm
: 177 ±18 Nm (130.5 ± 13 lbf·ft)
60
60
60
W3-3-2
SWIVEL JOINT E215B-E245B
60
60
Installation
W3-3-3
E215B-E245B SWIVEL JOINT
View from X
Section G-G
60
1 - Body 7 - O-Ring
2 - Stem 8 - Socket Bolt (M8 x 20)
3 - Thrust plate 9 - Socket Bolt (M8 x 30)
4 - Cover 12 - Plug
5 - Seal assy 13 - O-ring
6 - Seal assy
W3-3-4
SWIVEL JOINT E215B-E245B
Disassembly
The part numbers used in this disassembly proce-
dure correspond to those of a construction drawing
in the figure on page W3-3-4.
1. Mark cover (4) and body (1) with matching
marks for convenient reassembly.
2. Place a 'V' (A) block on a work bench, place a
swivel joint set on the side, fix it and loosen
socket bolt (9) by means of a pipe and wrench.
Alternately, the swivel joint may be fixed by
holding stem (2) in a vise.
$
: 6 mm
60
60
60
W3-3-5
E215B-E245B SWIVEL JOINT
$ 60
60
$
'
60
W3-3-6
SWIVEL JOINT E215B-E245B
Assembly
Prior to assembly, clean each parts (excluding the %
O- Ring and slipper ring), and arrange in the se-
quence of assembly.
1. Make sure that oil and grease remains have
been completely removed.
2. Apply grease on the groove where are seated
the O- Ring (6).
3. Apply hydraulic oil to O-ring (13) thinly and in-
sert it into O-ring groove. Check the twist of O-
ring.
4. Slipper ring (B) is assembled, after first insert-
ing the backup ring, by slightly-distorting the
shape as shown in figure. Also after inserting all 60
60
W3-3-7
E215B-E245B SWIVEL JOINT
60
60
W3-3-8
SWIVEL JOINT E215B-E245B
MAINTENANCE STANDARD
Allowable Limit
Item Remedy
(basis of judgment)
Sliding surface and sealed
Scored or something hurt it. Replace
parts
Sliding surface exception 1. Scored more than 0.1 mm. Replace
sealed parts 2. Scored less than 0.1 mm. Repair with oil stone
Body, Stem
1. Wear more than 0.5 mm deep. Replace
2. Wear less than 0.5 mm deep. Repair
Sliding surface ring
3. Scored less than 0.5 mm and able to
Repair
repair.
1. Wear more than 0.5 mm. Replace
2. Wear less than 0.5 mm. Repair
Cover Sliding surface ring
3. Scored less than 0.5 mm and able to
Repair
repair.
1. Protruded excessively from seal groove.
Replace
(with back-up ring)
60
PPPD[
60
PPPD[
Replace (with
back-up ring)
60
W3-3-9
E215B-E245B SWIVEL JOINT
W3-3-10
TRACK ADJUSTER E215B-E245B
Removal
WARNING
Be sure cables are anchored and the anchor point is
strong enough to handle the expected load. Keep
exposed personnel clear of anchor point and cables
or chain.
Installation
WARNING
Be sure cables are anchored and the anchor point is
strong enough to handle the expected load. Keep
exposed personnel clear of anchor point and cables
or chain.
60
W3-4-1
E215B-E245B TRACK ADJUSTER
WARNING
Prevent personal injury. The spring force of the track
adjuster is extremely large. Thoroughly inspect the
special tool for any damage. Carefully perform as-
sembly work referring to the procedure below. 60
60
9
60
W3-4-2
TRACK ADJUSTER E215B-E245B
60
$
60
60
W3-4-3
E215B-E245B TRACK ADJUSTER
60
60
W3-4-4
TRACK ADJUSTER E215B-E245B
Assembly
1. Insert grease cylinder (1) and collar (7) into
spring (5) and attach lifting eye nut (W) to screw
M48 at the tip of the grease cylinder. Lift the
grease cylinder by crane and erect it in the
center of the jig stand upright (380001029).
60
60
W3-4-5
E215B-E245B TRACK ADJUSTER
60
TOOL TABLE
W3-4-6
FRONT IDLER E215B-E245B
Disassembly
1. Remove plug (8) on the side of collar (3) to
drain oil.
: 5 mm
60
60
%
60
W3-5-1
E215B-E245B FRONT IDLER
the procedure described in the previous step.
%
60
W3-5-2
FRONT IDLER E215B-E245B
Assembly
1. Align inner hole of idler (1) and bushing (2) and
press fit it vertically with press so that jig (D)
'
(380001054) for bushing press-fitting is inser-
ted into bushing.
60
60
60
W3-5-3
E215B-E245B FRONT IDLER
MAINTENANCE STANDARD
Front Idler
& '
$
%
60
Unit: mm
Standard Allowable Remedy
A 84 66
B 159 -
C 500 482 Buildup weld and finishing
D 540 -
E 20 -
IMPORTANT: Consult NEW HOLLAND KOBELCO for any inqueries concerning welding procedures.
TOOL TABLE
W3-5-4
UPPER AND LOWER ROLLER E215B-E245B
Removal
WARNING
Do not loosen valve (1) quickly or loosen it too much
as high-pressure grease in the adjusting cylinder
may spout out. Loosen carefully, keeping body parts
and face away from valve (1).
Never loosen grease fitting (2).
60
60
WARNING
Insert a piece of non-sliding rag between track
frame (5) and hydraulic jack to prevent that the latter
slides.
60
60
W3-6-1
E215B-E245B UPPER AND LOWER ROLLER
60
60
Installation
1. Install the support roller (1) and, after coating
with Loctite #232, tighten screws (2).
: 19 mm
: 265 Nm (195.4 lbf·ft)
60
W3-6-2
UPPER AND LOWER ROLLER E215B-E245B
: 19 mm
: 59 Nm (43.5 lbf·ft)
60
60
: 6 mm
: 23 Nm (17.0 lbf·ft)
60
W3-6-3
E215B-E245B UPPER AND LOWER ROLLER
Removal
1. Remove the roller guard and loosen bolts M18
(5).
: 27 mm
60
60
WARNING
Do not loosen valve (3) quickly or loosen it too much
as high-pressure grease in the adjusting cylinder
may spout out. Loosen carefully, keeping body parts
and face away from valve (3).
Never loosen grease fitting (4).
60
60
W3-6-4
UPPER AND LOWER ROLLER E215B-E245B
60
Installation
1. Securely hold the lower roller using a fork lift.
Put lower rollers (1) on the tracks as illustration.
60
60
60
W3-6-5
E215B-E245B UPPER AND LOWER ROLLER
: 19 mm
: 59 Nm (43.5 lbf·ft)
60
60
W3-6-6
UPPER AND LOWER ROLLER E215B-E245B
: 15 mm
$
60
W3-6-7
E215B-E245B UPPER AND LOWER ROLLER
60
60
60
W3-6-8
UPPER AND LOWER ROLLER E215B-E245B
60
60
60
W3-6-9
E215B-E245B UPPER AND LOWER ROLLER
10. Fill in 0.2 cm3 of engine oil SAE40 through the 60
W3-6-10
UPPER AND LOWER ROLLER E215B-E245B
60
W3-6-11
E215B-E245B UPPER AND LOWER ROLLER
: 14 mm
60
60
60
W3-6-12
UPPER AND LOWER ROLLER E215B-E245B
60
W3-6-13
E215B-E245B UPPER AND LOWER ROLLER
60
60
60
4. Add engine oil via plug (1) hole on collar (2). Ap-
ply sealant (Loctite 503 or equivalent) to plug (1).
Tighten plug (1).
Engine oil quantity: 211 cm3
: 6 mm
: 9.8 Nm (7.2 lbf·ft)
60
W3-6-14
UPPER AND LOWER ROLLER E215B-E245B
MAINTENANCE STANDARD
Upper Roller
&
$
% 60
Unit: mm
Standard Allowable Limit Remedy
A 84 -
B 150 - Replace
C 140 130
Lower Roller
'
& $ &
%
60
Unit: mm
Standard Allowable Limit Remedy
A 172 181.5
B 218 - Buildup
weld and
C 23 11.5 finishing
D 150 132
W3-6-15
E215B-E245B UPPER AND LOWER ROLLER
TOOL TABLE
W3-6-16
TRACKS E215B-E245B
Removal
WARNING
Do not loosen valve (1) quickly on loosen too much
since high-pressure grease in the adjusting cylinder
may spout out.
Loosen carefully, keeping body parts and face away
from valve (1).
Never loosen grease fitting (2).
60
60
60
W3-7-1
E215B-E245B TRACKS
WARNING
The front idler may jump out of position due to
strong spring force when the tracks is disconnected.
Especially, the strong spring force is always applied
to the bolt part of the rod. If the rod and/or the bolt
are damaged, metal fragments may fly off when the
tracks is disconnected.
60
60
* % $
60
60
60
W3-7-2
TRACKS E215B-E245B
Installation
1. Jack up the machine and put the track under
the lower roller.
Be sure to position the track in correct direction,
as illustrated.
: Sprocket side
: Idler side
60
60
60
60
W3-7-3
E215B-E245B TRACKS
60
W3-7-4
TRACKS E215B-E245B
MAINTENANCE STANDARD
60
Unit: mm
Standard Allowable Limit
Remedy
E215B E245B E215B E245B
A 761 760 774 778 Replace
Master Pin
(% (%
60 60
Unit: mm
Standard Allowable Limit
Remedy
E215B E245B E215B E245B
A 207 220 200 -
Replace
B 38 39.7 36.5 37
W3-7-5
E215B-E245B TRACKS
Master Bushing
% &
$
60
Unit: mm
Standard Allowable Limit
Remedy
E215B E245B E215B E245B
A 129.2 135 - -
B 38 40 ++00.87 39.5 42.8 Replace
C 58.7 60 54.1 57
Grouser Shoe
&
$
60
Unit: mm
Standard Allowable Limit
Remedy
E215B E245B E215B E245B
A 220 222.5 - -
B 9.5 12.5 - - Replace
C 25.5 28 15 14
W3-7-6
TRACKS E215B-E245B
TOOL TABLE
W3-7-7
E215B-E245B TRACKS
NOTES
W3-7-8
SECTION 4 E215B-E245B
FRONT ATTACHMENT
CONTENTS
WARNING
Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries. Prevent this
dangers by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes. Press the
valve located on the hydraulic oil tank to bleed the residual pressure trapped inside the tank.
Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns.
Before starting any intervention, make sure that oil and components have cooled off.
Always ensure that hooks and chains used for lifting are in good condition and adequate to the expected load.
Metal fragments may fly off when a hammer is used to remove pins. Be sure to wear necessary protection.
Removal
1. Park the machine on firm, level ground.
Position the front attachment as illustated and
lower the bucket to the ground.
boom cylinder.
: 24 mm
SM0201
5 4 2
4 3 SM0202
W4-1-1
E215B-E245B FRONT ATTACHMENT
SM0203
7. Disconnect hoses (7) and (8) of bucket cylinder
and arm cylinder.
9 9 10
10
NOTE: if the machine is equipped with the hammer/
7 7
crusher, bucket rotation or anti-drop valves variants,
disconnect the relevant hoses (9), (10) and (11).
8 8
Bucket (7) and arm (8) cylinder hoses:
11 11
: 41 mm
: 36 mm
: 12 mm
SM0206
W4-1-2
FRONT ATTACHMENT E215B-E245B
18
11. Disconnect fuel transfer pump hose (16).
: 41 mm
17
15
12. Loosen lock nuts (17) and remove bolt (18).
: 30 mm
SM0207
SM0208
14. Pull out the boom lower pivot pin (20) to the
frame using the appropriate puller
(XXXXXXXX).
20
W4-1-3
E215B-E245B FRONT ATTACHMENT
Installation
1. Lift the front attachment.
NOTE: approximate mass of the front equipment:
3450 kg
16
Install dust seals to boom foot. Align the boom
foot boss with the main frame boss. Insert a
18
thrust plate to both right and left sides of the
boom foot boss to take out clearance between
the boom foot boss and the main frame boss.
W4-1-4
FRONT ATTACHMENT E215B-E245B
6
12. Connect centralised lubrication hoses (12)
located between the boom cylinders.
: 17 mm 4 3 SM0202
: 20 Nm
Using a grease gun, inject grease via nipples
(21) (boom) and (22) (boom cylinders). 5
1
NOTE: fill the hydraulic oil tank with hydraulic oil to 3
the specified level. Run the engine at idle. Check
hose connections for any oil leakage.
4
IMPORTANT: bleed air from hydraulic circuit.
2
SM0201
12
22 21 22
SM0212
W4-1-5
E215B-E245B FRONT ATTACHMENT
F E G H
A B C J K
D I
SM0213
Unità di misura: mm
Allowable
Parts name Standard Remedy
limit
Pin 90 89
A
Bushing 90 91.5
Pin 85 84
B Boss (Main Frame) 85 86.5
Bushing (Boom Cylinder) 85 86.5
Pin 85 84
C Bushing (Boom Cylinder) 85 86.5
Foro (Boom) 85 86.5
Pin 90 89
D
Bushing 90 91.5
Pin 85 84
E Boss (Arm) 85 86.5
Bushing (Arm Cylinder) 85 86.5
Pin 85 84
Replace
F Boss (Boom) 85 86.5
Bushing (Arm Cylinder) 85 86.5
Pin 80 79
G Boss (Arm) 80 81.5
Bushing (Bucket Cylinder) 80 81.5
Pin 80 79
H Bushing 80 81.5
Bushing (Bucket Cylinder) 80 81.5
Pin 70 69
I
Bushing 70 71.5
Pin 80 79
J
Bushing 80 81.5
Pin 80 79
K
Bushing 80 81.5
W4-1-6
FRONT ATTACHMENT E215B-E245B
WARNING
Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries. Prevent this
dangers by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes. Press the
valve located on the hydraulic oil tank to bleed the residual pressure trapped inside the tank.
Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns.
Before starting any intervention, make sure that oil and components have cooled off.
Always ensure that hooks and chains used for lifting are in good condition and adequate to the expected load.
Metal fragments may fly off when a hammer is used to remove pins. Be sure to wear necessary protection.
Removal
1. Park the machine on firm, level ground.
Position the front attachment as illustated and
lower the bucket to the ground.
3
4. Attach each boom cylinder to a crane. 1
5
SM0216
5 4 2
4 3 SM0217
W4-1-7
E215B-E245B FRONT ATTACHMENT
SM0221
W4-1-8
FRONT ATTACHMENT E215B-E245B
19
11. Disconnect fuel transfer pump hose (17).
: 41 mm
18
16
12. Loosen lock nuts (18) and remove bolt (19).
: 30 mm
SM0222
SM0223
14. Pull out the boom lower pivot pin (21) to the
frame using the appropriate puller
(XXXXXXXX).
21
W4-1-9
E215B-E245B FRONT ATTACHMENT
Installation
1. Lift the front attachment.
NOTE: approximate mass of the front equipment:
4100 kg
Install dust seals to boom foot. Align the boom 16
foot boss with the main frame boss. Insert a
thrust plate to both right and left sides of the 18
boom foot boss to take out clearance between
the boom foot boss and the main frame boss.
2. Install boom foot pin (20) using a hammer and
bar. 15 20
17
3. Install bolt (18) and tighten lock nuts (17).
: 30 mm
SM0210
: 200 Nm
4. Install fuel transfer pump hose (16).
14
: 41 mm
: 30 Nm 13
W4-1-10
FRONT ATTACHMENT E215B-E245B
6
12. Connect centralised lubrication hoses (12)
located between the boom cylinders.
: 17 mm 4 3 SM0217
: 20 Nm
Using a grease gun, inject grease via nipples
(21) (boom) and (22) (boom cylinders). 3
1
5
NOTE: fill the hydraulic oil tank with hydraulic oil to
the specified level. Run the engine at idle.
Check hose connections for any oil leakage.
SM0216
12
22 21 22
SM0212
W4-1-11
E215B-E245B FRONT ATTACHMENT
F E L M G
A B C D H J K
N I
SM0238
Unità di misura: mm
Allowable
Parts name Standard Remedy
limit
Pin 90 89
A-D-N
Bushing 90 91.5
Pin 90 89
B Boss (Main Frame) 90 91.5
Bushing (Boom Cylinder) 90 91.5
Pin 85 84
C Bushing (Boom Cylinder) 85 86.5
Boss (Boom) 85 86.5
Pin 90 89
E Boss (Positioner) 90 91.5
Bushing (Positioner Cylinder) 90 91.5
Pin 90 89
F Boss (Boom) 90 91.5
Bushing (Positioner Cylinder) 90 91.5
Pin 80 79
Replace
G Boss (Arm) 80 81.5
Bushing (Bucket Cylinder) 80 81.5
Pin 80 79
H Bushing 80 81.5
Bushing (Bucket Cylinder) 80 81.5
Pin 70 69
I
Bushing 70 71.5
Pin 80 79
J-K
Bushing 80 81.5
Pin 85 84
L Boss (Positioner) 85 86.5
Bushing (Arm Cylinder) 85 86.5
Pin 85 84
M Boss (Arm) 85 86.5
Bushing (Arm Cylinder) 85 86.5
W4-1-12
FRONT ATTACHMENT E215B-E245B
o p q
g
h
k
j
Section A
d
l
B
m
c
n
e
a b
Section B
f
A SM0214
E215B-E245B E215-E245
a (*) 419
b (*) 31 23
c 630
d 610
e 430
f 1464
g 433
h 326
i 80
j 428.7
k 33
l 433
m 307
n 80
o 20°
p 3.73°
q 449
W4-1-13
E215B-E245B FRONT ATTACHMENT
REPLACEMENT OF BUCKET
CAUTION
- Replace the bucket on firm level ground. Pay close
attention to safety.
- When aligning the pin bores, DO NOT INSERT YOUR
HAND OR FINGERS into the bores. It may cause
severe injury. Align the bores visually or using a tool.
- Hold the removed bucket in the stable condition.
W4-1-14
FRONT ATTACHMENT E215B-E245B
WARNING
Keep people not involved in the maintenance work
outside the working area.
Wear adequate personal clothes and glasses with
side shields as a protection against flying debris.
W4-1-15
E215B-E245B FRONT ATTACHMENT
WARNING
Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries. Prevent this
dangers by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes. Press the
valve located on the hydraulic oil tank to bleed the residual pressure trapped inside the tank.
Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns.
Before starting any intervention, make sure that oil and components have cooled off.
Always ensure that hooks and chains used for lifting are in good condition and adequate to the expected load.
Metal fragments may fly off when a hammer is used to remove pins. Be sure to wear necessary protection.
SM0226
SM0227
W4-1-16
FRONT ATTACHMENT E215B-E245B
SM0228
W4-1-17
E215B-E245B FRONT ATTACHMENT
SM0228
4. Align the bucket cylinder rod with bucket links
(13) and (14).
Install shims (7) and pin (6).
SM0229
W4-1-18
FRONT ATTACHMENT E215B-E245B
SM0230
3. Loosen lock nuts (4), remove bolt (5) and pull-
out pin (6) with the help of a mallet and a bar so 6
that the end of the cylinder is free, then remove 7 4
adjusting shims (7).
: 24 mm
5
4. Disconnected hoses (8) and (9) from arm
cylinder.
Put plugs on cylinder pipes and hoses.
: 10 mm
: 36 mm
SM0231
10
6. Using a hoist, slightly lift arm cylinder (1).
Loosen locking nuts (11) remove screw (12)
and pull-out pin (13) with the help of a mallet 9
and a bar so that the end of the cylinder is free,
then remove adjusting shims (14).
: 24 mm SM0232
13
14 11
7. Remove arm cylinder (1).
12
SM0233
W4-1-19
E215B-E245B FRONT ATTACHMENT
12
3. Connect lubrication hoses (10) and hoses (8)
and (9) to the arm cylinder.
: 10 mm
: 83 ± 5 Nm
: 36 mm
: 177 Nm SM0233
SM0231
W4-1-20
FRONT ATTACHMENT E215B-E245B
SM0201
NOTE: boom cylinder weight: 176 kg
SM0235
W4-1-21
E215B-E245B FRONT ATTACHMENT
NOTE: fill the hydraulic oil tank with hydraulic oil to 4 3 SM0202
the specified level. Run the engine at idle. Check
hose connections for any oil leakage.
5
IMPORTANT: bleed air from hydraulic circuit.
1
3
4
2
SM0201
W4-1-22
FRONT ATTACHMENT E215B-E245B
2
SM0236
3. Loosen lock nuts (4), remove bolt (5) and pull-
out pin (6) with the help of a mallet and a bar so 6
that the end of the cylinder is free, then remove 7 4
adjusting shims (7).
: 24 mm
5
4. Disconnected hoses (8) and (9) from arm
cylinder.
Put plugs on cylinder pipes and hoses.
: 10 mm
: 36 mm
SM0237
10
6. Using a hoist, slightly lift positioner cylinder (1).
Loosen locking nuts (11) remove screw (12)
and pull-out pin (13) with the help of a mallet 9
and a bar so that the end of the cylinder is free,
then remove adjusting shims (14).
: 24 mm SM0232
13
14 11
7. Remove positioner cylinder (1).
12
SM0233
W4-1-23
E215B-E245B FRONT ATTACHMENT
: 177 Nm
9
NOTE: for easy alignment, start the engine and use
the arm control lever.
SM0232
SM0237
W4-1-24
FRONT ATTACHMENT E215B-E245B
13
19
20
15
16
17
18
16
19
20
21
24
23 22
11
12
1
2
3
8 4
5
6
9
10
SM0240
W4-1-25
E215B-E245B FRONT ATTACHMENT
Bucket cylinder disassembly 6. Loosen nut (24) using special tool (xxxxxxxxx).
Remove piston (15), shim (21) cushion bearing.
Socket to loosen nut (24):
Be sure to thoroughly read all the precautions for
- bucket cylinder: 90 mm (XXXXXXXX)
disassembly/assembly work on page W1-1-1 before
starting the disassembly procedure.
: 10 mm
W4-1-26
FRONT ATTACHMENT E215B-E245B
Bucket cylinder assembly 9. Align the holes on cylinder rod (11) and nut
(24).
Insert steel ball (23) into the hole, and tighten
1. Install bushing (5) to cylinder head (7) using a set screw (22) into the hole.
press. Mushroom the head of set screw (22) at two
Special tools for bushing installation (5): places using a punch and hammer.
- Bucket cylinder: Ø 80 mm (XXXXXXXX)
: 10 mm
: 56.9 ± 10.7 Nm
IMPORTANT: be sure that the rings are installed
correctly.
IMPORTANT: be sure to align cylinder rod (11) with
the center of cylinder tube (12) when inserting, in
order to avoid damaging the rings.
2. Install seal (3), back-up ring (2), elastic ring (6)
and seal (4) on the cylinder front sleeve (7).
W4-1-27
E215B-E245B FRONT ATTACHMENT
Arm cylinder
14
13
19
20
15
23 22
16
17
18
16
20 11
19 25
26
27
28
12
1
2
3
8 4
5
6
9
10
SM0241
W4-1-28
FRONT ATTACHMENT E215B-E245B
Arm cylinder disassembly 7. Remove seal ring (17), slide rings (19) and (20),
O-ring (18) and backup rings (16) from piston
(15).
Be sure to thoroughly read all the precautions for
disassembly/assembly work on page W1-1-1 before
starting the disassembly procedure.
8. Remove cylinder head (7) from cylinder rod
The disassembly procedure below starts on the
(11).
premise that the hydraulic lines and the line
securing bands have been removed.
W4-1-29
E215B-E245B FRONT ATTACHMENT
Arm cylinder assembly 9. Align the holes on cylinder rod (11) and piston
nut (15). Insert steel ball (23) into the hole, and
tighten set screw (22) into the hole.
1. Install bushing (5) to cylinder head (7) using a Mushroom the head of set screw (22) at two
press. places using a punch and hammer.
Special tools for bushing installation (5):
(XXXXXXXX) : 10 mm
: 56.9 ± 10.7 Nm
IMPORTANT: be sure that the rings are installed
correctly.
IMPORTANT: be sure that the cushion seal slit
faces toward the piston and that the cushion bearing
oil groove faces the correct direction.
2. Install seal (3), back-up ring (2), elastic ring (6)
and seal (4) on the cylinder front sleeve (7).
10. Install snap ring (25) and cushion seal (26) to
cylinder rod (11). Install cushion bearing (27)
and stopper (28) to cylinder rod (11).
3. Install wiper ring (1) to cylinder head (7) using a
plastic hammer.
IMPORTANT: be sure to keep cylinder rod (11)
aligned with the center of cylinder tube (12) when
4. Install O-Rings (10) and backup ring (9) to inserting, in order to avoid damaging the rings.
cylinder head (7).
W4-1-30
FRONT ATTACHMENT E215B-E245B
19
20
15
16
17
18
16
19
20
21
24
23 22
11
12
1
2
3
8 4
5
6
9
10
SM0242
W4-1-31
E215B-E245B FRONT ATTACHMENT
Positioner cylinder disassembly 8. Remove cylinder head (7) from cylinder rod
(11).
Be sure to thoroughly read all the precautions for
disassembly/assembly work on page W1-1-1 before
starting the disassembly procedure. 9. Remove O-Rings (10), backup rings (9) and (2)
from cylinder head (7), then remove wiper ring
The disassembly procedure below starts on the
(1), seal (3), buffer ring (4), snap ring (6), and
premise that the hydraulic lines and the line
bushing (5).
securing bands have been removed.
W4-1-32
FRONT ATTACHMENT E215B-E245B
W4-1-33
E215B-E245B FRONT ATTACHMENT
Boom cylinders
13
19
20
15
16
17
18
16
19
20
21
24
23 22
11
12
1
2
3
8 4
5
6
9
10
SM0240
W4-1-34
FRONT ATTACHMENT E215B-E245B
Boom cylinders disassembly 7. Remove seal ring (17), slide rings (19) and (20),
O-ring (18) and backup rings (16) from piston
(15).
Be sure to thoroughly read all the precautions for
disassembly/assembly work on page W1-1-1 before
starting the disassembly procedure.
8. Remove cylinder head (7) from cylinder rod
The disassembly procedure below starts on the
(11).
premise that the hydraulic lines and the line
securing bands have been removed.
W4-1-35
E215B-E245B FRONT ATTACHMENT
Boom cylinders assembly 9. Align the holes on cylinder rod (11) and nut
(24).
Insert steel ball (23) into the hole, and tighten
1. Install bushing (5) to cylinder head (7) using a set screw (22) into the hole.
press. Mushroom the head of set screw (22) at two
Special tools for bushing installation (5): places using a punch and hammer.
- Boom cylinders: Ø 85 mm (XXXXXXXX)
: 10 mm
: 56.9 ± 10.7 Nm
IMPORTANT: be sure that the rings are installed
correctly.
IMPORTANT: be sure to align cylinder rod (11) with
the center of cylinder tube (12) when inserting, in
order to avoid damaging the rings.
2. Install seal (3), back-up ring (2), elastic ring (6)
and seal (4) on the cylinder front sleeve (7).
W4-1-36
FRONT ATTACHMENT E215B-E245B
Special tools
Tool for the installation and removal of the rod guide bushing:
W4-1-37
E215B-E245B FRONT ATTACHMENT
SM0243
Boom 85 ± 0.03
Arm 95 ± 0.03
Replace
or plate with chromium
Bucket 80 ± 0.03
W4-1-38