E215B E245B Workshop Manual
Workshop Manual
Print No. 87677762A English - Printed in Italy
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.
NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. - Product Support Print No. 87677762A Edition - June 2007
INTRODUCTION
E215B-E245B
TO THE READER - If you have any questions or comments, or if you found any errors regarding the contents of this manual, please contact:
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. Strada Settimo, 323 San Mauro Torinese (TO) 10099 ITALIA PRODUCT SUPPORT Fax. ++39 011 0077357
- Be sure to thoroughly read this manual for correct information concerning the service procedures.
ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this service manual: - Operation Manual
and
Maintenance
Instruction
- Parts Catalog
WORKSHOP MANUAL COMPOSITION - The “Operational Performance Test” part includes the information needed to carry out the machine operational performance test.
• The Workshop Manual consists of five parts: - “Safety Precautions” - “Operational Principle” - “Operational Performance Test”
- The “Troubleshooting” part includes the technical information needed for troubleshooting and malfunction detection.
- “Troubleshouting” - “Repair Instructions” - The “Safety Precaution” part includes the recommended procedures that, if followed, can avoid the risk of accident for operator and for staff related to the work and maintenance machine operations.
- The “Repair Instruction” part includes information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, 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 Consecutive page number for each group Group number (if exist)) 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. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attentio in to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.
UNITS USED SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parentheses just behinds SI units. Example: 24.5 MPa (250 kgf/cm2) A table for conversion from SI units to other system units is shown below for reference purposes.
Quantity
To convert from (SI)
Into (Others)
Multiply by
Quantity
To convert from (SI)
Into (Others)
Multiply by
Lenght
mm
in
0.03937
Pressure
MPa
kgf/cm2
10.197
mm
ft
0.003281
MPa
psi
145.0
L
US gal
0.2642
kW
CV-PS
1.360
L
US qt
1.057
kW
HP
1.341
m3
yd3
1.308
Temperature
°C
°F
°C x 1.8 + 32
Mass
kg
lb
2.205
Velocity
km/h
mph
0.6214
Force
N
kgf
0.10197
min-1
rpm
1.0
N
lbf
0.2248
L/min
US gpm
0.2642
N.m
kgf.m
0.10197
mL/rev
cc/rev
1.0
N.m
lbf.ft
0.7375
Volume
Torque
Power
Flow rate
IN - 2
INDEX
E215B-E245B
MANUAL INDEX SAFETY PRECAUTIONS
Page
Section 1 GENERALITIES ..................................................................... S1 Section 2 SAFETY PRECAUTIONS ..................................................... S2 Section 3 SAFETY PLATES .................................................................. S3
OPERATIONAL PRINCIPLE Section 1 GENERAL Group 1 Group 2
Specifications................................................................................. T1-1 Component Layout ........................................................................ T1-2
Section 2 SYSTEM Group 1 Group 2 Group 3
Mechatro control system................................................................ T2-1 Hydraulic System........................................................................... T2-2 Electrical System ........................................................................... T2-3
Section 3 COMPONENT OPERATION Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8
Hydraulic Pump Assy..................................................................... T3-1 Pilot Valve ...................................................................................... T3-2 Control Valve ................................................................................. T3-3 Swing Device ................................................................................. T3-4 Travel Device ................................................................................. T3-5 Swivel Joint.................................................................................... T3-6 Cylinders........................................................................................ T3-7 Air Conditioner system................................................................... T3-8
OPERATIONAL PERFORMANCE TEST Section 4 OPERATIONAL PERFORMANCE TEST Group 1 Group 2 Group 3 Group 4
Introduction ................................................................................... T4-1 Standard Performances ................................................................. T4-2 Test Procedures ............................................................................ T4-3 Mechatro Controller ....................................................................... T4-4
TROUBLESHOOTING Section 5 TROUBLESHOOTING Group 1 Group 2 Group 3
Troubleshooting (by error codes)................................................... T5-1 Troubleshooting (by trouble) .......................................................... T5-2 Troubleshooting (trouble diagnosis mode)..................................... T5-3
E215B-E245B
INDEX
REPAIR INSTRUCTIONS Section 1 GENERAL INFORMATION Group 1 Group 2
Precautions for Disassembly and Assembly.................................W1-1 Tightening Torque ........................................................................W1-2
Section 2 UPPERSTRUCTURE Group 1 Group 2 Group 3 Group 4 Group 5
Upperstructure ..............................................................................W2-1 Pump Device.................................................................................W2-2 Control Valve ................................................................................W2-3 Swing Device ...............................................................................W2-4 Pilot Valve .....................................................................................W2-5
Section 3 UNDERCARRIAGE Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7
Swing Bearing ..............................................................................W3-1 Travel Device ...............................................................................W3-2 Swivel Joint ..................................................................................W3-3 Track Adjuster ..............................................................................W3-4 Front Idler .....................................................................................W3-5 Upper and Lower Roller ...............................................................W3-6 Tracks ...........................................................................................W3-7
Section 4 FRONT ATTACHMENT Group 1
Front attachment...........................................................................W4-1
SAFETY PRECAUTIONS
M0103
SAFETY PRECAUTIONS
E215B-E245B
INDEX Section 1
GENERALITIES
Section 2
SAFETY PRECAUTIONS
Section 3
SAFETY PLATES
GENERALITIES
E215B-E245B
SAFETY PRECAUTIONS GENERALITIES Do not leave the machine until it has come to a complete stop.
Read the Operation and Maintenance Instruction Manual carefully before starting, operating, maintaining, fuelling or servicing the machine.
Always check height, width and weight limitations which may be encountered in the working site and ensure the machine does not exceed them.
Carefully read the explanation to each and all safety signs in the special section of this Manual before starting, operating, maintaining, fuelling or servicing the machine.
Assess exact paths of gas ducts, water mains, telephone lines, sewers, overhead and underground electric lines and all other possible obstacles.
Machine-mounted safety plates are colour coded yellow with black borders when they refer to points where special ATTENTION must be paid and failure to observe them may cause a serious DANGER to the integrity of machine operators. They are white with red borders and black lettering when they refer to a FORBIDDEN practice.
Such paths should be opportunely defined by competent Authorities. If necessary, require that the service is interrupted or said installations are moved prior to starting the work. You must know the working capacity of the machine. Define the rear upperstructure swing area and provide for opportune barriers to prevent access into it.
It is fundamental that all machine operators know very well the meaning of each safety plate as this considerably decreases operating hazards and accidents.
Never exceed machine lifting capacity. Remain within the limits shown in the loading capacity chart which located on the machine.
Do not allow unauthorised personnel to operate or service this 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 caught in moving parts. Wear certified safety clothes such as: hard hat, no-slip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators every time the job requires it. Ask your employer about safety regulations in force and protective equipment.
STARTING Never start or operate a failed machine. Walk all around the machine before mounting. Before operating the machine, make sure that any possible dangerous condition has been properly removed. Before starting machine, check that steering and attachment controls are in the neutral position and the safety lever is in the LOCK position. Immediately report any malfunction of parts or systems to the maintenance managers for proper action.
Always keep the operator’s compartment, step plates, grab-rails and handles clean and clear of foreign objects, oil, grease, mud or snow to minimise the danger of slipping or stumbling. Remove mud or grease from your shoes before operating the machine.
Prior to starting the engine, check, adjust and lock the driver’s seat for maximum riding comfort and control accessibility. Prior to operating the machine and/or its attachments, check that bystanders are outside the machine operating range. Sound the horn.
Do not jump on or off the machine. Always keep both hands and one foot, or both feet and one hand in contact with steps and/or grab rails. Do not use controls or hoses as hand holds. Hoses and controls are movable parts and do not provide solid support. Besides, controls may be inadvertently moved and cause unexpected movement of the machine or its attachments.
Obey all hand signals, safety indications and signs.
Never operate the machine or its attachments from any position other than sitting in the driver’s seat. Keep head, body, limbs, hands and feet inside the operator’s compartment at all times to reduce exposure to external hazards.
Ensure that nobody is within the excavator operating area before starting the machine, swinging the upper structure or moving in any direction.
Be careful of possible slippery conditions of the steps and hand rails as well as of the ground around the machine. Wear protective boots or shoes with the soles made of highly no-slip rubber
Ensure that engine speed is appropriate to the job to be carried out.
Due to the presence of flammable fluids, never check fuel level, refuel, charge the batteries in the presence of smoking materials, open flames or sparks.
Adjust all rear-view mirrors for maximum visibility of the area behind the machine.
S1 - 1
E215B-E245B
GENERALITIES
If any hydraulic control or system exhibits erratic performance or responds abnormally, have the machine checked for air in the system.
properly protected against possible backlash in case of cable or chain failure or detachment. Be alert of soft ground conditions close to newly constructed walls. The fill material and machine weight may cause the wall to collapse under the machine.
Air in these circuits may cause incorrect movements with consequent accident hazard. Refer to the Operation and Maintenance Instruction Manual 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. 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 proper action.
OPERATING Do not run the engine of this machine in closed buildings without proper ventilation capable to remove harmful exhaust gases which concentrate in the air.
Do not operate the machine until this condition is corrected. Regularly check all exhaust system components, as exhaust fumes are toxic for the operator.
Keep the operator’s compartment free of foreign objects, especially if not firmly secured. Never use the machine to transport objects, unless proper securing points are provided.
Operators must know the performance of the machine they are driving. When working on slopes or near sudden level drops in the terrain, pay attention not to lose adherence and avoid loose soft ground since overturn or loss of machine control could result.
Do not carry riders on the machine. Study and familiarise with escape routes alternative to normal exit routes. For your personal safety, do not climb on or off the machine while it is in motion.
If noise level is high and exceeds 90 dB (A) over 8 hours at the operator’s ear, wear approved ear protection in compliance with local regulations.
Make sure that bystanders are clear of the machine operating range before starting the engine and operating the attachment. Sound the horn. Obey all hand signals, safety indications and signs.
Do not operate the machine if you are extremely tired or feel ill. Be especially careful towards the end of the working shift.
When backing, always look to where the machine is to be moved.
Where removable counterweights are provided, do not operate the machine if they have been removed.
Be alert of the position of bystanders. Should someone enter the work area, stop the machine. Maintain a safe distance from other machines or obstacles to ensure required visibility conditions.
When operating the machine, keep in mind height limits of overhead doors, arches, overhead cables and lines as well as width limits of corridors, roads and narrow passages.
Always give way to loaded machines.
Also, get to know load limits of the ground and paving type of the ramps you are to work on.
Maintain a clear vision of the surroundings of the travel or work area at all times. Keep cab windows clean and repaired.
Beware of fog, smoke or dust that obscure visibility. Always inspect the working area to identify potential risks such as: inclines, overhangs, trees, demolition rubble, fires, ravines, steep slopes, rough terrain, ditches, crowns, ridge trenches,diggings in traffic areas, crowded parking lots, crowded service areas, fenced zones. In such conditions, proceed with extreme care.
When pulling loads or towing through a cable or chain, do not start suddenly at full throttle. Take-up slack carefully. Avoid kinking or twisting chains or cables. Carefully inspect the towing items for flaws or problems before proceeding. Do not pull through a kinked chain or cable as the high anomalous stresses existing in this condition may induce failures in the kinked portion.
Whenever possible, avoid crossing over obstacles such as very rough terrain, rocks, logs, steps, ditches, railroad tracks.
Always wear heavy gloves when handling chains or cables.
When obstructions must be crossed, do so with extreme care and at a square angle, if possible. Slow down.
Chains and cables should be securely anchored using suitable hooks. Anchor points should be strong enough to withstand the expected load.
Ease up to the break-over point, pass the balance point slowly and ease down the other side also using the attachment, if necessary.
Keep anyone clear of anchor points and cables or chains.
To overcome deep trenches or sinking ground, place the machine perpendicular to the obstacle, drastically reduce ground speed and start crossing using also
Do not pull or tow unless the operator’s compartments of the machines involved are S1 - 2
GENERALITIES
E215B-E245B
the attachment if necessary, only after assessing that ground conditions allow the traverse safely and without risks.
The load must always be properly arranged in the bucket; move with extreme care when transporting oversize loads.
The gradient you may attempt to overcome is limited by factors such as ground conditions, load being handled, machine type and speed, and visibility. There is no substitute for good judgement and experience when working on slopes.
Do not lift and move the bucket overhead where persons are standing or working, nor downhill when working on a slope as this would decrease machine stability. Load the bucket from the uphill side. Loads to be raised using the machine should be exclusively hooked to the hitch specially provided.
Avoid operating the attachment too close to an overhang or high wall, either above or below the machine. Beware of caving edges, falling objects and landslides. Remember that such hazards are likely to be concealed by bushes, undergrowth and such.
The excavator is no lifting and transportation means, therefore it should not be used to position loads accurately. Should it be exceptionally used to lift and lay building components, special caution must be taken as follows:
Avoid faggots, bushes, logs and rocks. Never drive over them, nor over any other surface irregularities that discontinue adherence or traction with the ground, especially near slopes or drop-offs.
- The machine must be equipped compulsorily with the appropriate variant provided upon request. - Secure the loads to be raised using cables or chains fastened with appropriate hooking mechanisms.
Be alert to avoid changes in adherence conditions that could cause loss of control. Work with extreme 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 for any reason whatever.
The word “bulldozing” generally refers to work in 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 tree limbs (possibly falling on the machine) and large roots (which may act as a leverage under the machine when up-rooted and cause the unit to overturn).
Never exceed specified loading capacity. Incorrect fastening of slings or chains may cause boom/arm failure or failure of the lifting means with consequent bodily injuries and even death. Always ensure that slings and chains used for lifting are adequate to the load and in good condition.
Position the machine dependent upon the loading and unloading areas in order to swing leftwards to load to obtain best visibility.
All loading capacities are referred to the machine on a level surface and should be disregarded when working on a slope.
Never use the bucket or attachment as a man lift or carry riders. Never use the machine as a work platform or scaffolding. The machine must not be improperly used for works not consistent with its features (such as pushing railway cars, trucks or other machines).
Avoid travelling across slopes. Proceed from uphill downhill and vice-versa. If machine starts slipping sideways when on a slope, lower the bucket and thrust bucket teeth into the ground. Working on slopes is dangerous. Grade the working area if possible. Reduce work cycle time if it is not possible to grade the working area.
Always pay attention to people within the machine operating range. Never move or stop the bucket, other loads or the attachment above ground personnel or truck cabs.
Do not move full bucket or a load from uphill downhill as this would reduce machine stability. Do not work with the bucket turned to the uphill side.
Ensure the truck driver is in a safe place before loading the truck.
Do not work with the bucket turned uphill as counterweights protruding downhill would reduce machine stability on the slope and increase risk of overturning.
Load trucks from side or rear. Use only the type of bucket recommended considering machine type, materials to be handled, material piling up and loading characteristics, ground type and other typical conditions of the work to be performed.
We recommend to work on slopes with the bucket downhill, after checking machine stability with the bucket empty and attachment retracted, by slowly swinging the upper structure by 360°.
When transporting a loaded bucket, keep it as rolled-back as possible. Keep boom and arm as low as possible.
Position the carriage at a right angle relative to slopes, hanging walls, etc. to exit the working area easily.
Ground speed should be adequate to the load and 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 - Look up the in the telephone directory.
motors be positioned at the front with regard to the actual travel direction. Remind relative to travel direction that controls are reversed.
- Define together with the Company representative which precautions should be taken to guarantee work safety.
Always check travel motor position before moving off.
- All electric lines should be considered as operative live lines even though it might be well known that the line in question is out of work and visibly connected to the ground.
Properly judge ground conditions with particular attention to consistency of the area you are going to work on. Keep the machine sufficiently edge.
far from the ditch
- The Electric Power Company, if previously advised and involved in the work, as well as machine Operator, Owner and/or any natural person or legal entity having rent orleased the machine or being responsible at the time by contract or by law, are liable for the adoption of the necessary precautions.
Never dig under the machine. Should it be necessary to dig under the machine, always ensure that digging walls are opportunely propped up against landslide to prevent the machine from falling into the trench. Do not swing the upperstructure, raise the load or brake abruptly if not required. This may cause accidents.
- Decrease work speed. Reaction time could be too slow and distance evaluation wrong. - Warn all ground personnel to keep clear of the machine and/or load at all times. If the load has to be guided down for laying, consult the Electric Power Company to know which precautions should be taken.
Prior to beginning the work near gas distribution mains or other public utilities: - Contact the company owner of the gas mains or its nearest branch before starting the work. Look up the number in the telephone directory.
- Appoint a person in charge of signalling duties. This person will have the responsibility of observing the machine, any part of it and/or the load approaching the electric lines from a standpoint more favourable than the Operator’s. This signal man (flag-man) must be in direct communication with the Operator and the Operator must pay undivided attention to the signals supplied.
- Define together which precautions should be taken to guarantee work safety. - Decrease work speed. Reaction time could be too slow and distance evaluation wrong. - When working near gas mains or other public utilities installations, appoint a person in charge of signalling duties. This person will have the responsibility of observing the machine, any part of it and/or the load approaching the gas mains from a standpoint more favourable than the Operator’s. This signal man (flag-man) must be in direct communication with the Operator and the Operator must pay undivided attention to the signals supplied.
When working in or near pits, in ditches or very high walls, check that the walls are sufficiently propped up to avoid cave-in hazards. Pay the utmost attention when working near overhang walls or where landslides may take place. Make sure that the support surface is strong enough to prevent landslides.
- The gas distributing Company, if previously advised and involved in the work, as well as machine Operator, Owner and/or any natural person or legal entity having rent or leased the machine or being responsible at the time by contract or by law, are liable for the adoption of the necessary precautions.
When digging, there is the risk of cave-ins and landslides. Always check ground conditions and conditions of the material to be removed. Support everywhere it is required to prevent possible cave-ins or landslides when: - Digging near previous trenches filled with material.
Working near electric lines can be very dangerous, therefore some special precautions must be observed.
- Digging in bad ground conditions. - Digging trenches subject to vibration from railroads, working machines or highway traffic.
Within this Manual, “work near electric lines” means when the attachment or load raised by the excavator (in any position) may reach the minimum safety distance established by local or international Safety Regulations.
STOPPING
To work without risks, keep maximum possible distance from electric lines and never trespass minimum safety distance.
When the machine is to be stopped for whatever reason, always check that all controls are in the neutral position and that the safety lever is on the lock position to guarantee risk-free start-up.
- Contact the Company owner of the electric lines or its nearest branch before starting the work. S1 - 4
GENERALITIES
E215B-E245B
Read all safety plates mounted on the machine and observe instructions they contain before starting, operating, repairing, fuelling or servicing the machine.
Never leave the machine unattended with the engine running. Prior to leaving the driver’s seat, and after making sure that all people are clear of the machine, slowly lower the attachment until resting it safely to the ground. Retract possible auxiliary tools to the closed safety position.
Do not allow unauthorised personnel to repair or service the machine. Follow all recommended maintenance and service procedures.
Check that all controls are in the neutral position. Move engine controls to the shut-down position. Switch off the key-start switch. Consult the Operation and Maintenance Instruction Manual.
Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, no-slip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators when required. Ask your employer about safety regulations in force and protective equipment.
Park the machine in a non-operating and no-traffic area. Park on firm level ground. If this is not possible, position the machine at a right angle to the slope, making sure there is no danger of uncontrolled sliding.
Do not use controls or hoses as hand holds. Hoses and controls are movable parts and do not provide solid support. Besides, controls may be inadvertently moved and cause unexpected movement of the machine or its attachments.
If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and other signals as required to adequately warn the oncoming drivers. Always switch off the key-start switch before cleaning, repairing, or parking the machine to prevent accidental unauthorised start-up.
Do not jump on or off the machine. Always keep both hands and one foot, or both feet and one hand in contact with steps and/or grab rails.
Never lower the attachment or auxiliary tools other than from sitting in the operator’s seat. Sound the horn. Make sure that nobody is within the machine operating range. Lower the attachment slowly.
Never service the machine with someone sitting in the driver’s seat, unless this person is an authorised operator assisting in the maintenance being carried out.
Securely block and lock the machine every time you leave it unattended. Return keys to the safe place previously agreed upon. Perform all necessary operations for stopping as detailed in the Operation and Maintenance Instruction Manual.
Keep the operator’s compartment, step plates, grab rails and handles clear of foreign objects, oil, grease, mud orsnow to minimise the danger of slipping or stumbling.
Drive the machine far from pits, trenches, rocky hanging walls, areas with overhead electric lines, and slopes before stopping it at the end of the working day.
Clean mud or grease from your shoes before climbing on the machine or driving it. Never attempt to operate the machine or its attachments from any position other than sitting in the operator’s seat.
Align the upperstructure to the tracks in order to allow to easily get on and off the driver’s compartment.
Keep the driver’s seat free from foreign objects, especially if these are not secured.
Move all controls to the position specified for machine stopping. Refer the Operation and Maintenance Instruction Manual.
Should it be necessary to move the attachment for maintenance purposes, do not raise or lower the attachment from any other position than sitting in the operator’s seat. Before starting the machine or moving its attachment, sound the horn and require that nobody remains near the machine.
Never park on an incline without accurately blocking the machine to prevent unexpected movement. Follow stopping instructions contained in the Operation and Maintenance Instruction Manual.
Raise the attachment slowly. Always lock all moving components or parts of the machine that must be lifted for 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 attachment. If you are not absolutely sure about your safety, do not stay or walk under a raised attachment.
MAINTENANCE GENERALITIES Carefully read the Operation and Maintenance Instruction Manual before starting, operating, maintaining, fuelling or servicing the machine in any manner.
Do not place head, body, limbs, hands, feet or fingers near articulated cutting edges deprived of the necessary guards, unless they are suitably and safely locked. S1 - 5
E215B-E245B
GENERALITIES flammable fluids to clean parts. Use proprietary certified non-flammable, non-toxic solvents only.
Never lubricate, repair or adjust the machine with the engine running, except when this is specifically required by the Operation and Maintenance Instruction Manual.
When using compressed air to clean parts, wear safety glasses with side shields. Limit pressure to max. 2 bars, in accordance with local and national safety regulations in force.
Do not wear loose clothing, jewellery near rotating parts.
Do not run the engine of this machine in closed buildings without proper forced ventilation capable to remove toxic exhaust gases concentrating in the air.
When service or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform conforming to local or national regulations to reach the working area. If such means are not available, use machine grab rails and steps. Always perform all service or maintenance work with the greatest care and attention.
Do not smoke, nor allow open flames or sparks nearby while refuelling the unit or handling highly flammable materials. Do not use open flames as light sources to look for leaks or inspect anywhere on the machine.
Shop and/or field service platforms or ladders should be manufactured and maintained in accordance with local or national safety regulations in force.
Make sure that all mechanical tools provided are in good condition at all times. Never use tools with mushroomed or damaged heads. Always wear eye protections with side shields.
Disconnect batteries and label all controls to warn that service work is in progress, according to local and national safety regulation requirements.
Move with extreme care when working under, on or near the machine or its attachments.
Block the machine and all attachments to be raised according to local and national safety regulation requirements.
In case of attachment tests during which the engine should be kept running, a qualified operator must sit in the driver’s seat at all times while the mechanic is at work.
Do not check or fill fuel tanks or install batteries near burning or smoking materials and open flames due to the presence of flammable vapours.
Keep hands and clothes far off moving parts.
The fuel filler pipe nozzle must be constantly kept in contact with the filler neck and this even before fuel starts flowing in. Keep this contact from the beginning to the end of the fuelling operation to avoid possible generation of sparks due to static electricity.
Stop the engine and move the safey lever to the lock position before starting adjusting or repairing an assembly. Do not carry out any work on the attachment without prior authorisation. Observe maintenance and repair procedures.
Use a truck or trailer to haul a failed machine. Should it be necessary to tow it, provide for suitable danger signals as required by the local norms and regulations and observe recommendations given in the Operation and Maintenance Instruction Manual. Load/unload the machine on firm level ground providing safe support to the wheels of the truck or trailer. Use strong access ramps, with adequate height and angle. Keep the trailer flatbed free of mud, oil or slippery materials. Tie the machine securely to the trailer and block carriages and upperstructure.
In case of field service, move the machine to level ground and block it. If work on an incline cannot be avoided, securely block the machine and its attachments. Move the machine to level ground as soon as possible. Do not twist chains and cables. Never use a twisted chain or cable for lifting or pulling. Always wear safety gloves to handle chains or cables. Be sure chains and cables are firmly fastened and that the anchor point is strong enough to withstand the expected load.
Never align holes or slots using your fingers; alwaysuse appropriate aligning tools. Remove all sharp edges and burrs from re-worked parts.
Keep all bystanders clear of the anchor point, cables or chains. Do not pull or tow unless the operator’s compartments of the machines involved are fitted with proper guards against cable or chain backlash.
Use only approved and effectively grounded auxiliary power sources for heaters, battery chargers, pumps and similar equipment to reduce electrical shock hazard.
Keep the maintenance area clean and dry at all times.
Lift and handle heavy components using hoisting devices of appropriate capacity. Ensure the parts are supported by appropriate straps and hooks.
Clean immediately all water and oil spillage. Do not pile up oily or greasy rags as they represent a major fire hazard. Always store them in closed metal containers.
Use lifting eyes provided to this aim. Pay attention to bystanders near the lifting area.
Before starting the machine or its attachment, check, adjust and lock the operator’s seat. Also ensure that nobody is within the machine or attachment
Never pour gasoline or diesel fuel into open containers. Never use gasoline, solvents or other S1 - 6
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injuries are most likely to occur. Pay attention to prevent possible part movements by means of blocks or by keeping clear of such zones when motion may take place during maintenance or repair.
operating range before starting or operating the machine and/or its attachments. Sound the horn. Rust inhibitors are volatile and flammable.
Move the hydraulic system lock safety lever to the lock position when stopping the machine for whatever reason.
Prepare parts in well ventilated areas. Keep open flames away. Do not smoke.
Always install the safety stays for the hood and other hinged covers before performing any maintenance or repair work in the engine compartment.
Store containers in a cool well ventilated place where they could not be reached by unauthorised people. Do not carry loose objects in your pockets that might fall unnoticed into open compartments. Wear appropriate safety clothing such as hard hat, safety shoes and gloves, safety glasses when splinters or other particles may be ejected.
TRANSFERS AND TRANSPORTATION Before moving or transporting the machine, block upperstructure swing to prevent accidental movement.
Wear the appropriate welder’s equipment such as dark safety glasses or mask, hard hat, protective clothing, safety gloves and footwear always while welding or arc-cutting. Wear dark safety glasses when you are near a welding in progress.
Pay particular attention during transfer on inclines, both uphill and downhill. Keep the bucket in a position to provide a possible anchor point into the ground in case of slipping.
Do not look the welding arc without proper eye protection.
During transfers on inclines, both uphill and downhill, keep the upperstructure aligned with the carriages. Do not travel across the slope.
Become acquainted with all your jacking equipment and their capacity. Ensure that the jacking point on the machine is appropriate for the load applied. Also, be sure the supports under the jack and between the jack and the machine are appropriate and stable.
Never transfer the machine in the working site, in a crowded area, or near people without having at least 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 appropriate blocking means as a safety measure before proceeding with service or maintenance work, in compliance with local or national safety regulations.
Sound the horn to inform that you are about to move off. It is necessary to know load limits of bridges and dimensional limits of tunnels. Such limits must never be exceeded. You should also know machine height, width, and weight. Have a signal-man help you when clearances are limited.
Metal cables produce steel splinters. Always wear certified protection clothes such as safety gloves and glasses while handling them.
Check distance between boom/arm and dimensional limits during transfer or transportation.
Do not use makeshift jacks to adjust track sag. Follow instructions given in the Repair Manual.
Rough terrain may cause the machine to sway and roll to such an extent that boom/arm could get to contact electric lines or other obstacles. Cross obstacles at a right angle at low speed. Pay attention to machine shaking when the centre of gravity overcomes the obstacle.
Handle all parts carefully. Keep hands and fingers away from gaps, gears, and similar. Always use and wear certified safety clothes such as safety glasses, gloves and footwear. The attachment is kept constantly in position by an oil column trapped into the high pressure circuit. Lower the attachment to the ground and relieve pressure from all circuits prior to carrying out any type of maintenance or repair work.
Keep the bucket down at all times during transfers. Drive with the lights on and use appropriate signals and flags. Get to know and respect local and national regulations.
Do not service or repair the machine if it is parked downhill. If this is unavoidable, in case of emergency, block the carriages to prevent unexpected movement, particularly if the work is to be carried out on the final reduction units or travel motors.
Consider boom/arm and upperstructure dimensions while turning. Use a ramp to load the machine on a trailer. If a ramp is not available, fabricate one using blocks. The ramp should be sufficiently strong to support machine weight. Always load and unload on level surface.
Consult the Operation and Maintenance Instruction Manual for correct maintenance procedure. Areas near articulated cutting edges where mechanical parts are in motion are where personal S1 - 7
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GENERALITIES Before any maintenance or repair, make sure that there are no fuel or electrolyte leaks from the 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 explosive gas released during charging.
Tow the machine following the instructions contained in the Operation and Maintenance Instruction Manual.
ENGINE
Disconnect batteries before working on the electrical system or carrying out any other type of work.
Do not run the engine in closed buildings without proper ventilation capable to remove harmful exhaust fumes. Do not place head, body, limbs, feet, hands or fingers near rotating fans or belts. Be especially careful near blower fans.
HYDRAULIC SYSTEM
Loosen the radiator cap very slowly to relieve system pressure before removing it. Always top-up coolant level with the engine off or idling if hot. See the Operation and Maintenance Instruction Manual.
Pressure fluid escaping from a very small hole can be almost invisible and still have sufficient force to penetrate the skin. Always check any suspected pressure leaks using a piece of cardboard or wood.
Keep the exhaust manifold and tube free from combustible matters. Fit the machine with shields and guards when working in the presence of combustible matter free in the air.
Do not use hands. If injured by escaping fluid, obtain medical attention immediately or serious infection or reaction may develop. Stop the engine and ensure pressure is relieved from all systems before removing side panels, housings, guards and covers. See the Operation and Maintenance Instruction Manual.
Do not refuel with the engine running, especially if hot, as this increases fire hazard in case of fuel spillage.
Always use gauges of adequate capacity for pressure testing. Refer to the Operation and Maintenance Instruction Manual or Repair Manual.
Never attempt to check or adjust fan belt tensions when the engine is running. 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 before servicing the engine.
TOOLS Always keep head, body, limbs, feet, hands, and fingers away from the bucket and attachments, when in the raised position.
ELECTRICAL SYSTEM
Prior to any maintenance or repair work, install all supports necessary to this aim according to local and national safety regulations.
Pay attention to connect connecting cables to correct poles (+ to +) and (- to -) at both ends. Do not shortcircuit terminals. Thoroughly follow instructions given in Operation and Maintenance Instruction Manual.
In case the attachment is to be operated for maintenance or repair purposes, do so exclusively while sitting in the driver’s seat. Sound the horn before starting the machine or moving the attachment. Require that nobody remain near the machine. Raise the attachment slowly.
Always move the key-start switch in the lock position before servicing or repairing the machine. Batteries contain SULPHURIC ACID. Protect the eyes when working near the batteries against possible sprays of the acid solution. Should acid contact skin, eyes, or clothes, RINSE IMMEDIATELY IN WATER FOR AT LEAST 15 MINUTES. Immediately seek medical attention.
Do not use the machine to transport loose objects, unless proper securing devices are provided. Never use gases other than nitrogen to charge the accumulators.
Battery released gas is highly flammable. Leave the battery compartment cover open during recharging to improve ventilation. Never check battery charge by placing metal objects across the posts. Keep sparks or open flames away from batteries. Do not smoke near the battery to prevent explosion hazard. S1 - 8
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RECOGNISE SAFETY INFORMATION • This is your SAFETY ALERT SYMBOL - When you see this symbol on your machine or in this Manual, be alert of the potential for personal injury. - Follow recommended precautions and safe operating practices.
UNDERSTAND SIGNAL WORDS • In this Manual you will find the following words referring to different hazard risks: - DANGER; - WARNING; - CAUTION.
DANGER
These words are always accompanied by the safety alert symbol. DANGER: indicates an imminent hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING: indicated a potential hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION IMPORTANT
CAUTION: indicates a potential hazardous situation which, if not avoided, may result in minor or moderate injury.
NOTE
IMPORTANT: indicates a situation which, if not avoided, may cause damage to the machine. NOTE: indicates an additional explanation for information purposes.
ENVIRONMENTAL PROTECTION • This Manual also contains this symbol accompanying instructions for correct behaviour as regards environmental protection.
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FOLLOW SAFETY PRECAUTIONS • Carefully read and observe all safety signs on the machine and read all safety precautions in this Manual. • Safety signs should be installed, maintained, and replaced when necessary. - If a safety sign or this Manual are damaged or missing, obtain a replacement from your Dealer in the same way you order a spare part (be sure to detail machine model and serial number upon ordering). • Learn how to operate the machine and its controls correctly and safely. • Allow only trained, qualified, authorised personnel to operate the machine. • Keep the machine in proper working conditions. - Unauthorised changes to the machine may impair function and/or safety and affect machine life. • Safety messages in this Chapter “SAFETY PRECAUTIONS”, are intended to illustrate basic safety procedures of the machine. However, it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any doubts, consult your direct supervisor prior to operating or servicing the machine.
PREPARE FOR EMERGENCIES • Be prepared if a fire starts or an accident occurs. - Keep the first-aid kit and fire extinguisher on hand. - Thoroughly read and understand the label attached to the fire extinguisher to use it properly. - Establish emergency priority procedures to cope with fires and accidents. - Keep emergency numbers for doctors, ambulance service, hospitals and fire department posted near the telephone.
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SAFETY PRECAUTIONS
WEAR PROTECTIVE CLOTHING • Wear close-fitting clothing and safety equipment appropriate to the job. You need: - A hard hat; - Safety shoes; - Safety glasses or face shield; - Heavy gloves; - Ear protection; - Reflective clothing; - Waterproof clothing; - Respirator or filter mask; Be sure to correctly wear equipment and clothing for the job. - Do not take any chances. - Avoid wearing loose clothing, jewellery, or other items that can catch on control levers or other parts of the machine. • Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.
PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. - Wear a suitable hearing protection such as earmuffs or earplugs to protect objectionable or uncomfortably loud noise.
INSPECT THE MACHINE • Inspect the machine carefully every day or workshift by an attentive visual inspection of machine outside prior to starting it to prevent damages and personal injuries.
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SAFETY PRECAUTIONS
USE HAND HOLDS AND STEPS • Falling is one of the major causes of personal injury. - When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. - Prior to climbing or leaving the machine, check that the fasteners of stepping points and the handrails are tightened and are undamaged. Repair them as required. - Keep the access to the machine clear of foreign objects and clean. Remove grease or mud from stepping points and rails to minimise the danger of slipping or stumbling. - Do not use the controls or the safety lever as hand holds when climbing on or off the machine. - Do not climb or leave the machine running. Do not jump on or off the machine. - Do not climb or leave the machine while holding tools or other objects in your hands. - Do not climb or leave the machine while it is moving.
ADJUST THE OPERATOR'S SEAT • A seat poorly adjusted for operator or work requirements may quickly fatigue the operator leading to improper operations. - The seat should be adjusted whenever machine operator changes. - The operator should be able to fully press the pedals and correctly move the control levers with his back resting against the seat back. - If not, move the seat fore and aft, and check again.
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SAFETY PRECAUTIONS
FASTEN SEAT BELT • Should the machine overturn, the operator may become injured and/or thrown from the cab. Not only, the operator may be crushed by the overturning machine resulting in serious injury or even death. - Prior to operating the machine, thoroughly examine belt webbing, buckle, and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. - Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimise injury hazard in case of accident. - After a significant accident, replace the seat belts even though they do not look damaged.
MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. - Pay the utmost attention not to run over bystanders. - Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. Sound horn to inform bystanders that the machine is going to be operated. - When operating, swinging, or moving the machine in a congested area use a signal man.
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OPERATE ONLY FROM THE DRIVER'S SEAT • Inappropriate engine starting procedures may cause the machine unexpected movement, possibly resulting in serious injury and even death. - Start the engine only from the operator’s seat. - NEVER start the engine while standing on the track or on the ground. - Do not start the engine by shorting across starter motor terminals. - Before starting the engine, ensure that all control levers are in the neutral position.
DO NOT CARRY PERSON ON THE MACHINE • Riders on the machine are exposed to serious injuries. - DO NOT carry riders on the machine. Besides precluding a full vision by the operator, there is the possibility of serious bodily harm or death due to accidental falls from the machine.
CONFIRM DIRECTION WHERE THE MACHINE IS TO BE DRIVEN • Incorrect travel controls operation may result in serious injury and even death. - Before driving the machine, be aware of the undercarriage position relative to the operator’s position. If travel motors are located at the front of the cab, the machine will move reverse when travel controls are moved towards cab front.
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SAFETY PRECAUTIONS
AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. • To avoid back-over and swing accidents: - Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR. - ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. - USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. - Use hand signals, which conform to your local regulations, when work conditions require a signal person. - No machine motions shall be made unless signals are clearly understood by both signalman and operator. - Learn the meanings of all flags, signs, and markings used on the job and confirm with the person in charge of signalling. - Always make sure that rear mirrors are clean and correctly adjusted. - Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.
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SAFETY PRECAUTIONS
DRIVE MACHINE SAFELY • Before moving the machine, confirm which way to move travel pedals/levers for the corresponding direction you wish to go. - Pushing down on the front of the travel pedals or pushing the levers forward moves the machine towards the idlers. • Traveling on a grade may cause the machine to slip or to overturn, possibly resulting in serious injury or death. - When traveling up or down a grade, keep the bucket in the direction of travel, approximately 20 to 30 cm (A) above the ground. - If machine starts to skid or becomes unstable, lower the bucket immediately. - Traveling across the face of a slope may cause the machine to skid or to overturn. When travelling (ascending/descending) on a slope, be sure to point the tracks uphill/downhill.
- Turning on an incline may cause the machine to tip over. If turning on an incline is absolutely unavoidable, do so at a place where the slope is gentle and the surface is firm. - Do not travel on slopes with an angle exceeding 30°. Do not travel across hill on slopes exceeding an angle of 15°.
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SAFETY PRECAUTIONS
AVOID OVERTURNING • When working on a slope or on unstable terrain, the danger of tipping over is present with the possibility of subsequent serious damages or fatal injuries. - Pay the utmost attention when working on a slope. If possible, level first the work area. - Avoid swing or steering the machine on a slope. - Decrease the operating speed and actuate the controls carefully, to prevent sudden movements that could result in slipping or tipping over. - In case the engine is cut-off, lower the bucket to the ground, move the controls in neutral and restart the engine. • Pay the utmost attention when operating the machine on frozen ground or in snowy conditions. - Frozen ground, when the ambient temperature increases, tends to be less firm jeopardising the stability of the machine. - Operate carefully when in snowy conditions. The snow could hide invisible dangerous spots. - Actuate the controls slowly and carefully to prevent the machine from making unwanted slippery manoeuvres or movements. - Even on minor slopes, when snow is present and on frozen ground, unwanted slippery manoeuvres or movements of the machine could occur.
PARK MACHINE SAFELY • 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.
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SAFETY PRECAUTIONS
INVESTIGATE JOB SITE BEFORE OPERATING THE MACHINE • Explore the working area to identify potential risks before starting and operating the machine. Make sure that the structure and the conditions of the ground are safe before starting operations. - Make sure that the digging area is sufficiently stable and firm to support the weight of the machine during the work operations. - Working near edges and ditches presents a risk for the stability of the machine. Check first that edges and the walls of the digging are sufficiently strong. If necessary, prop the edges appropriately to prevent caving-ins. - DO NOT dig too near the machine. - Always position the tracks perpendicular to the edge of the digging with the travel motors on the rear side. - When working on a slope or near the edge of the road, have a flagman available.
PROTECTING AGAINST THE FALL OF ROCKS AND LANDSLIDES • When operating in zones where the possibility of falling rocks or landslides exists or when there is the risk for front impacts with objects that could penetrate the cab, make sure that protection structures are installed: F.O.P.S. (Falling Object Protection Structure) and FRONT GUARD. - DO NOT install any cab lifting device to the protection structures. - DO NOT weld, drill or modify protective structures. Any type of modification could weaken the structural integrity of the safety system, with serious consequences for the operator, in case of collision, falling objects or landslides. - After an accident, DO NOT try to straighten or repair protective structures. Contact a Dealer to verify the functionality, to repair or to completely or partially replace the protective structures.
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SAFETY PRECAUTIONS
DIG WITH CAUTION • Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. - Before digging, check the location of cables, gas lines, and water lines. - Keep the minimum distance required by law from cables, gas lines, and water lines. If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury. - Contact local authorities and/or the utility companies directly (electric power, gas, telephone, water, sewers, telecommunications, etc.) to obtain information about underground utility lines.
OPERATE WITH CAUTION • If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may results as well. - Take care to avoid hitting overhead obstacles with the boom or arm.
AVOID ELECTRIC LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. - When operating near an electric line, NEVER MOVE any part of the machine or load closer than 5 m plus twice the line insulator length (L). - Check and comply with any local regulations that may apply. - Wet ground will expand the area that could cause any person on it to be affected by electric shock. - Keep all bystanders or co-workers away from the site.
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SAFETY PRECAUTIONS
KEEP PERSONNEL CLEAR FROM WORKING AREA • A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. - Keep all persons clear from the area of operation and machine movement. - Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.
NEVER MOVE THE BUCKET OVER ANY ONE • Never lift, move, or swing bucket above anyone or a truck cab. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.
SP0030
DO NOT OPERATE IN TUNNELS • DO NOT operate the machine in enclosed spaces or, in any case, without appropriate ventilation. Operations in tunnels or underground sites where potential explosive conditions exist are not allowed. There is a danger for explosions and potentially deadly injuries. Please comply with the ATEX regulation relative to devices to be used in a potentially explosive environment.
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SAFETY PRECAUTIONS
NEVER UNDERCUT A HIGH BANK • The edges could collapse or a land slide could occur causing serious injury or death.
SAFETY LOADS MOVING • The excavator is a machine designed specifically to perform digging/loading works, thus it must not be used to handle suspended loads. In the event, under exceptional conditions, it becomes necessary to handle materials, the following indications must be strictly implemented: - The machine must be equipped compulsorily with the appropriate variant provided upon request. Also, totally comply with the safety precautions for the operation of the excavator as a lifting equipment. - Secure the loads to be raised using cables or chains fastened with appropriate hooking mechanisms. - Never hook cables or chains to the bucket teeth. - Nobody should be allowed to remain under the raised load or within the excavator operating range for any reason whatever. - Never exceed specified loading capacity. Incorrect fastening of slings or chains may cause boom/arm failure or failure of the lifting means with consequent bodily injuries and even death. - Always ensure that slings and chains used for lifting are adequate to the load and in good condition. - All loading capacities are referred to the machine on a level surface and should be disregarded when working on a slope. - In any case, comply with the current national or local regulations on this matter.
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SAFETY PRECAUTIONS
AVOID EXCESSIVE DIGGING EFFORTS • Operate the machine complying with the load limits in accordance with the "table of lifting loads" located inside the cab. - Do not exceed the prescribed load limits. - Do not use the strength of the attachment to travel or move the machine. - Do not try digging exploiting the mass of the machine.
PAY ATTENTION WHEN DIGGING DEEPLY • When digging deeply, pay special attention to prevent contacts of the attachment and the relevant hydraulic hoses with the ground. • DO NOT swing the turret or the undercarriage when the attachment boom is fully lowered. Under these conditions there is the danger that the boom collides with the track chains.
DO NOT USE THE TRACTION FORCE OF THE MACHINE FOR DIGGING • Do not travel the machine to dig. In doing this, an excessive stress on the front attachment could results in damages to the structure. Use the undercarriage for travelling only.
DO NOT USE THE TURRET SWING FOR DIGGING • Do not use the turret swing for digging or moving rocks. An excessive stress on the front attachment could results in damages to the structure reducing the operating life of the swing system. Also, this inappropriate use of the machine could cause serious injuries or fatalities.
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SAFETY PRECAUTIONS
DO NOT USE THE BUCKET AS A HAMMER • The use of the bucket as a hammer or for piling operations could cause serious damages to the bucket itself and the components of the front attachment. Also, this inappropriate use of the machine could cause serious injuries or fatalities.
AVOID OPERATING THE CYLINDERS TO FULL STROKE • Do not extend repeatedly the bucket and the arm cylinders full stroke with the purpose of cleaning the bucket from residual materials. This could cause damages to the cylinders. To remove residues from the bucket, use water under pressure or remove them manually. Tolerance A ≥ 50 mm
PROVIDE SIGNALS FOR JOBS INVOLVING A NUMBER OF MACHINES For jobs involving several machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to co-ordinate the job site. Make sure that all personnel obey the signal person’s directions.
TRANSPORTING THE MACHINE UNDER SAFE CONDITIONS • During loading or unloading operations of the machine on a truck or trailer the danger for tipping over is always present. - Use a truck or trailer appropriate for transporting the machine. - Secure safely the machine to the trailer with appropriate chains or cables. Please refer to the chapter "TRANSPORTATION" of this Manual for the safe loading and unloading procedures. - Make sure that you comply with National and local regulations when transporting the machine on open roads.
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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 position to stop the engine.
to the OFF
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.
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SAFETY PRECAUTIONS
WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury. - Before performing any work on the machine, attach a maintenance in progress tag (see also SAFETY PLATES in this Chapter) . This tag can be applied o the left-hand control lever, safety lever or cab door.
SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first. - Always lower the attachment or tool to the ground before working on the machine. - If you must work on a lifted machine or attachment, securely support the machine or attachment. - Do not support the machine on cinder blocks, bollow tires, or props that may crumble under continuous load. - Do not work under a machine that is supported solely by a jack.
STOP THE ENGINE PRIOR TO PERFORMING • DO NOT perform any maintenance operation with the engine running. Trapping by moving parts could cause serious injuries. Stop the engine and wait that it cools-off prior to performing maintenance operations. In case it is indispensable to perform maintenance operations with the engine running, have a person co-operating with you sitting in the operator's seat, to cut-off the engine immediately in case of necessity.
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SAFETY PRECAUTIONS
DISPOSE OF WASTE IN THE APPROPRIATE MANNER • Waste improperly disposed of represents a danger for the envinronment. Potentially dangerous waste used on the excavators includes lubricants, fuel, coolant, brake fluid, filters and batteries. - Used sealed containers when discharging fluids. Do not use containers for food or beverages which may induce drinking. - Do not spill waste over the ground, into drains, or water beds. - Obtain information about the correct methods to recycle or dispose of waste from local Authorities, collection centres or your Dealer.
WORK IN A CLEAN AREA - Before starting an operation, clean the working area. Clear the area from all the objects that can be dangerous for mechanics or people in the working area.
PROPERLY LIGHT THE WORKING AREA • Properly and safely light the working area. - Use safe portable lamps in order to work inside and under the machine. - Make sure that the lamp is shielded by a cage; the incandescent filament of a lamp, accidentally broken, can cause fuel or oil fire.
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SAFETY PRECAUTIONS
KEEP CLEAN THE MACHINE • Keep clean the engine compartment, radiator, batteries, hydraulic pipes, fuel tank and operator's position. - The engine compartment temperature can quickly rise, after stopping the engine. IN THESE CASES, BE CAREFUL TO POSSIBLE FIRES. Open the access doors in order to quicken the engine cooling process and clean the compartment. • Remove all the traces of grease, oil and deposits, in order to avoid people accidents or damages to things. - Do not spray water or steam in the cab.
PREVENT ACID SCALDS • The sulphuric acid, contained in the battery, is poisonous. It is strong enough to scald the skin, corrode clothes and cause blindness, if it is sprayed into the eyes. To avoid dangers: - Fill the batteries in airy areas. - Wear eye protections and rubber gloves. - Avoid breathing the electrolyte vapours when topping up. - Avoid spilling or dripping the electrolyte. - Use proper emergency starting techniques. If you are touched with acid sprays: - Rinse your skin well with water. - Put on your skin sodium bicarbonate or clay to help the acid neutralization. - Rinse your eyes with water for 10-15 minutes. - Immediately see a doctor. If you have swallowed the acid: - Immediately see a doctor.
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SAFETY PRECAUTIONS
STARTING THE ENGINE WITH BOOSTER BATTERIES • If the engine is to be started using booster batteries, ensure to comply with all procedures detailed in the chapter OPERATING INSTRUCTIONS. - The operator should be sitting in the driver’s seat to keep the machine under control when the engine starts. Starting the engine with booster batteries is a two man operation. - Do not use batteries that have been stored in the cold for a long time. - Mistakes in following procedures detailed for starting the engine with slave batteries may cause the batteries to explode or machine to move unexpectedly
PREVENT BATTERY EXPLOSIONS • Battery gas can explode. - Keep sparks, lighted matches, and flames away from the top of battery. - Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. - Do not charge a frozen battery; it may explode. Warm battery to 16 °C. • Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness. - Be sure to wear eye protection when checking electrolyte specific gravity.
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SAFETY PRECAUTIONS
PREVENT BURNS Hot spraying fluids: • After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. - To prevent possible injury from hot spraying water. Do not remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. - The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.
Hot fluids and surfaces: • Engine oil, reduction gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. - Wait for the oil and components to cool down before starting any maintenance or inspection work.
STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic breakers and blades can fall and cause serious injury or death. - Securely store attachments and implements to prevent falling. - Keep bystanders away from storage areas.
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SAFETY PRECAUTIONS
AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. - Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. - Tighten all pressure.
connections
before
applying
- Search for leaks with a piece of cardboard; take care to protect hands and body from highpressure fluids. Wear a face shield or goggles for eye protection. - In an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.
PREVENT PARTS FROM FLYING OFF • Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. - NEVER attempt to remove GREASE FITTING or VALVE ASSEMBLY. - As pieces may fly off, be sure to keep body and face away from valve.
• Travel reduction gears are under pressure. - 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.
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SAFETY PRECAUTIONS
PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. - Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. - Keep bystanderds away from the working area before striking any object.
HANDLE FLUIDS SAFELY - AVOID FIRES • Handle fuel with care: it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injuty or death. - Do not refuel the machine while smoking or when near open flame or sparks. - Always stop the engine before refuelling the machine. - Fill the tank outdoors.
• All fuels, most lubrificants, and some antifreeze fluids are flammable. - Store flammable fluids well away from fire hazards. - Do not burn or puncture pressurized containers. - Do not store oily rags; they can ignite and burn spontaneously.
S2 - 23
E215B-E245B
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 oilcooler 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
EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: - Stop the engine by turning the key-start switch to the OFF position if there is time. - Use a fire extinguisher if there is time. - Exit the machine.
BEWARE OF EXHAUST FUMES • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. - If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
SP0062
USE APPROPRIATE TOOLS • Use tools appropriate for the job to be performed. - Inappropriate tools, parts and procedures might generate dangerous conditions. - Use tools of correct size to tighten or loosening securing elements, in order to avoid injuries caused by a wrench getting out of control. - Do not use U.S. Standard or British Standard tools on metric fasteners and vice versa. • Use only genuine spare parts (please refer to the Spare Parts Catalogue).
S2 - 25
E215B-E245B
SAFETY PRECAUTIONS
AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other materials when welding, soldering, etc.
AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS - Do not weld or flame cut pipes or tubes that contain flammable fluids. - Clean them thoroughly with non-flammable solvent before welding or flame cutting them.
REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paints is heated by weiding, soldering, or using a torch. If inhaled, these fumes may cause sickness. - Avoid breathing potentially toxic fumes and dust. - Do all such work outside or in a well-ventilated area. - Dispose of paint and solvents properly. - Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
S2 - 26
SAFETY PRECAUTIONS
WELDING REPAIR INTERVENTIONS • Welding repair interventions must be performed only by a certified welder with sufficient experience. Also, appropriate safety rules must be implemented by all the personnel involved in the operations. The duration through time of the welding depends upon the quality and the accuracy with which the operation is performed. - Identify first all the fracture points and the zones in which welding is required. - Clean accurately the zones involved. - Remove all paint and inspect the parts with penetrating liquid or a magnetic particle tester. - Move the starter switch into position "OFF" and wait for 4 seconds to cut-off electricity from the system. - Disconnect the negative terminal (-) from the battery. - Connect the ground cable of the welder at least 1 m from the component to be welded. - Make sure that the ground cable is NOT connected to a seal or bearing and that there are noo seals or bearings between the ground cable and the part to be welded. - Avoid welding pieces at low temperature i. e. below 16 °C. If necessary, warm-up the part involved prior to welding it. - Remove paints from all surfaces prior to warming-up or welding. Painted surfaces, when warmed-up or when welded, can generate toxic fumes. - Use appropriate masks or protective glasses. - Wear gloves and adequate clothing to protect the skin.
S2 - 27
E215B-E245B
E215B-E245B
SAFETY PRECAUTIONS
NOTE:
S2 - 28
SAFETY PLATES
SAFETY PLATES Triple articulation version
Triple articulation version
1. Attachment operating range safety plate. 2. Track adjuster plate. S3 - 1
E215B-E245B
E215B-E245B
SAFETY PLATES
9. Controls lock/unlock plate (safety lever).
3. Counterweight operating range safety plate. 4. Read-your-manual plate.
10. Hydraulic oil pressurised tank warning plate.
5. Boom and arm movement warning plate (Triple articulation version).
11. Burns warning plate. 12. Safety distance plate.
6. Open windscreen warning plate aperta (inside the cab).
13. No-stepping warning plate. 14. Special equipment movement warning plate
7. Tag indicating maintenance in progress. 8. Engine hood warning plate.
S3 - 2
SAFETY PLATES 1 - Attachment operating range safety plate Ensure that any person near the working site is outside the machine operating range before starting the machine or operating the attachments. Sound the horn. Background: yellow Border and icons: black
2 - Track adjuster plate It shows that obligation is made to consult the Operation and Maintenance Instruction Manual prior to acting on the track adjust valve. Danger of severe injuries. Background: yellow Border and icons: black
3 - Counterweight operating range safety plate Ensure that any person near the working site is outside the machine operating range before starting the machine or operating the attachments. Sound the horn. Background: yellow Border and icons: black
S3 - 3
E215B-E245B
E215B-E245B
SAFETY PLATES
4 - Read-your-manual plate It is positioned in the cab to recommend to carefully read the Operation and Maintenance Instruction Manual prior to starting, operating, servicing, refuelling or carrying out any other work on the machine. Background: yellow Border and icons: black
5 - Boom and arm movement warning plate (triple articulation version) It shows the danger represented by the bucket hitting the cab. Pay special attention as no stops are provided to prevent this problem. Background: yellow Border and icons: black
SP0073
6 - Open windscreen warning plate It indicates the risk of injuries deriving from the windscreen not being locked or being improperly locked in the open position. Background: yellow Border and icons: black
S3 - 4
SAFETY PLATES 7 - Tag indicating maintenance in progress Maintenance staff is obliged to apply the tag that indicates that the machine is not fully efficient and warns about maintenance staff being located in not visible positions. This tag should be applied to the left-hand control lever, safety lever or cab door. Background: yellow Border and icons: black
8 - Engine hood warning plate It highlights the obligation to stop the engine before opening engine hood. Danger of severe injuries following the presence of rotating parts such as fan, pulleys, and belts. Background: yellow Border and icons: black
9 - Controls lock/unlock plate It shows the position that the safety lever can assume when the engine is running. When the operator is about to leave the cab with the engine running, even if for a short time, he must move the safety lever to the LOCK position. Controls are disabled and therefore no accidental machine or attachment movement is possible. Background: white Border and icons: black
S3 - 5
E215B-E245B
E215B-E245B
SAFETY PLATES
10 - Hydraulic oil pressurised tank warning plate It indicates that the hydraulic oil is pressurised. Consult the Operation and Maintenance Instruction Manual. Prior to intervening on the hydraulic oil tank, bleed the pressure by actuating the appropriate bleeding button located on the cap. The hydraulic oil, at operating temperature, can cause burns in case of contact with the skin. Background: yellow Border and icons: black
11 - Burns danger plate It indicates that a burns danger exists, since the zone is characterised by high temperature. Background: yellow Border and icons: black
12 - Safety distance plate It instructs to keep at a safe distance from a zone dangerous for personal safety. Background: yellow Border and icons: black
S3 - 6
SAFETY PLATES 13 - No-stepping warning plate It instructs not to step on the zone where this decal is attached. Background: yellow Cross: red Border and icons: black
14 - Special equipment movement warning plate It shows the danger represented by the special equipment hitting the cab. Pay special attention as no stops are provided to prevent this problem. Background: yellow Border and icons: black
S3 - 7
E215B-E245B
E215B-E245B
SAFETY PLATES
NOTE:
S3 - 8
OPERATIONAL PRINCIPLE
M0103
OPERATIONAL PRINCIPLE
E215B-E245B
SECTION AND GROUP CONTENTS Section 1
GENERAL
Group 1
Specifications
Section 2
SYSTEM
Group 1 Group 2 Group 3
Mechatro Control System Hydraulic System Electrical System
Section 3
COMPONENT OPERATION
Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8
Hydraulic Pump Assy Pilot Valve Control Valve Swing Device Travel Device Swing Joint Cylinders Air Conditioner
SECTION 1
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
E215B-E245B
SPECIFICATIONS
E215B-E245B
MAIN COMPONENTS
12345678910 -
Bucket Bucket link Idler link Bucket cylinder Arm Arm cylinder Boom Boom cylinder Cab Swivel joint
11 12 13 14 15 16 17 18 19 20 -
Swing motor Fuel tank Hydraulic oil tank Control valve Engine muffler Hydraulic pump Engine Counterweight Engine radiator Travel motor
T1-1-1
21 22 23 24 25 26 27 28 29 -
Track link Batteries Upper roller Track guide Lower roller Air cleaner Crawler adjuster Front idler Shoe plate
E215B-E245B
SPECIFICATIONS
Main Components – Upper Structure
1
8
7
2 6
5
3
4 SM0012
1-
Control Cab
5-
Hydraulic Pump
2-
Proportional Solenoid Valve Block
6-
Control Valve
3-
Radiators
7-
Swing Motor Unit
4-
Engine
8-
Center Joint
T1-1-2
SPECIFICATIONS
E215B-E245B
Main Components – Under Carriage
5
4
1
2 3
section A - A SM0013
1-
Right Travel Motor Unit
4-
Swing Gear
2-
Left Travel Motor Unit
5-
Front Idler Assy
3-
Center joint
T1-1-3
E215B-E245B
SPECIFICATIONS
Main Components – Front Attachment
2
7
5
1 3
6
4
2
8
7
3 1
SM0014
1-
Boom cylinder
5-
Monoblock Boom
2-
Arm cylinder
6-
Boom (Triple Articulation Version)
3-
Bucket Cylinder
7-
Arm
4-
Positioning Cylinder (Triple Articulation Version)
8-
Positioner (Triple Articulation Version)
T1-1-4
SPECIFICATIONS
E215B-E245B
HYDRAULIC COMPONENTS HYDRAULIC PUMP Main pump
Gear pump for pilot
Pump
Item
K3V112DTP1KMR-YTOK-HV
ZX10LPRZ7-07G
Type
Variable displacement plunger pump: regulator attached type
Fixed displacement type gear pump
110 x 2
10
2000
←
Max. displacement capacity
cm3
Revolution
rpm (Clockwise seen from shaft end)
Pressure
Rated Rated ATT boost
34.3
MPa
Max. flow
L/min
Max. input Power (at 2000 rpm) Max. input torque (at 1200 rpm)
220 x 2 at 7.8 MPa
20
kW
118
3.4
Nm
665
14.7
Model Regulator
Mass
5.0
37.8
KR3G-YTOK-HV
Control function
Electric flow control, positive flow control, total power control at emergency mode and power shift control
Others
With solenoid proportional reducing valve (KDRDE5K-31/ 30C50)
kg
143
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 Main relief valve set pressure
L/min
220 x 2
MPa
34.3 at 70 x 2 L/min
When power boost pressure Over load relief valve set pressure
37.8 at 60 x 2 L/min MPa
Boom H, Bucket H, Arm R
39.7 at 30 L/min
Boom R, Bucket R, Arm H Mass
37.8 at 30 L/min kg
Item
OPT VALVE
Model Over load relief valve set pressure
KADV22Y / 501103A03 MPa
Positioner R
39.7 at 30 L/min
Positioner H Mass
232
37.7 at 30 L/min kg
T1-1-5
2.8
E215B-E245B
SPECIFICATIONS
PILOT VALVE ATTACHMENT
TRAVEL
PV48K2004
6TH6NRZ
5.0 MPa
4.9 MPa
0.6 ~ 3.2 MPa
0.54 ~ 2.35 MPa
Model Primary pressure Secondary pressure Rated flow Mass
20 L/min
25 L/min
Approx. 2 kg
Approx. 8 kg
Hydraylic motor
SWING MOTOR UNIT
Antireaction valve block
Model
M5X130CHB–10A–41C/295
Type
Swash-plate type, fixed-displacement plunger motor
Displacement
cm3
129.2
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
Type Mass
Hydraulic motor assy mass
2KAR6P72/240-712 kg
2.5
kg
51.5
Speed reduction type
Planetary 2-stage
Reduction unit
Reduction ratio
Total mass
15.38
Lubicate oil Lubicate oil volume
Gear oil SAE90 (API class GL–4 grade) L
Grease
3.0 Extreme pressure lithium base # 2 grease
Grease volume
kg
Approx. 1.0
Mass
kg
145
kg
Approx. 197
T1-1-6
SPECIFICATIONS
E215B-E245B
TRAVEL DEVICE Item
E215B
Reduction gear unit
E245B
Epicycloidal, three-stage planetary type
Model
710 C3 K
Gearbox ratio
1 : 55.2
Travel motor
Two speed, axial piston swash plate type
Model Displacement
MAG 170 VP
MAG 170 VP
high speed
81.2 cm3/rev
112.6 cm3/rev
low speed
129.3 cm3/rev
181.3 cm3/rev
220 L/min
246 L/min
high speed
38949 Nm
42827 Nm
low speed
24469 Nm
25600 Nm
static
32060 Nm
25000 Nm
dynamic
26707 Nm
20900 Nm
Max. flow Max. gearbox torque
1 : 43.2
output
Parking brake torque
Min. pressure parking brake release Relief valve set pressure
11 bar
cracking
311 bar at 1.2 L/min
total flow
353 bar at 40 L/min
Mass
235 kg
262 kg
CYLINDERS Cylinder bore / Rod Dia.
Stroke
(mm)
(mm)
Center distance of pins Full extend B / Full retract A (mm)
Boom
Ø 120 / Ø 85
1345
3200 / 1855
Arm
Ø 135 / Ø 95
1558
3637 / 2079
Bucket
Ø 120 / Ø 80
1080
2684 / 1604
Positioning
Ø 145 / Ø 90
992
2662 / 1670
Use
T1-1-7
Cushion
Mass (kg)
With cushion on rod side With cushion on both sides With cushion on rod side Without cushion
176 255 153 220
E215B-E245B
SPECIFICATIONS
EXCAVATOR PERFORMANCE GRADEABILITY ......................................................................................................................................... 70% TRAVEL SPEED Excavator
E215B
E245B
First speed
3.6 km/h
3.2 km/h
Second speed
6.0 km/h
5.2 km/h
Speed
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
DIGGING DATA E215B (Monoblock Version)
(Dimensions in mm) Arm
2080
2400
2940
3500
A
9185
9446
9929
10366
A’
8991
9258
9750
10195
B
5840
6160
6700
7260
B’
5620
5954
6519
7082
C
9440
9519
9733
9749
D
6737
6793
7037
7149
E
3679
3559
3544
3478
F
4268
3955
3503
2942
G
5005
5346
5879
6588
T1-1-9
E215B
SPECIFICATIONS
DIGGING DATA E215B (Triple Articulation Version)
(Dimensions in mm) Arm
2080
2400
2 940
3500
A
9322
9598
10098
10555
A’
9131
9413
9922
10387
B
5590
5891
6417
6932
B’
5467
5775
6310
6832
C
10682
10882
11280
11544
D
7755
7952
8351
8632
E
2929
2742
2524
2695
F
5016
4575
3724
3196
G
2470
2747
3151
3818
T1-1-10
SPECIFICATIONS
E215B
TRANSPORTING DIMENSIONS E215B (Monoblock Version)
VERSIONS
E215BEL
E215BL
E215BLC
A
3656
3656
3656
B
4451
4451
4451
C
D
1035
1035
1035
2800
2800
2800
E
F
(1) 9617
(1) 3133
(2) 9580
(2) 3044
(3) 9493
(3) 2884
(4) 9568
(4) 3044
(1) 9617
(1) 3133
(2) 9580
(2) 3044
(3) 9493
(3) 2884
(4) 9568
(4) 3044
(1) 9617
(1) 3133
(2) 9580
(2) 3044
(3) 9493
(3) 2884
(4) 9568
(4) 3044
G
H
I
L
2503
3027
948
471
2503
3027
948
471
2503
3027
948
471
Arm: (1) 2080 mm (2) 2400 mm (3) 2940 mm (4) 3500 mm
(dimensions in mm)
E215BEL
E215BL
E215BLC
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 Spec. ground pres.
(kg) 20590 20850 21120 20920 21190 21460 21730 20940 21210 21480 21750 (bar)
0.55
0.47
0.40
0.47
(*) With arm 2940 mm and bucket 1.3 m3
T1-1-11
0.41
0.36
0.32
0.47
0.41
0.36
0.32
E215B
SPECIFICATIONS
TRANSPORTING DIMENSIONS E215B (Triple Articulation Version)
E
G D
H
I
L
F C
M
A B
N
VERSIONS
E215BEL
E215BL
E215BLC
A
3656
3656
3656
B
4451
4451
4451
C
D
1035
1035
1035
2800
2800
2800
NH0148
E
F
(1) 9683
(1) 3062
(2) 9665
(2) 3014
(3) 9643
(3) 2954
(4) 9631
(4) 3237
(1) 9683
(1) 3062
(2) 9665
(2) 3014
(3) 9643
(3) 2954
(4) 9631
(4) 3237
(1) 9683
(1) 3062
(2) 9665
(2) 3014
(3) 9643
(3) 2954
(4) 9631
(4) 3237
G
H
I
L
2503
3027
948
471
2503
3027
948
471
2503
3027
948
471
Arm: (1) 2080 mm (2) 2400 mm (3) 2940 mm (4) 3500 mm
(dimensions in mm)
E215BEL
E215BL
E215BLC
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 Spec. ground pres.
(kg) 21220 21490 21760 21560 21830 22100 22360 21580 21850 22120 22390 (bar) 0.57
0.48
0.42
0.48
(*) With arm 2940 mm and bucket 1.3 m3
T1-1-12
0.42
0.37
0.33
0.48
0.42
0.37
0.33
SPECIFICATIONS
E215B
BUCKET APPLICATIONS AS A FUNCTION OF THE ARMS E215B E215B Monoblock BUCKETS Width (mm)
Capacity (dm3) SAE J296 (ISO 7451)
Mass (kg)
750
525
503
850
625
537
1000
789
634
1200
1000
651
1300
1105
698
1500
1315
760
E215BEL
E215BL
E215BLC
Arm (mm)
Arm (mm)
Arm (mm)
2080 2400 2940 3500 2080 2400 2940 3500 2080 2400 2940 3500
E215B Triple Articulation BUCKETS Width (mm)
Capacity (dm3) SAE J296 (ISO 7451)
Mass (kg)
750
525
503
850
625
537
1000
789
634
1200
1000
651
1300
1105
698
1500
1315
760
E215BEL
E215BL
E215BLC
Arm (mm)
Arm (mm)
Arm (mm)
2080 2400 2940 3500 2080 2400 2940 3500 2080 2400 2940 3500
General digging work (specific weight of material < 1.8 t/m3) Slightly heavy digging work (specific weight of material < 1.5 t/m3) Loading work (specific weight of material < 1.2 t/m3)
T1-1-13
E245B
SPECIFICATIONS
DIGGING DATA E245B (Monoblock Version)
(Dimensions in mm) Arm
2080
2400
2940
3500
A
9185
9446
9929
10366
A’
8991
9258
9750
10195
B
5822
6142
6682
7242
B’
5602
5936
6501
7064
C
9458
9537
9751
9767
D
6755
6811
7055
7167
E
3679
3559
3544
3478
F
4286
3973
3521
2960
G
5005
5346
5879
6588
T1-1-14
SPECIFICATIONS
E245B
DIGGING DATA E245B (Triple Articulation Version)
(Dimensions in mm) Arm
2080
2400
2940
3500
A
9322
9598
10098
10555
A’
9131
9413
9922
10387
B
5572
5873
6399
6914
B’
5449
5757
6292
6814
C
10700
10900
11298
11562
D
7773
7970
8369
8650
E
2929
2742
2524
2695
F
5034
4593
3742
3214
G
2470
2749
3151
3818
T1-1-15
E245B
SPECIFICATIONS
TRANSPORTING DIMENSIONS E245B (Monoblock Version)
VERSIONS
E245B
A
3840
B
4645
C
D
1053
2800
E
F
(1) 9617
(1) 3141
(2) 9577
(2) 3050
(3) 9487
(3) 2886
(4) 9564
(4) 3044
Arm: (1) 2080 mm (2) 2400 mm (3) 2940 mm (4) 3500 mm
G
H
I
L
2503
3045
970
486
(dimensions in mm)
E245B M Track shoe width
(mm)
550(*)
700
800(*)
N Gauge
(mm)
2490
2690
2890
(**) Working weight
(kg)
22000
22500
22850
Spec. ground pres.
(bar)
0.51
0.41
0.37
(**) With arm 2940 mm and bucket 1.3 m3 (*) Asymmetric type shoes
T1-1-16
SPECIFICATIONS
E245B
TRANSPORTING DIMENSIONS E245B (Triple Articulation Version)
E
G D
H
I
L
F C
M
A B
N
VERSIONS
E245B
A
3840
B
4645
C
D
1053
2800
NH0148
E
F
(1) 9684
(1) 3067
(2) 9665
(2) 3014
(3) 9641
(3) 2957
(4) 9634
(4) 3235
Arm: (1) 2080 mm (2) 2400 mm (3) 2940 mm (4) 3500 mm
G
H
I
L
2503
3045
970
486
(dimensions in mm)
E245B M Track shoe width
(mm)
550(*)
700
800(*)
N Gauge
(mm)
2490
2690
2890
(**) Working weight
(kg)
22600
23100
23450
Spec. ground pres.
(bar)
0.53
0.42
0.38
(**) With arm 2940 mm and bucket 1.3 m3 (*) Asymmetric type shoes
T1-1-17
E245B
SPECIFICATIONS
BUCKET APPLICATIONS AS A FUNCTION OF THE ARMS E245B E245B Monoblock BUCKETS
E245B Arm(mm)
Width (mm)
Capacity (dm3) SAE J296 (ISO 7451)
Mass (kg)
750
525
503
850
625
537
1000
789
634
1200
1000
651
1300
1105
698
1500
1315
760
2080
2400
2940
3500
E245B Triple Articolation BUCKETS Capacity (dm3) Width (mm) SAE J296 (ISO 7451)
E245B Mass (kg)
750
525
503
850
625
537
1000
789
634
1200
1000
651
1300
1105
698
1500
1315
760
Arm (mm) 2080
2400
2940
3500
General digging work (specific weight of material < 1.8 t/m3) Slightly heavy digging work (specific weight of material < 1.5 t/m3)
T1-1-18
SECTION 2
E215B-E245B
SYSTEM
CONTENTS Group 1 - Mechatro Control System 1 Preface .............................................. T2-1-1 2 Summary of Mechatro control system T2-1-2 2.1
Mechatro control system in general ..................................... T2-1-2
2.2
Unload valve control ................. T2-1-4
2.3
Positive control & P-Q control... T2-1-5
2.4
Boom up conflux control ........... T2-1-7
2.5
Arm in recirculation & conflux control....................................... T2-1-8
2.6
Arm-in anti-cavitation control .... T2-1-10
2.7
Arm-out conflux control............. T2-1-11
2.8
Bucket digging (dump) conflux control....................................... T2-1-12
2.9
Bucket digging anti-cavitation control....................................... T2-1-13
5 Positioning circuit (triple articulation version) .............................................. T2-2-8 6 Color coding standard for hydraulic circuits................................................ T2-2-10 7 Neutral circuit .................................... T2-2-10 8 Travel circuit ...................................... T2-2-12 9 Bucket circuit ..................................... T2-2-14 10 Boom circuit ...................................... T2-2-16 11 Swing circuit ...................................... T2-2-20 12 Arm circuit ......................................... T2-2-22 13 Combined circuit ............................... T2-2-28 14 Pressure draining (releasing) circuit . T2-2-32
Group 3 - electrical system Electrical system main components........ T2-3-1 Electrical system (Overall system) ..... T2-3-1
2.10 Swing priority control ................ T2-1-15
Electrical system diagram ...................... T2-3-12
2.11 Travel straight control ............... T2-1-16
Electrical system diagram (No. 1) ...... T2-3-13
2.12 Pressure release control........... T2-1-18
Electrical system diagram (No. 2) ...... T2-3-15
2.13 N&B switch control (option) ...... T2-1-19
Electrical system diagram (No. 3) ...... T2-3-17
2.14 Option conflux control (option).. T2-1-20
Electrical system diagram (No. 4) ...... T2-3-19
3 Mechatro controller ............................ T2-1-21 3.1
Summary of multi display ......... T2-1-21
3.2
Self diagnosis display ............... T2-1-27
3.3
Service diagnosis display function ..................................... T2-1-29
3.4
Trouble history diagnosis.......... T2-1-39
3.5
Trouble diagnosis mode ........... T2-1-40
3.6
Set procedure of maintenance schedule ................................... T2-1-41
3.7
Adjusting procedure of display . T2-1-42
3.8
Mechatro control equipment ..... T2-1-48
Group 2 - Hydraulic circuits 1 Summary ........................................... T2-2-1 2 Hydraulic circuits and components .... T2-2-2 3 N&B hydraulic circuit (option) ............ T2-2-4 4 Holding valve for boom & arm (option)T2-2-6
Electrical system diagram (No. 5) ...... T2-3-21 Wiring harness ........................................ T2-3-22 Cluster gauge wiring harness assembly................................... T2-3-23 Platform wiring harness assembly .... T2-3-25 Upper frame wiring harness assembly . T2-3-27 Engine wiring harness (KSB & STOP) . T2-3-29
MECHATRO CONTROL SYSTEM
E215B-E245B
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 2
MECHATRO CONTROL SYSTEM
SUMMARY OF MECHATRO CONTROL SYSTEM
2.1
MECHATRO CONTROL SYSTEM IN GENERAL
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 FOR TRAVEL
PILOT VALVE FOR ATT
SE-9 SE-10
SE-11 LOW PRESSURE SENSOR
SE-4
(4)
GAUGE CLUSTER LCD DISPLAY FOR SELECTION FUEL GAUGE COOLANT TEMP. GAUGE SWITCH
SENSOR BLOCK
SE-3
SE-7
SCREEN CHANGE BUZZER STOP
(1)
(8) (7)
L4
(6)
WASHER
SE-5
WIPER
ACCEL DIAL SE-16
SERIAL COMMUNICATION
TRAVEL AUTO-IDLE
(5)
OUTPUT VOLTAGE
MODE
SERIAL COMMUNICATION
(2)
SE-1 SE-8
L2 L3
(3)
SE-2
PSV-R SHORT-CIRCUIT VALVE
PROPORTIONAL VALVE
SE-23 HIGH PRESSURE SENSOR
C-1
SE-22
MECHATRO CONTROLLER
ENGINE GOVERNOR MOTOR
M-2
A1
L5 A2
A3
SPEED SENSOR
SE-13
PSV -P1 P1 PUMP PROPORTIONAL VALVE
: HIGH PRESSURE SENSOR (FOR P1,P2 : 2pcs)
PSV -P2 P2 PUMP PROPORTIONAL VALVE
: GOVERNOR MOTOR : E/G SPEED SENSOR
L6
: LOW PRESSURE SENSOR (ATT : 7pcs, TRAVEL : 2pcs)
L7 VOLTAGE 24V
PROPORTIONAL COMMAND CURRENT
SM0116
T2-1-2
MECHATRO CONTROL SYSTEM
L1
E215B-E245B
MAIN CONTROL VALVE SE-29
(3)
UP
REVERSE
REVERSE
L2 L3
LEFT ARM OUT
(5)
(7)
SV-13 N&B SELECTOR VALVE
(8)
OPTION
(6)
BOOM UP CONFLUX P2 UNLOAD
TRAVEL LEFT
PL1 ATTACHMENT BOOST P1 P2
(3)
ARM 1 SPEED
DIGGING
FORWARD
(4)
SWING
(1)
DOWN FORWARD
TRAVEL P1 UNLOAD STRAIGHT
BUCKET
ARM 2 SPEED
(2)
TRAVEL RIGHT
DUMP
(8)
BOOM LOW SPEED
ARM OUT
SOL
RIGHT ARM IN
SOLENOID VALVE
L4 SWING MOTOR PARKING RELEASE
PSV -A
PSV PSV PSV -D -C -B
SV -2
SV -3
SV -1
BOOM CYLINDER BOOM DOWN RECIRCULATION BOOM CONFLUX
SAFETY LOCK LEVER
SWING PARKING BRAKE
TRAVEL 1,2 SPEED
ATTACHMENT BOOST
P2 UNLOAD
TRAVEL STRAIGHT
P1 UNLOAD
L5
ARM IN 2 SPEED
TRAVEL MOTOR 1,2 SPEED SELECT
SV -4
ARM CYLINDER ARM OUT CONFLUX ARM IN CONFLUX
(7)
ARM IN
L6
BUCKET CYLINDER DIGGING / DUMP CONFLUX
L7 PROPORTIONAL VALVE SOLENOID VALVE
) BLOCK SM0117
T2-1-3
E215B-E245B
P2
(LEFT)
(RIGHT)
OPTIONAL PILOT VALVE
PILOT VALVE
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
UNLOAD VALVE CONTROL
OPTION
2.2
MECHATRO CONTROL SYSTEM
P1
PILOT VALVE
PILOT VALVE FOR TRAVEL
SE-11 SE-10
SE-9
LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4
SE-5,7,8
pi
PILOT SIGNAL PROCESS
PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
P1 UNLOAD PROPORTIONAL VALVE PSV-D
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
P2
SE-23
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
OPTIONAL PILOT VALVE
P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
POSITIVE CONTROL & P-Q CONTROL
OPTION
2.3
E215B-E245B
P1
SE-22
SE-11
(LEFT)
(RIGHT)
PILOT VALVE
PILOT VALVE
PILOT VALVE FOR TRAVEL
SE-10
SE-9
LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4
SE-5,7,8
pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE COMMAND
P2 PUMP PROPORTIONAL VALVE PSV-P2
PILOT SECONDARY PRESSURE
pi
pi
PILOT SIGNAL PROCESS PILOT SECONDARY PRESSURE
P1 PUMP PROPORTIONAL VALVE COMMAND
P1 PUMP PROPORTIONAL VALVE PSV-P1
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.
P-Q CONTROL
PILOT SIGNAL PROCESS
PUMP PROPORTIONAL SECONDARY PRESSURE
PUMP PROPORTIONAL SECONDARY PRESSURE
POSITIVE CONTROL
PILOT PRESSURE
PILOT SIGNAL PROCESS
PUMP DELIVERY PRESSURE
SM0120
T2-1-6
MECHATRO CONTROL SYSTEM
P2
PILOT VALVE
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
BOOM UP CONFLUX CONTROL
OPTION
2.4
E215B-E245B
P1
LOW PRESSURE SENSOR SE-3
pi
PILOT SIGNAL PROCESS
BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS MECHATRO CONTROLLER BOOM UP PILOT SECONDARY PRESSURE
P2 PUMP PROPORTIONAL VALVE PSV-P2
P1 PUMP PROPORTIONAL VALVE PSV-P1
P2 UNLOAD PROPORTIONAL VALVE PSV-B
P2 UNLOAD PROPORTIONAL VALVE PSV-D
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
SM0121
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
P2
LOW PRESSURE SENSOR SE-1~6
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
PILOT VALVE
P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
ARM IN RECIRCULATION & CONFLUX CONTROL
OPTION
2.5
MECHATRO CONTROL SYSTEM
P1
LOW PRESSURE SENSOR SE-7
CONTROL PROCESS FOR 2 SPEED
pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
ARM IN PILOT SECONDARY PRESSURE P1 PUMP PROPORTIONAL VALVE PSV-P1
PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
ARM IN PILOT SECONDARY PRESSURE P1 UNLOAD PROPORTIONAL VALVE PSV-D
pi PILOT SECONDARY PRESSURE
pi
ARM PILOT SECONDARY PRESSURE
P2 PUMP PRESSURE
REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL
MECHATRO CONTROLLER
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A
pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0122
T2-1-8
MECHATRO CONTROL SYSTEM
E215B-E245B
1. Recirculation and conflux (Low loading) 1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool and 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, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool. In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal according to the combined operation and outputs command, which is different from the armin independent operation, to P1 pump proportional valve, P1 unload proportional valve and reverse proportional valve for arm-in 2 spool. 3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure and it switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls recirculation rate and conflux rate.) The other proportional valves output proportional secondary pressure according to command from mechatro controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload valve. 4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2 unload spools and arm 2 spool are switched according to the command output by mechatro controller, and consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil during arm operation. 2. Recirculation cut The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is raised during arm operation the mechatro controller processes pilot signal processing according to the pressure detected by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for arm-in 2 spool. The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently recirculation passage is blocked.
T2-1-9
E215B-E245B
P2
LOW PRESSURE SENSOR SE-7
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL LEFT
TRAVEL STRAIGHT
PILOT VALVE
P2 UNLOAD
SWING
SOLENOID
ARM 1 SPEED
N&B SELECTOR VALVE
BOOM UP CONFLUX
ARM-IN ANTI-CAVITATION CONTROL
OPTION
2.6
MECHATRO CONTROL SYSTEM
P1
ACCEL POTENTIO
pi
PILOT SIGNAL PROCESS
ARM IN PILOT SECONDARY PRESSURE pi
PILOT SIGNAL PROCESS
pi P2 PUMP PROPORTIONAL VALVE PSV-P2
REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL PSV-Bpi
ARM IN PILOT SECONDARY PRESSURE
pi REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL COMMAND
ENGINE SPEED (COMMAND VALUE)
MECHATRO CONTROLLER
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A
pi
pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0123
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
PILOT VALVE
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
ARM-OUT CONFLUX CONTROL
OPTION
2.7
E215B-E245B
P1
LOW PRESSURE SENSOR SE-8
pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
ARM OUT PILOT SECONDARY PRESSURE pi P1 PUMP PROPORTIONAL VALVE PSV-P1
ARM OUT PILOT SECONDARY PRESSURE
pi P2 UNLOAD PROPORTIONAL VALVE PSV-B
ARM OUT PILOT SECONDARY PRESSURE pi
MECHATRO CONTROLLER ARM OUT PILOT SECONDARY PRESSURE
P1 UNLOAD PROPORTIONAL VALVE PSV-D
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
SM0124
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
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
BOOM UP CONFLUX
TRAVEL LEFT
TRAVEL STRAIGHT
PILOT VALVE
P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
BUCKET DIGGING (DUMP) CONFLUX CONTROL
OPTION
2.8
MECHATRO CONTROL SYSTEM
P1
LOW PRESSURE SENSOR SE-1(2) pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P1 PUMP PROPORTIONAL VALVE PSV-P1
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P1 UNLOAD PROPORTIONAL VALVE PSV-D
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
TRAVELSTRAIGHT PROPORTIONAL VALVE PSV-C
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0125
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
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
PILOT VALVE
P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
BUCKET DIGGING ANTI-CAVITATION CONTROL
OPTION
2.9
E215B-E245B
P1
LOW PRESSURE SENSOR SE-1 (2)
pi
PILOT SIGNAL PROCESS
BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS ACCEL POTENTIO
P2 PUMP PROPORTIONAL VALVE PSV-P2
P1 PUMP PROPORTIONAL VALVE PSV-P1
P2 UNLOAD PROPORTIONAL VALVE PSV-B
BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
P1 UNLOAD PROPORTIONAL VALVE PSV-D
TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C
BUCKET DIGGING PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
BUCKET ANTI-CAVITATION PROCESS
ATT BOOST SOLENOID VALVE SV-2
ENGINE SPEED (COMMAND VALUE)
MECHATRO CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE
P1 PUMP PRESSURE
T2-1-13
SM0126
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
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
PILOT VALVE
OPTION
2.10 SWING PRIORITY CONTROL
P1
LOW PRESSURE SENSOR SE-5
SE-7
pi
ARM IN PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
pi
pi
SWING PILOT SECONDARY PRESSURE
P1 PUMP PROPORTIONAL VALVE PSV-P1 P2 UNLOAD PROPORTIONAL VALVE PSV-B P1 UNLOAD PROPORTIONAL VALVE PSV-D
ARM IN PILOT SECONDARY PRESSURE
SWING PILOT SECONDARY PRESSURE
P2 PUMP PROPORTIONAL VALVE PSV-P2
TRAVEL STRAIGHT PROPORTIONAL VALVE COMMAND
TRAVEL STRAIGHT COMMAND PROPORTIONAL VALVE PSV-C
REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A
MECHATRO CONTROLLER
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
SM0127
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
(RIGHT)
PILOT VALVE
P2
PILOT VALVE FOR TRAVEL
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL LEFT
BOOM UP CONFLUX
PILOT VALVE
TRAVEL STRAIGHT
(LEFT)
P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
OPTIONAL PILOT VALVE
OPTION
2.11 TRAVEL STRAIGHT CONTROL
P1
SOLENOID SHORT CIRCUIT VALVE
SE-10
SE-9
SE-11
LOW PRESSURE SENSOR
VALVE SIGNAL TRAVEL STRAIGHT SIGNAL
pi
PILOT SIGNAL PROCESS
PROPORTIONAL VALVE PSV-R IN SHORT-CIRCUIT VALVE
ޓޓ PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C
ޓޓ PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
ޓޓޓ PILOT SECONDARY PRESSURE pi
PILOT SIGNAL PROCESS
P1 PUMP PROPORTIONAL VALVE PSV-P1
PILOT ޓ SECONDARY PRESSURE pi
PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
PILOT SECONDARY PRESSURE pi
PILOT SIGNAL PROCESS
PILOTޓޓޓ SECONDARY PRESSURE
T2-1-16
P1 UNLOAD PROPORTIONAL VALVE PSV-D
SM0128
MECHATRO CONTROL SYSTEM
E215B-E245B
1. Judgment travel straight 1) During travel operation (right and left), pilot pressure switches each travel spool and is input to low pressure sensor on carrying out attachment system operation. 2) Mechatro controller decides as travel straight on receiving the input according to the combination shown in the table from the low pressure sensor and turns travel straight signal on. 3) On turning travel straight signal on, the following commands are output to each proportional valve. 2. Operation of each proportional valve (Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump in travel straight condition.) 1) Travel straight proportional valve outputs switching pressure according to the high priority select pressure in the attachment system operating (Boom, arm, bucket, swing, option) pilot pressure during operation. 2) Short-circuit proportional valve outputs pressure according to the high priority select pressure in the both attachment and travel system operating pilot pressure during operation. 3) P1 unload proportional valve outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation. 4) P2 unload proportional valve outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation. 5) P1 pump proportional valve outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation. 6) P2 pump proportional valve outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation. ATT operation
Boom
Arm
Right travel operation (P1) Left travel operation (P2)
T2-1-17
Bucket
Swing
Option
E215B-E245B
MECHATRO CONTROL SYSTEM
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
PILOT VALVE
P2 UNLOAD
GAUGE CLUSTER
SWING
SOLENOID
ARM 1 SPEED
N&B SELECTOR VALVE
OPTION
2.12 PRESSURE RELEASE CONTROL
P1
SE-23
SE-22
ENGINE (M-2)
PRESSURE RELEASE CONTROL
ENGINE SPEED CONTROL
pi
pi
pi
pi
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS MECHATRO CONTROLLER
P2 PUMP PROPORTIONAL VALVE PSV-P2
P1 PUMP PROPORTIONAL VALVE PSV-P1
P2 UNLOAD PROPORTIONAL VALVE PSV-B
P1 UNLOAD PROPORTIONAL VALVE PSV-D
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
SM0130
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
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SWING
SOLENOID
OPTION
PRESSURE SENSOR N&B FOR BREAKER SELECTOR SE-29 VALVE
ARM 1 SPEED
2.13 N&B SWITCH CONTROL (OPTION)
P1
A MODE
B MODE GAUGE CLUSTER
pi
B MODE SWITCH
MECHATRO CONTROLLER
pi : OUTPUT OF N&B SELECTOR SOLENOID
SM0131
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
P2
LOW PRESSURE SENSOR
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SOLENOID
SWING
PILOT VALVE
ARM 1 SPEED
N&B SELECTOR VALVE
OPTION
2.14 OPTION CONFLUX CONTROL (OPTION)
P1
SINGLE / CONFLUX SWITCH
SE-11
pi
PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
P1 PUMP PROPORTIONAL VALVE PSV-P1
OPTION PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE
P2 UNLOAD PROPORTIONAL VALVE PSV-B
P1 UNLOAD PROPORTIONAL VALVE PSV-D
TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE CONTROLLER SECONDARY PRESSURE
SM0132
1. Select the Conflux with the aid of Conflux/Single switch. 2. On starting option operation, option operating pilot pressure switches option spool and is input to low pressure sensor. 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 pressure proportional valves and travel straight proportional valve. 4. Each proportional valves output pilot proportional valve 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. 5. The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.
T2-1-20
MECHATRO CONTROL SYSTEM 3.
E215B-E245B
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 SWITCH
GAUGE CLUSTER SAFETY LOCK LEVER RIGHT CONTROL LEVER WITH ATT BOOST SW.
FUSE & RELAY BOX
STARTER SWITCH ACCEL DIAL
DETAIL A
SM0133
A
2. Gauge cluster
11
22:00 H 1
2 3 10 4
9
8
5
7
6
No.
Name
1
Engine coolant temperature gauge
2
Fuel level gauge
3
Screen change switch
4
Buzzer stop switch
5
Work mode select switch
6
Washer switch
7
Wiper switch
8
Travel high speed, low speed select switch
9
Auto accel switch
10
Select switch
11
Multi display (LCD)
SM0134
T2-1-21
E215B-E245B
MECHATRO CONTROL SYSTEM
3. Screen selection by work mode select switch After starting engine, "S" mode is usually set. The work modes "S","H","B" and "A" are selected in order every time ( ) is pressed. Select efficient work mode according to the working condition and the purpose from the following table. The selected mode is displayed on the left lower corner on multi display. • • • •
S mode: For standard digging work H mode: For heavy duty digging work B mode: For works with breaker A mode: For works with crusher (nibbler)
10:25 H
SM0135
Work mode
Display
S mode
10:25
Contents "S mode"is suitable for standard digging and loading works and is in fuel saving and is maintained well-balanced relations with workload.
㧿
10:25
H mode
"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.
10:25
For the work with crusher (nibbler), select "A mode".
㧮
A mode
㧭
T2-1-22
MECHATRO CONTROL SYSTEM 1) Pump flow rate adjustment (A mode /B mode)
1
No. Switches 1
Screen change switch
2
Buzzer stop switch
3
KPSS work mode select switch
4
Washer switch
5
Wiper switch
6
Travel speed select switch
7
Auto accel switch
8
Select switch
8
E215B-E245B
2
3
7
4
5
6
SM0140
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. Main screen
Attachment mode (A mode)
10:25
Flow rate
H
130 L/m
Flow rate
Enter
A
(a)
Flow rate
100 L/m
(b)
(d)
100 L/m
A
Increase/Decrease
In Breaker mode (B mode) Flow rate
130 L/m
Flow rate
Enter
B Screen in Attachment/Breaker mode A mode Flow rate
(c)
(d)
Flow rate
A
100 L/m
B
Increase/Decrease When the conflux switch is tuned on, the double flow rate is displayed.
B mode 130 L/m
Flow rate
100 L/m
130 L/m
B (b)
(c)
SM0141
1) Turn starter key switch on and display main screen (a). 2) The display on the left lower corner of screen is changed in order of "S" → "H" → "B" → "A" each time the "MODE" switch (3) is pressed under the condition where main screen (a) is displayed. 3) Select "A" and A mode screen is displayed, and select "B" and B mode screen is displayed. 4) Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and the screen (d) is displayed. In this condition, press FEED (4)/ (5) and the flow rate value increases or decreases. 5) Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.
T2-1-23
E215B-E245B
MECHATRO CONTROL SYSTEM
4. MAINTENANCE SCREEN DISPLAYS This screen displays the remaining time to the end of recommended replacement/change interval specified for filter/oil. For the initial set value of recommenced replacement/change time, see the following table. Replacement interval Item
Default
Engine oil
500 Hr
Fuel filter
500 Hr
Hydraulic oil filter
1,000 Hr
Hydraulic oil
5,000 Hr
This menu is available for confirmation of the following items. The maintenance screen changes each time the screen change switch is pressed.
1) Remaining time display to the engine oil change This display shows the remaining time to the coming engine oil change.
492Hr
ENGINE OIL
H
2) Remaining time display to the coming fuel filter replacement This display shows the remaining time to the coming engine fuel filter replacement.
492Hr
FUEL FILTER
H
3) Remaining time display to the coming hydraulic oil filter replacement This display shows the remaining time to the coming hydraulic oil filter replacement.
992Hr
HYD. FILTER
H
4) Remaining time display to the coming hydraulic oil change This display shows the remaining time to the coming hydraulic oil change.
4992Hr HYD. OIL
H
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
5. Gauge cluster display After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen. The display functions of multi display are explained below.
CLOCK DISPLAY SELF DIAGNOSIS / WARNING MACHINE CONDITION
H MULTI DISPLAY INDICATIONS
SM0146
1) Display function for operator .........................Screen usually displayed during operation 1.1 Clock display function ............................Current time is displayed. 1.2 Self-diagnosis display ............................When abnormality is detected on mechatro system like sensor, proportional valve, etc., this displays error code. 1.3 Warning display .....................................When machine was thrown into dangerous state, or was failed, displays warning symbol. (For warning contents, see items shown on the next page.) 1.4 Machine condition display ......................Displays machine operating condition. 2) Display function for maintenance...................Displays remaining time up to replacement/change of following items. (1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil 3) Failure history display function.......................Stores abnormality occurred on mechatro system in the past and displays in order of recent occurrence. 4) Mechatro adjustment display .........................Displays procedure for adjustment of mechatro system like output adjustment and unload adjustment, etc. 5) Service diagnosis display...............................Displays information like pressure sensor sensed value, proportional valve command, etc. output by mechatro controller 6) Failure diagnosis mode display function .......Specifies failed section automatically for failures which are not detected by self diagnosis and displays the results.
T2-1-25
E215B-E245B
MECHATRO CONTROL SYSTEM
• Warning table These descriptions indicate error codes stored as “trouble history code”
W009
CAUTION ATTACHMENT
W005
LOW ENG OIL PRESS.
W011
PREHEAT
W006
POWER BOOST ON
HIGH ENG WATER TEMP.
CPU
CHARGE ERROR
W004
DATA COMMUNICATION ERROR
LOW ENG WATER LEVEL
W001
W010
SWING BRAKE DISENGAGED
DRAIN WATER SEPARATOR
LOW FUEL LEVEL
AUTO WARMING UP
W008
ENG LOW PRESSURE (ENGINE STOP)
CLOGGED AIR FILTER
CHANGE ENG OIL
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
Level Priority (*)
A
Screen
1
DATA COMMUCATION ERROR
1
SWING BRAKE DISENGAGED
1
ENGINE STOP
2
FAIL DRAIN HYD. PRESSURE
2
DRAINING HYD. PRESS.
1
Condition
Engine Only Key ON Run
Data from Mechatro controller is not received The swing parking brake switch is turned ON Engine is stopped after engine oil pressare low warning Impossible to drain hyd. Pressure
Auto Stop
O
3
x
O
O
O
2
O
O
1
O
x
O
1
x
O
Possible to drain hyd. Pressure
O
4
x
O
CAUTION ATTACHMENT
The selector valve (OPT) is malfunction
O
2
x
O
2
POWER BOOST ON
The power boost switchis turn ON
2
FINISH WARM-UP
After finishing warming up control
O
2
O
x
Low engine oil pressure
O
2
x
O
W005
3
LOW ENG OIL PRESS.
O
O
3
x
O
W006
O
O
3
x
O
W010
O
O
3
x
O
W008
O
O
3
x
O
O
O
3
O O
O
O
W001
W009
-
O
The engine water is more than 105 °C Water in water separator filter is increased
3
HIGH ENG. WATER TEMP.
3
DRAIN WATER SEPA
3
CLOGGED AIR FLTR
3
(SELF DIAGNOSIS SCREENS)
3
PREHEAT
4
CHARGE ERROR
No signal from the alternator
4
LOW FUEL LEVEL
The fuel level is less than 10 %
4
LOW ENG WATER LEVEL
5
AUTO WARMING UP
5
CHANGE ENG OIL
The air filter is clogged According to the self diagnosis control The heater relay contact is faulty
The warter engine coolant reservoir is low The auto warming up control is activated The remaining time is reached zero Huors
(*) 1: these extremely influence safety and the machine performance 2: these warn the machine control mode is switched 3: fatal failure 4: normal priority warning 5: low priority message
3.2
Type (**)
O
Disconnection
B
Trouble History Manual Code Stop
Buzzer sounds
O
O
-
O
-
O
O
O
O
-
O
-
W011
W004
(**) 1: Continuation 2: Beep ON 0.2 sec. OFF 0.3 sec. 3: Beep ON 0.5 sec. OFF 0.5 sec. 4: Beep ON 0.5 sec. OFF 1.0 sec.
SELF DIAGNOSIS DISPLAY
CONTROL
1. Outline This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during machine operation through self diagnosis. The failed items are displayed on multi display of gauge cluster. For connector No. and pin No., refer to the section "Mechatro Control Equipment" explained later. Electric circuit diagram or harness is available to identify wire No. and wire color. 2. I/O configuration Pressure sensor, Governor motor INPUT Proportional valve, Battery relay Selector valve (SOL)
SERIAL COMMUNICATION Gauge cluster (Buzzer sound) SM0147
T2-1-27
E215B-E245B
MECHATRO CONTROL SYSTEM
3. Self diagnosis display items As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with the aid of error code. Alphabet: Decide system failure occurred.
10:25
B 01 3
B013
Last 2nd and 3rd digits: Specifies failed section.
Last 1 digit: Specifies failure type. This failure symbol is displayed simultaneously with error code during failure diagnosis.
ERROR CODE
SM0148
ALPHABET A Controller memory
B
C
Low pressure sensor
High pressure sensor
D Proportional valve for
E
F
Proportional valve for
2
nd
Solenoid valve
G Speed sensor
Throttle
Boom up
P1 pump
P1 unload
P1 pump
ATT boost
Step motor
02
Torque adjust data
Boom down
P2 pump
P2 unload
P2 pump
Swing parking brake
Step motor
03
Unload adjust data
Arm out
Boom head
Travel straight
05
Bucket digging
06
Bucket dump
07
Swing
09
Travel right
10
Travel left
11
Selector position
K
R
Communication
Battery relay
Relay output
Battery relay
Wiper ark prevention
AND 3 DIGIT
01
Arm in
I
rd
Engine adjust data
04
H Potentiometer etc.
Wiper ark forward
Travel 1,2 speed
Wiper ark reverse
Option selector
Washer motor
Arm 2 spool for arm in
Fuel sensor
13 14 PSV-R Short Cricuit valve
15 16
P1 side option
AIS relay2
17
P2 side option
Engine stop relay Safety lock lever relay
18 21
Adjustment data sector 1
22
Adjustment data sector 2
23
Hourmeter sector 1
24
Hourmeter sector 2
25
Proportional valve adjust
Safety relay
Cluster communication
31
LAST DIGIT Larger than normal range
0 1
-
2
-
Larger than normal range Transistor OFF failure/
Wrong output
Wrong output
3
-
Disconnection
Disconnection
4
-
Power source short circuit
Power source short circuit
5
Transistor ON failure Disconnection
Transistor ON failure Disconnection
Over run Transistor ON failure /
Disconnection
Disconnection Power source short circuit
Obnormal data
T2-1-28
Time is over Contact point is melted and adhered
Power source short circuit
MECHATRO CONTROL SYSTEM 3.3
E215B-E245B
SERVICE DIAGNOSIS DISPLAY FUNCTION
The current service diagnosis is displayed on multi display based on the data received from mechatro controller. This section explains the operating procedure and examples of each screen. The values in display changes according to the conditions like engine speed, attachment position, etc. 1. Service diagnosis display screen operating procedure 1)
Turn starter switch ON keeping buzzer stop switch pressed.
2) After logo mark is displayed, the screen changes in service diagnosis mode. The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first. The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in "Screen No.1". The screen number each mode can display differs. The screen number displayed by each mode is as follows. • Mode No.1: Screen No.1~No.30 • Mode No.2: Screen No.1, Screen No.31~No.40 • Mode No.3: Screen No.1, Screen No.41~No.50 3) The screen changes each time each switch is pressed from now on. Washer switch: Screen gains by 1 in order. (No.2→No.3→No.4→...) Wiper switch: Screen loses by 1 in order. (No.24→No.23→No.22→...) 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. Service diagnosis display screen (Example) The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low speed and lever to neutral position.) 1) Service diagnosis “Mode No.1”
No. 1
Displays
Contents
NO.1 MAIN CONT. P/N YN22E00207F1 PROGRAM VERSION 1-VER 2.00 2-VER 0.00
P/No. indication
NO.2 ENG G-3 SPEED SET MEAS G-5 ENG PRS. WATER TEMP
Service diagnosis mode
MODE H-1 ACCEL VOLT. POS. G-1 MOTOR STEP POS. COIL A COIL B G-2 LIMIT SW.
3
NO.3 SOL.VALVE F-1 POWER BOOST COMP. MEAS. SWITCH F-2 SWING-BRAKE COMP. MEAS. RELEASE SW F-3 1/2-TRAVEL COMP. MEAS. SWITCH
5 1000 1000 LIVE 20 °C OFF H 0.3 V 0% 30 0% 1.5 A 1.5 A OFF
No load setting rpm Actual rpm Engine oil pressure Coolant temperature sensor / Coolant tempreature switch
Work mode Potentiometer voltage Voltage % indication Number of step Step % indication A phase current B phase current Limit switch
6 OFF OFF OFF
Set value in computer Measured value Switch
ON ON OFF
Set value in computer Measured value Switch
OFF OFF OFF
Set value in computer Measured value Switch
Displays
Contents
NO.4 RELAY K-1 AIS RELAY 2 K-2 SAFETY RLY K-3 ENG STOP KEY SWITCH START SWITCH CHARGE K-4 LOCK LEVER SWITCH
Program version indication
SERVICE DIAG 1
2
No. 4
NO.5 PRESS.SENSOR B-1 BOOM RAISE 0.4 V 0.0 M B-2 BOOM LOWER 0.4 V 0.0 M B-3 ARM OUT 0.4 V 0.0 M B-4 ARM IN 0.4 V 0.0 M B-5 BUCKET DIG 0.4 V 0.0 M B-6 BUCKET DUMP 0.4 V 0.0 M
NO.6 PRESS.SENSOR B-7 SWING 0.4 V 0.0 M B-9 TRAVEL (R) 0.4 V 0.0 M B-10 TRAVEL (L) 0.4 V 0.0 M B-16 P1 OPT. 0.4 V 0.0 M B-17 P2 OPT. 0.5 V 0.0 M B-18 DOZER 1 0.0 V 0.0 M B-19 DOZER 2 0.0 V 0.0 M
ON ON OFF ON OFF LIVE OFF ON
Indicated value Indicated value Indicated value Key switch Starter switch Alternator Indicated value Switch
Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
SM0149
T2-1-30
MECHATRO CONTROL SYSTEM
No. 7
8
9
10
11
Displays
Contents
NO.7 P.SENSOR PROPO-V C-1 PUMP P1 0.4 V 0.3 M C-2 PUMP P2 0.4 V 0.0 M C-3 BOOM-HEAD 0.5 V 0.9 M C-4 BOOM-ROD 0.0 V 0.0 M PROPO-VALVE E-3 OPT RELIEF 1 COMP. 0 mA 2.0 M MEAS. 0 mA 2.0 M E-4 OPT RELIEF 2 COMP. 0 mA 2.0 M MEAS. 0 mA 2.0 M
Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure
NO.8 PROPO-VALVE D-1 P1 UN-LOAD(BP-CUT) COMP. 750 mA 3.0 M MEAS. 750 mA 3.0 M D-2 P2 UN-LOAD(BP-CUT) COMP. 750 mA 3.0 M MEAS. 750 mA 3.0 M D-3 S-TRAVEL COMP. 350 mA 0.6 M MEAS. 350 mA 0.6 M D-6 ARM IN-2-SPEED COMP. 750 mA 0.0 M MEAS. 750 mA 0.0 M
NO.9 PROPO-VALVE E-1 P1 PUMP COMP. 417 mA MEAS. 417 mA POWER SHIFT FLOW RATE E-2 P2 PUMP COMP. 417 mA MEAS. 417 mA POWER SHIFT FLOW RATE
Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure
1.0 M 1.0 M 0 mA 30 L
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
1.0 M 1.0 M 0 mA 30 L
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
Power shift Flow rate of pump P1
Power shift Flow rate of pump P2
20 Fuel level Hydraulic oil temperature Glow switch Air filter clogging Water separator clogging Engine oil filter clogging Front window open/close switch Conflux/Single flow select switch Command from grid heater Engine oil level Coolant level
21 OFF OFF
SPOOL POS. NIB SELECT SWITCH NIB F-5 FAN PUMP COMP. --MEAS. --F-6 COMP. --MEAS. ---
15
18
19
NO.10 SENSOR,SWITCH H-9 FUEL LEVEL 1.2 V 77% H-10 HYD.OIL TEMP 0.0 V 0 ͠ GLOW --AIR FILTER LIVE WATER SEPA. LIVE ENG OIL FILTER --FRONT WINDOW OFF DOUBLE FLOW ON KPSS SW --HEATER OFF ENG OIL LEVEL OK COOLANT LEVEL OK NO.11 SOL.VALVE F-4 OPT SELECT COMP. MEAS.
No. 16
NO.15 PROPO-VALVE D-11 P1 I-TRAVEL COMP. 0 mA MEAS. 0 Ma D-12 P2 I-TRAVEL COMP. 0 mA MEAS. 0 mA D-15 P1 BY PASS VALVE COMP. 347 mA MEAS. 347 mA D-16 P2 BY PASS VALVE COMP. 0 mA MEAS. 0 mA
Set value in computer Measured value (Feed back value) Spool position Mode of selector valve Set value in computer Measured value Set value in computer Measured value
22 0.0 M 0.0 M
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
0.0 M 0.0 M
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
0.6 M 0.6M
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
0.0 M 0.0 M
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
Displays NO.16 PRESS.SENSOR B-11 0.4 V 0.0 M B-12 0.0 V 0.0 M B-13 0.0 V 0.0 M B-14 0.0 V 0.0 M B-15 0.0 V 0.0 M B-20 0.0 V 0.0 M
E215B-E245B
Contents
Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
NO.18 DIGITAL INPUT DI1 OFF DI2 ON DI3 OFF DI4 OFF DI5 OFF DI6 OFF DI7 --DI8 OFF DI9 OFF DI10 OFF DI11 --DI12 --DI13 ON DI14 ---
ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication
NO.19 DIGITAL INPUT DI15 --DI16 ON DI17 ON DI18 OFF DI19 --DI20 OFF DI21 --DI22 --DI23 ON DI24 OFF DI25 ON DI26 --DI27 OFF DI28 ---
ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication
NO.20 DIGITAL INPUT DI29 OFF DI30 --DI31 --DI32 --DI33 ON DI34 --DI35 --DI36 OFF DI37 --DI38 OFF DI39 --DI40 OFF DI41 --DI42 ---
ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication
NO.21 DIGITAL OUTPUT DO1 COMP. OFF MEAS. OFF DO2 COMP. OFF MEAS. OFF DO3 COMP. OFF MEAS. OFF DO4 COMP. OFF MEAS. OFF DO5 COMP. --MEAS. --DO6 COMP. --MEAS. --DO7 COMP. OFF MEAS. OFF
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
NO.22 DIGITAL OUTPUT DO8 COMP. ON MEAS. ON DO9 COMP. OFF MEAS. OFF DO10 COMP. --MEAS. --DO11 COMP. OFF MEAS. OFF DO12 COMP. --MEAS. --DO13 COMP. --MEAS. --DO14 COMP. --MEAS. ---
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
See Mechatro controller connector
SM0150
T2-1-31
E215B-E245B
No. 23
24
25
MECHATRO CONTROL SYSTEM
Displays
Contents
NO.23 DIGITAL OUTPUT DO15 COMP. --MEAS. --DO16 COMP. ON MEAS. ON DO17 COMP. OFF MEAS. OFF DO18 COMP. OFF MEAS. OFF DO19 COMP. OFF MEAS. OFF DO20 COMP. --MEAS. --DO21 COMP. ON MEAS. ON
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
NO.24 DIGITAL OUTPUT DO22 COMP. --MEAS. --DO23 COMP. OFF MEAS. ON DO24 COMP. --MEAS. --DO25 COMP. --MEAS. --DO26 COMP. --MEAS. --DO27 COMP. --MEAS. --DO28 COMP. --MEAS. ---
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
NO.25 WIPER SYSTEM WIPER SW RISEUP SW REVERSE SW PREVENT ARC CW MOTOR RLY CCW MOTOR RLY WASHER SW MOTOR RELAY
OFF ON ON OFF OFF OFF OFF OFF
Wiper switch Wiper rise-up switch Wiper reverse rotation switch Wiper motor ark prevention relay Wiper normal rotation relay Wiper reverse rotation relay Washer switch Washer motor relay
SM0151
T2-1-32
MECHATRO CONTROL SYSTEM
E215B-E245B
2) Service diagnosis “Mode No.2”
No. 1
Displays
Contents
NO.1 MAIN CONT. P/N YN22E00207F1 PROGRAM VERSION 1-VER 2.00 2-VER 0.00
P/No. indication Program version indication MERIT controller program version
SERVICE DIAG 2
31
32
No. 33
Service diagnosis mode 2
34
NO.31 BOOM C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) B-1 BOOM RAISE B-2 BOOM LOWER G-3 ENG SPEED POWER SHIFT
0.2 M 0.0 M 417 mA 417 mA 750 mA 750 mA 0.0 M 0.0M 1000 0 mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Boom up pressure sensor Boom down pressure sensor Engine actual speed Power shift current
NO.32 ARM,SWING C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) D-3 S-TRAVEL D-6 ARM-IN-2 B-3 ARM OUT B-4 ARM IN B-1 BOOM RAISE B-7 SWING G-3 ENG SPEED POWER SHIFT
0.2 M 0.0 M 417 mA 417 mA 750 mA 750 mA 350 mA 750 mA 0.0 M 0.0 M 0.0 M 0.0 M 1000 0 mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current Arm out pressure sensor Arm in pressure sensor Boom up pressure sensor Swing pressure sensor Engine actual speed Power shift current
35
Displays
Contents
NO.33 BUCKET C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) D-3 S-TRAVEL B-5 BUCKET DIG B-6 BUCKET DUMP G-3 ENG SPEED POWER SHIFT
0.2 M 0.0 M 417 mA 417 mA 750 mA 750 mA 350 mA 0.0 M 0.0 M 1000 0 mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Bucket digging pressure sensor Bucket dump pressure sensor Engine actual speed Power shift current
NO.34 TRAVEL C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) D-3 S-TRAVEL B-9 TRAVEL(R) B-10 TRAVEL(L) Pi-P1 Pi-P2 G-3 ENG SPEED POWER SHIFT
0.2 M 0.0 M 417 mA 417 mA 750 mA 750 mA 350 mA 0.0 M 0.0 M 0.0 M 0.0 M 1000 0 mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Travel right pressure sensor Travel left pressure sensor Pilot pressure at travel straight (P1 side) Pilot pressure at travel straight (P2 side) Engine actual rpm Power shift current
NO.35 OPT C-1 P1 PUMP 0.2 M C-2 P2 PUMP 0.0 M E-1 P1-PSV 417 mA E-2 P2-PSV 417 mA D-1 P1-UL(BPC) 750 mA D-2 P2-UL(BPC) 750 mA D-3 S-TRAVEL 350 mA E-3 OPT RELIEF 110 mA B-16 P1 OPT 0.0 M B-17 P2 OPT 0.0 M F-4 OPT SELECT NIB DOUBLE FLOW SW OFF G-3 ENG SPEED 1000 POWER SHIFT 0 mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current P1 side option pressure sensor P2 side option pressure sensor Optional selector SOL (Nibbler line) Conflux/ Single selector switch Engine actual rpm Power shift current SM0152
3) Service diagnosis “Mode No.3” No. 1
Displays NO.1 MAIN CONT. P/N YN22E00207F1 PROGRAM VERSION 1-VER 2.00 2-VER 0.00 SERVICE DIAG 3
41
NO.41 ADJUSTMENT 1 ENG HI-IDLE 2230 PUMP ACT I 515 mA 7 mA PUMP P 35.0 M ESS N 930 UN-LOAD P1 565 mA P2 565 mA BOOM 0 0 ARM 0 0 OFFSET 0 0 INTER-B 0 0
Contents
No. 43
P/No. indication Program version indication MERIT controller program version Service diagnosis mode 3
44 Engine speed high idle Current at pump adjustment Current correction at pump adjustment Pressure at pump adjustment Engine speed sensor rpm P1 unload corrective current P2 unload corrective current Angle adjustment Angle adjustment Angle adjustment Angle adjustment
Displays NO.43 MACHINE-INFORM. HOUR METER 3550 TRIP METER 3500 OPERATION 3300 TRAVEL 300 SWING 3000 HAMMER 100 CRANE 100 STARTER 1200
Contents Hour meter of controller Trip meter of controller All accumulated operating time All accumulated traveling time All accumulated swing time All accumulated breaker operating time All accumulated high-reach crane operating time
All accumulated starter operating time
NO.44 MACHINE-INFORM. PUMP PRESS. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%
Pump pressure distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours
WATER TEMP. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%
Coolant temperature distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours SM0153
T2-1-33
E215B-E245B
MECHATRO CONTROL SYSTEM
3. Service diagnosis data list Preface and precaution The following is the data decided as normal status after service diagnosis for every operation. Use these data to decide normal/abnormal status. • The values in following display are reference values with standard attachment attached machine. • The value of pressure sensor is calculated taking variation into accounts. When compared to performance check reference criteria, measure it with the aid of calibrated measuring instrument. • The current of proportional valve is not the measured value, but command value. The measured value should be confirmed by the value in the displayed value for each proportional valve. • The current value of pump proportional valve is reference value because it varies according to pump pressure and adjusted torque value. • The value in display during operation shows the value in steady state, rather than, at start of operation. • Check on machine after sufficiently warming up machine. • The value in display may differ according to software version. Contact our dealer/distributor.
Operation No.1 : No operation H mode Hi idle
Operation No.2 : No operation S mode Hi idle
No.32 ARM, SWING
No.32 ARM, SWING
C-1 P1-PRES
0.2~1.5 M
C-1 P1-PRES
0.2~1.5 M
C-2 P2-PRES
0.2~1.5 M
C-2 P2-PRES
0.2~1.5 M
E-1 P1-PSV
350 mA
E-1 P1-PSV
350 mA
E-2 P2-PSV
350 mA
E-2 P2-PSV
350 mA
D-1 P1-UL(BPC)
750 mA
D-1 P1-UL(BPC)
750 mA
D-2 P2-UL(BPC)
750 mA
D-2 P2-UL(BPC)
750 mA
D-3 S-TRAVEL
350 mA
D-3 S-TRAVEL
350 mA
D-6 ARM-IN-2
750 mA
D-6 ARM-IN-2
750 mA
B-3 ARM OUT
0.0 M
B-3 ARM OUT
0.0 M
B-4 ARM IN
0.0 M
B-4 ARM IN
0.0 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 POWER SHIFT
1970~2030
G-3 ENG SPEED
0 mA
POWER SHIFT
1770~1830 0 mA
Operation No.3 : Boom up in full lever operation & relief H mode Hi idle
Operation No.4 : Boom up in full lever operation & in operation H mode Hi idle
No.31 BOOM
No.31 BOOM
C-1 P1-PRES
33.0~35.8 M
C-1 P1-PRES
11.0~16.0 M
C-2 P2-PRES
33.0~35.8 M
C-2 P2-PRES
11.0~16.0 M
E-1 P1-PSV
415~525 mA
E-1 P1-PSV
560~750 mA
E-2 P2-PSV
415~525 mA
E-2 P2-PSV
560~750 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
B-1 BOOM RAISE
3.0 M
B-1 BOOM RAISE
3.0 M
B-2 BOOM LOWER
0.0 M
B-2 BOOM LOWER
0.0 M
G-3 ENG SPEED POWER SHIFT
1970~2060
G-3 ENG SPEED
0 mA
POWER SHIFT T2-1-34
1970~2060 0 mA
MECHATRO CONTROL SYSTEM
E215B-E245B
Operation No.5 : Boom down in full lever operation & in operation H mode Hi idle
No.31 BOOM C-1 P1-PRES
12.5~16.0 M
C-2 P2-PRES
0.2~1.5 M
E-1 P1-PSV
600~617 mA
E-2 P2-PSV
350 mA
D-1 P1-UL(BPC)
427~477 mA
D-2 P2-UL(BPC)
750 mA
B-1 BOOM RAISE
0.0 M
B-2 BOOM LOWER
3.0 M
G-3 ENG SPEED POWER SHIFT
1970~2060 0 mA
Operation No.6 : Arm-in in full lever operation & relief H mode Hi idle
Operation No.7 : Arm-in in full lever operation & in operation
No.32 ARM, SWING
No.32 ARM, SWING
H mode Hi idle
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 POWER SHIFT
1970~2060
G-3 ENG SPEED
0 mA
POWER SHIFT
T2-1-35
1970~2060 0 mA
E215B-E245B
MECHATRO CONTROL SYSTEM
Operation No.8 : Arm-out in full lever operation & relief H mode Hi idle
Operation No.9 : Arm-out in full lever operation & in operation 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
15.0~22.0 M
C-2 P2-PRES
33.0~35.8 M
C-2 P2-PRES
15.0~22.0 M
E-1 P1-PSV
415~525 mA
E-1 P1-PSV
488~677 mA
E-2 P2-PSV
415~525 mA
E-2 P2-PSV
488~677 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
750 mA
D-6 ARM-IN-2
750 mA
B-3 ARM OUT
3.0 M
B-3 ARM OUT
3.0 M
B-4 ARM IN
0.0 M
B-4 ARM IN
0.0 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
POWER SHIFT
G-3 ENG SPEED
0 mA
1970~2060
POWER SHIFT
0 mA
* Measure the values after a lapse of 5 minutes or after release of low temperature mode
* Measure the values after a lapse of 5 minutes or after release of low temperature mode
Operation No.10 : Swing in full lever operation & relief H mode Hi idle
Operation No.11 : Swing in full lever operation & in operation H mode Hi idle
No.32 ARM, SWING
No.32 ARM, SWING
C-1 P1-PRES
0.2~1.5 M
C-1 P1-PRES
0.2~1.5 M
C-2 P2-PRES
28.0~35.8 M
C-2 P2-PRES
10.0~15.0 M
E-1 P1-PSV
350 mA
E-1 P1-PSV
350 mA
E-2 P2-PSV
528~750 mA
E-2 P2-PSV
750 mA
D-1 P1-UL(BPC)
750 mA
D-1 P1-UL(BPC)
750 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
750 mA
D-6 ARM-IN-2
750 mA
B-3 ARM OUT
0.0 M
B-3 ARM OUT
0.0 M
B-4 ARM IN
0.0 M
B-4 ARM IN
0.0 M
B-1 BOOM RAISE
0.0 M
B-1 BOOM RAISE
0.0 M
B-7 SWING
3.0 M
B-7 SWING
3.0 M
G-3 ENG SPEED POWER SHIFT
1970~2060
G-3 ENG SPEED
0 mA
POWER SHIFT
T2-1-36
1970~2060 0 mA
MECHATRO CONTROL SYSTEM
E215B-E245B
Operation No.12 : Bucket digging in full lever operation & relief H mode Hi idle
Operation No.13 : Bucket digging in full lever operation & in operation H mode Hi idle
No.33 BUCKET
No.33 BUCKET
C-1 P1-PRES
33.0~35.8 M
C-1 P1-PRES
4.0~8.0 M
C-2 P2-PRES
33.0~35.8 M
C-2 P2-PRES
4.0~8.0 M
E-1 P1-PSV
415~525 mA
E-2 P2-PSV
415~525 mA
E-1 P1-PSV
650~750 mA
E-2 P2-PSV
540~563 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
720 mA
D-3 S-TRAVEL
720 mA
B-5 BUCKET DIG
3.0 M
B-5 BUCKET DIG
3.0 M
B-6 BUCKET DUMP
0.0 M
B-6 BUCKET DUMP
0.0 M
G-3 ENG SPEED
1970~2060
POWER SHIFT
G-3 ENG SPEED
0 mA
POWER SHIFT
1970~2060 0 mA
Operation No.14 : Bucket dump in full lever operation & relief H mode Hi idle
Operation No.15 : Bucket dump in full lever operation & in operation H mode Hi idle
No.33 BUCKET
No.33 BUCKET
C-1 P1-PRES
33.0~35.8 M
C-1 P1-PRES
C-2 P2-PRES
33.0~35.8 M
6.0~15.0 M
C-2 P2-PRES
6.0~15.0 M
E-1 P1-PSV
415~525 mA
E-1 P1-PSV
577~750 mA
E-2 P2-PSV
415~435 mA
E-2 P2-PSV
415~435 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
720 mA
D-3 S-TRAVEL
720 mA
B-5 BUCKET DIG
0.0 M
B-5 BUCKET DIG
0.0 M
B-6 BUCKET DUMP
3.0 M
B-6 BUCKET DUMP
3.0 M
G-3 ENG SPEED POWER SHIFT
1970~2060
G-3 ENG SPEED
0 mA
POWER SHIFT
T2-1-37
1970~2060 0 mA
E215B-E245B
MECHATRO CONTROL SYSTEM
Operation No.16 : P2 side option in full lever operation & relief A mode Hi idle
Operation No.17 : P2 side option in full lever operation & relief B mode Hi idle
No.35 OPT
No.35 OPT
C-1 P1-PRES
22.5~26.0 M
C-1 P1-PRES
0.2~1.5 M
C-2 P2-PRES
22.5~26.0 M
C-2 P2-PRES
22.5~26.0 M
E-1 P1-PSV
459~584 mA
E-1 P1-PSV
500 mA
E-2 P2-PSV
459~584 mA
E-2 P2-PSV
665~750 mA
D-1 P1-UL(BPC)
360 mA
D-1 P1-UL(BPC)
750 mA
D-2 P2-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-3 S-TRAVEL
720 mA
D-3 S-TRAVEL
350 mA
E-3 OPT RELIEF
0 mA
E-3 OPT RELIEF
0 mA
B-16 P1 OPT
0.0 M
B-16 P1 OPT
0.0 M
B-17 P2 OPT
2.0~2.6 M
B-17 P2 OPT
2.0~2.6 M
F-4 OPT SELECT DOUBLE FLOW SW. G-3 ENG SPEED POWER SHIFT
NIB
F-4 OPT SELECT
ON
DOUBLE FLOW SW.
1970~2060
G-3 ENG SPEED
0 mA
POWER SHIFT
BRK OFF 1970~2060 0 mA
* Conflux switch is ON. Relief set pressure is value of shipping.
* Conflux switch is OFF. Relief set pressure is value of shipping.
Operation No.18 : Travel right in full lever operation & travel idling H mode Hi idle
Operation No.19 : Travel left in full lever operation & travel idling H mode Hi idle
No.34 TRAVEL
No.34 TRAVEL
C-1 P1-PRES
5.0~12.0 M
C-1 P1-PRES
0.2~1.5 M
C-2 P2-PRES
0.2~1.5 M
C-2 P2-PRES
5.0~12.0 M
E-1 P1-PSV
750 mA
E-1 P1-PSV
350 mA
E-2 P2-PSV
350 mA
E-2 P2-PSV
750 mA
D-1 P1-UL(BPC)
360 mA
D-1 P1-UL(BPC)
750 mA
D-2 P2-UL(BPC)
750 mA
D-2 P2-UL(BPC)
360 mA
D-3 S-TRAVEL
350 mA
D-3 S-TRAVEL
350 mA
B-9 TRAVEL (R)
2.0~2.5 M
B-9 TRAVEL (R)
0.0 M
B-10 TRAVEL (L)
0.0 M
B-10 TRAVEL (L)
2.0~2.5 M
Pi-P1
0.0 M
Pi-P1
0.0 M
Pi-P2
0.0 M
Pi-P2
0.0 M
G-3 ENG SPEED POWER SHIFT
1970~2060
G-3 ENG SPEED
0 mA
POWER SHIFT
T2-1-38
1970~2060 0 mA
MECHATRO CONTROL SYSTEM 3.4
E215B-E245B
TROUBLE HISTORY DIAGNOSIS
The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as one of history. And the errors are able to be indicated on the multi display. • •
A part of warning contents is stored (the stored items are listed in warning table). The error code for self diagnosis is stored.
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
Error detected in the past
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. 2. How to delete contents of trouble history 1) 2) 3) 4)
Display trouble history screen. Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more. When "NO ERROR" is displayed, the deletion is completed. Turn starter switch off.
NOTE: all the stored items are erased. It is impossible to erase data partially.
T2-1-39
E215B-E245B 3.5
MECHATRO CONTROL SYSTEM
TROUBLE DIAGNOSIS MODE
The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be detected through the use of self diagnosis function (the failure can be specified through the use of error code) like disconnection and abnormal output. This is useful to save the time for troubleshooting. 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. 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 3.6
E215B-E245B
SET PROCEDURE OF MAINTENANCE SCHEDULE
This machine is equipped with multi-display which allows confirmation of remaining time to the coming replacement/change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the remaining time reaches to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc. and perform the initial setting by the following order. NOTE: interval of replacement of parts is mentioned below. • • • •
Screen change switch
Buzzer stop switch
KPSS work mode select switch Washer switch
Engine oil : 500 Hr Fuel filter : 500 Hr Hydraulic filter : 1,000 Hr Hydraulic oil : 5,000 Hr
Select switch
Auto accel switch
Travel speed select switch
Wiper switch SM0155
Procedure
1
2
3
4
5
Operating Procedure
Display on Multidisplay NEW HOLLAND
Turn starter key switch on.
KOBELCO
Press " " switch press once display change switch on the switch panel once. And the clock display changes to the display of remaining time for coming engine oil change. Press " " switch press once select switch once and the display for the engine oil change reverses. When required to adjust the interval to the coming change time by 10 hours, press " " switch and the time to the coming engine oil change is added. Press " " switch and the time to the coming engine oil change is reduced. When desired to return to the initial set time, press " " buzzer stop switch once. Press " " select switch once and the set time is stored.
10:25 H
250 Hr ENGINE OIL
H
250 Hr ENGINE OIL
500 Hr ENGINE OIL
After several seconds, display is changed to clock autmatically.
Press screen change switch once more.
Press select switch once more.
Replacing interval is changed with each pressing of switch.
To set the desired interval, press the select switch
10:25 H
250 Hr ENGINE OIL
H
250 Hr ENGINE OIL
500 Hr ENGINE OIL
500 Hr ENGINE OIL
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 3.7
MECHATRO CONTROL SYSTEM
ADJUSTING PROCEDURE OF DISPLAY
1. For operator 1) Clock Adjustment Switches No.
1
2
3
4
Switches
1
Screen Change Switch
2
Buzzer Stop Switch
3
Work Mode Select Switch
4
Washer Switch
5
Wiper Switch
6
Travel Speed Select Switch
7
Auto Accel Switch
8
Select Switch Main screen
10:25
8
7
6
SM0140
(a) SWITCH STATUS CLOCK/CONTRAST
13:15
H (a)
5
H (b)
(c) SWITCH STATUS CLOCK/CONTRAST
(d)
(e)
ADJUST CLOCK ADJ CONTRAST
Y M D H M 06 04 01 13 15
Select Year/Month/Day/Hour/Minute
Enter
Increase/Decrese SM0157
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 operations of FEED (6) and FEED (7).
(4) and FEED
(5) and vary the values in
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
2) Contrast Adjustment Switches No.
1
E215B-E245B
2
3
4
Switches
1
Screen Change Switch
2
Buzzer Stop Switch
3
Work Mode Select Switch
4
Washer Switch
5
Wiper Switch
6
Travel Speed Select Switch
7
Auto Accel Switch
8
Select Switch Main screen
10:25
8
7
5
6
SM0140
SWITCH STATUS CLOCK/CONTRAST
H (a)
(b)
(c) SWITCH STATUS CLOCK/CONTRAST
(d)
(a)
ADJUST CLOCK ADJ CONTRAST
10:25 H
(e) ADJUST CLOCK ADJ CONTRAST
(f) Enter
ADJ CONTRAST 55555
Adjustable range 11111~99999 (Default 55555)
Increase/Decrease 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 The available setting range is in 9 steps from "11111" to "99999". [Example] 11111 (faint) → 99999 (clear) * The initial set value is 55555.
(5).
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
2. Function for service Following items are provided for adjustment of service function. •
LANGUAGE/LOGO Function
Explanation
Range
All language data is stored in 15 one gauge cluster languages
LANGUAGE
To change language
LOGO
To change Company Logo
•
Note
5 Logos
Default ISO NHK
ADJUSTING MODE 1 Function
Explanation
RISE-UP WIPER
Note
To change wiper control, when special CAB is installed on demolition OFF is for special CAB machine
Range ON/OFF
Default ON
P1 OPT SENSOR To activate the self-diagnosis when P1 Switch to ON when 2PB is ON/OFF ACTIVE OPT pressure sensor is failed installed
OFF (*)
P2 OPT SENSOR To activate the self-diagnosis when P2 Switch to ON when N&B ON/OFF ACTIVE OPT pressure sensor is failed option is installed
OFF (*)
PRIORITY MODE
Only for EU, to activate the priority valve
ON/OFF
OFF
LEFT ACTIVE
To use P1 option pedal for P4-rotation circuit, releasing auto accel. And not activating unload valve
ON/OFF
OFF
PEDAL
SELECT SYSTEM
OPT
1:No selector valve Switch to ON when N&B 2:Selector Valve + Mechanical relief 1 or 3 option is installed 3:Selector Valve + Electrical relief
1 or 3 (*)
ADJ OVERLOAD To change the pressure for overload PRESS alarm in EU
10 - 27
18
ENG DISPLAY
ON/OFF
OFF
SPEED To activate the engine information for customer
speed
AUTO ACCEL
To change auto accel control type
START MODE
To change (S,H,B,A)
the
starting
6, 8, 10, 12, 18 14, 16, 18
MODE X: return to default MODE S, H, B, A, X S 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 TEMP MODE ACTIVE temp.
OFF
DRAIN PRESS
OFF
HYD. To activate the pressure function
drain
hydraulic When switch is ON, this ON/OFF function starts.
To adjust Pressure and Flow for ADJ OPT HAMMER Follow setting procedure Hammer (9set)
20 35 15 Mpa (at Pressure 220 L/min) 30 - 220 220 L/min Flow rate
To adjust Pressure and Flow for Follow setting procedure Nibbler (9set)
20 35 15 Mpa (at Pressure 220 L/min) 30 - 220 220 L/min Flow rate
ADJ OPT NIBBLER
(*) Autodetect
T2-1-44
MECHATRO CONTROL SYSTEM
E215B-E245B
2.1 Setting the language To modify the language, proceed as follows: 1. Keep BUZZER CUT-OFF button (1) pressed and, at the same time, move the STARTER SWITCH onto “ON”; the screen shows display (A).
10:25
2. Keep BUZZER CUT-OFF button (1) pressed, then press SELECT button (2) three times; the screen shows display (B). 3. Press SELECT button (2); the screen shows display (C) indicating the symbol of the language previously set, for example: ENG (English). 4. Press WIPER button (3) or WINDSHIELD WASHER button (4), once or more until the symbol of the desired language is displayed, for example FRA (French); the screen shows display (D).
S
1 4 5 3
2
5. Press SELECT button (2) to memorize the language selected, the screen shows display (E). At this stage, the language is selected and after about three seconds returns automatically to display (B). To exit the program, move the STARTER SWITCH onto “OFF”.
SM0069
NO. 1
(A) List of the languages available:
MAIN CONT. P/N YN 22E 00207 F1 PROGRAM VERSION 1 VER 2.00 2 VER 0.00 SERVICE DIAG 1
1
EU (ISO icons only)
2
ITA
(B)
USA
LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY
CHN IDN THA
SELECT LANGUAGE
ESP
(C)
FRA
ENG FEED
DEU VNM
4
MYS
3
MMR TAM
SELECT LANGUAGE
POR
(D)
ENG
FRA FEED
JPN
SELECT LANGUAGE
(E)
FRA FEED SM0070
T2-1-45
E215B-E245B
MECHATRO CONTROL SYSTEM
2.2 Setting Adjusting Mode 1
NO. 1
To enter the displays Adjusting Mode 1 proceed as follows: 1. Keep BUZZER CUT-OFF button (1) pressed and, at the same time, move the STARTER SWITCH onto “ON”; the screen shows display (A) 2. Keep BUZZER CUT-OFF button (1) pressed, then press SELECT button (2) three times; the screen shows display (B). 3. Press WINDSHIELD WASHER button (3) to get ADJUSTING MODE 1, the screen shows display (C).
(A)
MAIN CONT. P/N YN 22E 00207 F1 PROGRAM VERSION 1 VER 1.00 2 VER 0.00 SERVICE DIAG 1
x3
1 (B)
2
LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY
3
(C)
4. By pressing SELECT button (2) you enter the Adjusting Mode 1 functions; the first function is shown on the screen, display (D). To enter the other functions, actuate WIPER button (3), to move forward or WINDSHIELD WASHER button (4), to return back.
LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY
11 RISE-UP WIPER ON
(D)
FEED
3
4
2.3Adj. Overload Press (tip-over momentum device)
SM0071
To modify the value of the pressure at which the pressure sensor goes ON to operate the tip-over momentum device, proceed as follows: 1. In function Adjusting Mode 1, display (C), press SELECT button (2) to enter the functions and use WIPER button (3), to select function 63 ADJ OVERLOAD PRESS on display (E).
(C) 2
3
2. Press SELECT button (2) to choose the number relative to the setting pressure, display (F). 18 = 180 bar
63
(E)
3. Press WINDSHIELD WASHER button (4), to increase the pressure, or WIPER button (3), to decrease it. 4. Set the desired pressure value (for example: 11), display (G), press SELECT button (2) to memorise it. By pressing SCREEN CHANGE button (5) you return to display (C). To exit the program, move the STARTER SWITCH onto “OFF”.
LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY
ADJ OVERLOAD PRESS 18
FEED
63
(F)
ADJ OVERLOAD PRESS 18
FEED
3
4 63
(G)
ADJ OVERLOAD PRESS 11
FEED
63 ADJ OVERLOAD PRESS 11
FEED
5 SM0073
T2-1-46
MECHATRO CONTROL SYSTEM
E215B-E245B
2.4 Drain Hyd. Press To drain the hydraulic pressure from the system, proceed as follows: 1. In function Adjusting Mode 1, display (C), press SELECT button (2) to enter the functions and using WIPER button (3), select on the display function DRAIN HYD. PRESS, display (H).
(C)
LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY
3
2
2. Press SELECT button (2) to show the writing OFF, display (I).
(H)
3. Press WINDSHIELD WASHER button (4) to activate function ON, display (L).
DRAIN HYD PRESS OFF
FEED
4. Press SELECT button (2) and start the engine. The screen shows display (M). At this point, with the engine in operation, actuate the pilot valves performing all the movements so that the pressure is drained from all the actuators. The function is automatically deactivated by returning the STARTER SWITCH onto “OFF”.
(I)
DRAIN HYD PRESS OFF
FEED
4 NOTE: if the monitor displays “FAIL DRAIN HYD PRES.” this means that the pressure draining operation has not been performed correctly. In this case, repeat the operation.
(L)
DRAIN HYD PRESS ON
FEED
10:25
(M)
PR
S SM0072
T2-1-47
E215B-E245B 3.8
MECHATRO CONTROL SYSTEM
MECHATRO CONTROL EQUIPMENT
1. C-1 Mechatro controller 1) Outside view 2 1
10
6
2 1
22
18
4 2 1 8
2
1
16 26 34 27 CN101 CN105
9
CN102
16 12 CN103
28
22
CN104
CN106 CN107 CN108 CN109 21 7 2 16 21 9 21 7 21
21
10
31
22
16
24
8
17
12
17
7
28 10 22 13 19 20 15 16
8
SM0159
2) List of connectors Connector No.
Pin No.
Port name
CN101
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
GA A1 +5VA +5VA A2 GA GA A3 +5VA +5VA A4 GA GA A5 +5VA +5VA A6 GA TXD1 RXD1 GP SHG1 TXD3 RXD3 DL GP CANH1 CANL1 DO 20 DO 21 DO 22 DO 23 DO 24 DI 36
Function
Input/putput
Boom up
Input
Boom down
Input
Arm in
Input
Arm out
Input
Bucket digging
Input
Bucket dump
Input
Gauge cluster
Transmission
Down load
Transmission
Reception
Reception
Spare Spare Safety relay Spare Extra pressure release Spare Heavy lift
Output Output Output Output Output Input
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V RS232C communication RS232C communication 0V Shield GND RS232C communication RS232C communication EARTH / OPEN(5V㧕 0V CAN communication CAN communication EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN SM0160
T2-1-48
MECHATRO CONTROL SYSTEM
Connector No. CN102
Connector No. CN103
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Port name GA A8 +5VA +5VA A9 GA GA A10 +5VA +5VA A13 GA GA A14 +5VA +5VA A27 GA GA A28 +5VA D1 37
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Port name GA A +5VA +5VA A11 GA GA A12 +5VA +5VA A15 GA GA A16 +5VA
Function
E215B-E245B
Input/putput
Travel right
Input
Travel left
Input
Accelation
Input
P1 option
Input
P2 option
Input
Spare
Input
Spare
Input
Spare
Input Function
Input/putput
Swing
Input
P1 pump
Input
P2 pump
Input
Boom angle
Input
Arm angle
Input
Reserved
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V
GND / OPEN
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V SM0161
T2-1-49
E215B-E245B
Connector No. CN104
Connector No. CN105
MECHATRO CONTROL SYSTEM
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Port name GA A17 +5VA +5VA A18 GA GA A19 +5VA +5VA A20 GA A21 GA A22 GP A23 GA GA A24 +5VA +5VA A25 GA GA A26 +5VA DI 1
Pin No. 1 2
Port name +24V +24V
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
+24V DO 7 DO 8 DO 9 DO 11 GND GND D10+ D1+ D1D2+ D2D3+ D3D4+ D4D5+ D5GND D10D6+ D6D7+ D7D8+ D8D9+ D9+24V
Function
Input/putput
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5㨪4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V
Boom head (Over load)
Input
Spare
Input
Extra pressure source
Input
Spare
Input
Engine coolant temperature
Input
Resistor
Fuel level
Input
Resistor
Spare
Input
Resistor
Selector detection
Input
Extra pressure source
Input
Spare
Input
Starting point of accel motor
Input
Function
Input/putput
Battery relay output side Battery relay output side
Output Swing P/B select valve Output Travel 1,2 speed select valve Output Attachment boost select valve Output Battery (-) Battery (-) OPT changeable relief 1 Output P1 unload Output Travel 1,2 speed select valve
P2 unload
Output
Travel straight
Output
Arm in
Output
P1 pump
Output
Battery (-) OPT changeable relief 1 P2 pump
Output Output
Spare
Output
Spare
Output
Spare
Output
Battery direct connection
0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V GND / OPEN Signal level 20~32V 20~32V 20~32V 24V/OPEN 24V/OPEN 24V/OPEN 24V/OPEN 0V 0V +0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA -0~800mA +0~800mA 20~32V SM0162
T2-1-50
MECHATRO CONTROL SYSTEM
Connector No. CN106
Connector No. CN107
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Port name +24V SHGF F1+ F1F2+ F2OIL OILG D11+ D11D12+ D12D13+ D13D14+ D14GND D12+ D12E1+ E1SHG3 CANH2 CANL2
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Port name DI 3 DI 8 DI 9 DI 10 DI 11 DI 12 DI 13 DI 14 DI 15 DI 20 DI 28 DI 32 DI 38 DI 39 DI 40 DI 41
Function Battery relay secondary side
E215B-E245B
Input/putput
0
Oil level (spare)
Output Output Output Output 0
OPT changeable relief 2
Output
Spare
Output
Bypass valve
Output
Spare
Output
Battery (-) Spare
Output
Accel motor A phase Accel motor A phase Accel motor B phase Accel motor B phase
E/G speed sensor
Input
Proportional vlave expand unit
Input/putput Function Grid heater feedback Input Engine coolant temperature Input Input E/G oil pressure Air filter Input Spare Input Spare Input E/G coolant level Input Spare Input Spare Input Heater temperature of fuel filter Input Spare Input Hand control nibbler Input Quick coupler Input Spare Input Heater temperature Input Spare Input Reserved
Signal level 20~32V Shield GND 1.5A 1.5A 1.5A 1.5A
+0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V +0~800mA -0~800mA XX~XXVp-p 0V Shiled GND CAN communication CAN communication Signal level +24V/OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN SM0163
T2-1-51
E215B-E245B
Connector No. CN108
MECHATRO CONTROL SYSTEM
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Connector No. CN109
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Port name
DI 2 DI 4 DI 5 DI 6 DI 7 DI 16 DI 17 DI 18 DI 19 DI 21 DI 22 DI 23 DI 24
DI DI DI DI DI
25 26 27 29 30
GP DI 33 DI 34 DI 35 H1+ H2H2+ H2Port name
DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 12 DO 13 DO 14 DO 15 DO 16 DO 17 DO 18 DO 19 GP TXD2 RXD2 RTS CTS SHG2 DO 10
Input Input Input Input Input Input Input Input Input Input Input Input Input
Signal level +24V / OPEN +24V / OPEN GND / OPEN +24V / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN +24V / OPEN +24V / OPEN +24V / OPEN GND / OPEN
Front window open or close Spare Conflux/single select Overload select Spare Reserved
Input Input Input Input Input
GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN
Charge Spare Spare Reserved Spare
Input Input Input
~12V / 12V~ +24V / OPEN +24V / OPEN
Function Key switch (ON) Water separator Swing P/B release E/G start Spare Wiper rise up㩩 Wiper reverse ATT boost Spare Spare Spare Lever lock Hand control rotation
Input/putput
0~5V 0V 0~5V 0V
Spare Function Wiper arc prevention Wiper normal moving Wiper reserve moving Washer motor Spare Reserved Spare Swing flasher (RH) Swing flasher (LH) Travel alarm Auto idle stop relay Engine stop Lever lock Grid heater Reserved
Input/putput
Output Output Output Output Output Output Output Output Output Output Output Output Output Output
Signal level GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN 0V
Tranmission RS232C communication
Spare
Spare
Reception RS232C communication RS232C communication RS232C communication Shiled GND 24V/OPEN SV SM0164
T2-1-52
MECHATRO CONTROL SYSTEM
E215B-E245B
2. Gauge cluster (symbol C-2) 1) General view
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. 6. BUZZER STOP SWITCH
7. WORK MODE SWIHCH SM0165
2) Connector CN-600 (Harness side) No.
Item name
Wire color
No.
Item name
Wire color
1
Gauge cluster → Mechatro controller (RS232C communication)
White
5
GND source (+24V Battery direct connection)
Yellow / Black
2
Mechatro controller → Gauge cluster (RS232C communication)
Red
6
GND
Black
3
—
—
7
Source (+24V starter switch ON)
White
4
—
—
8
GND communication)
Black
(RS232C
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. 4) Summary of display and drive item No.
Item
Remarks
1
Monitor display
LCD dot 120×168
2
Gauge display (Coolant temp., Fuel level)
Stepping motor
3
—
4
Buzzer
5
Screen change switch
6
Buzzer stop switch
7
Work mode select switch
Piezo-electricity type
T2-1-53
E215B-E245B
MECHATRO CONTROL SYSTEM
3. Relay & fuse box (symbol E-1) 1) General view
(Overhead view of box)
LABEL
INSIDE Note) These circles indicate the parts which are used in standard specification
1
14
CN2-1
20
1
14
1
12
CN2-2
20
CN4-1
17
11
22
1
7
1
10
CN5
15
1
3
26
13
13
1
CN3-2
12
8
16
24
12 CN8
9
1
17
CN3-1
1
26
13
2
1 CN9
2
9
20
6
12
1 CN2-3 3
1
2
2
2
6
1
3
1
3
6
2
6
1
3
1
3
2
2
CN15
2
3 CN12
CN1
3
6
CN14
CN4-2
1 CN17
CN16
CN13 6
2 1
4
6 2
CN10
LOCATION OF CONNECTORS (Seen from backside)
LOCATION OF RELAY & FUSE
LABEL OF RELAY & FUSE BOX No. CODE IN CIRCUIT
PARTS NAME
SM0166
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
4) High pressure sensor : YN52S00048P1
SPECIFICATION :
ECONOSEAL SERIES MARK(+)> 3POLES CAP MATING HOUSING174357-2
PRESSURE RANGE : 0
50 MPa
POWER SOURCE VOLTAGE : 5.0+0.5V DC OUTPUT : 1/10Vs-9/10Vs
COMMON
(Vs=5V DC 0.5
OUTPUT (+)
INSURANCE RESISTANCE : 100M
POWER SOURCE (+)
PLASTIC POTTING
(BETWEEN CASING AND ALL IN/OUT
TERMINAL
TERMINALS AT 50V DC MEGGER)
CONDENSER
DIE
ELECTRIC CONNECTING DIAGRAM
CASING
FLEXIBLE BOARD CIRCUIT
OR MORE
HOUSING
COVER
(Ex. Construction of internal controller)
DIAPHRAGM
O-RING P14 JIS B2401 CLASS1B PF 3/8 Tightening torgue 73.5N.m (54.2lbf.ft)
4.5V DC)
PIPE THREAD
STRUCTURE
SM0170
5) Low pressure sensor : YX52S00013P1 Tightening torgue
Vout
29.434.3N.m (21.725.3lbf.ft) PF1/4
Vcc
GND
ELECTRIC CONNECTING DIAGRAM (Ex. Construction of internal controller)
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.
• 1-2 travel speed change and low speed / high torque at heavy duty
• Auto parking brake
• Automatic braking when parking
• Motor overrun protection
• Prevents overrunning of travel motor on the
• Travel pilot operation
• Prevents hunting by the built in travel
• Reverse rotation protective function
• Easy positioning to protect it from swinging back when stops swinging.
• Swing priority circuit (simultaneous operation of arm in and swing motions)
• Easy operation of stable swing speed, arm slanted leveling, swing press digging
• Automatic swing parking brake
• Swing parking brake when operating at on a slope
• Hydraulic pilot control system
• Light action with operating lever
• Pilot safety lock system
• Cut out of pilot circuit by safety lock lever.
• Lock valve (boom / arm)
• Protect boom and arm from unexpected drop (Natural fall).
• Holding valve for boom (Option)
• Prevention of boom falling when boom head side piping breaks
manual
valve
for
lowering
Pump
• Travel 2-speed change & Auto 1st (low) speed return
Device
Attachment
• Travel straight at combined operation
Mass handling capability
Performance
Micro computer
Swing Attachment
Features
• Travel straight
• Emergency attachment
Others
Easy operability and safety
Function
Low fuel consumption
Device
Travel
Performance
Function
Features
• Electric flow controlled variable displacement pump
• Pump delivery rate control by a current command to the solenoid proportional valve of the variable displacement pump
• Positive flow rate control
• Flow control by positive pilot control pressure
• Hydraulics backup control
• Backup control by hydraulic when the electric flow controlled variable displacement pump fails.
• Boom up conflux circuit
• Speed up of boom up operation
• Arm conflux circuit
• Speed up of arm operation
• Bucket conflux circuit
• For speed-up of bucket operation (digging & dump)
• Optimum operation by work mode select (H,S,A,B)
• Efficient operation in all work modes
• Auto accel
• Reduce fuel consumption and noise by lowering engine speed when control lever is in neutral position.
• For safety, this valve lowers risen 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 malfunctioning
• Return circuit oil filter
• To prevent hydraulic oil from contamination
• 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 the cab (Option)
• Switching of return line for N&B machine is able to change with a switch in the cab
operating
circuit
from
T2-2-1
E215B-E245B
HYDRAULIC SYSTEM
2. HYDRAULIC CIRCUITS AND COMPONENTS HYDRAULIC DIAGRAM READING KEY Item
T2-2-2
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
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. SELECTION
Conflux/single flow changeover switch
Electromagnetic command signal of selector valve (50) (W:O, W/O: -)
Conflux flow of nibbler
Conflux “ON”
Single flow of nibbler Breaker
P1 Pump
P2 Pump
Travel Straight
P1 Unload
P2 Unload
-
O
O
O
O
O
Conflux “OFF”
-
-
O
-
-
O
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
Command signal of solenoid proportional valve (W:O, W/O: -)
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
T2-2-6
Component name
54
Holding valve for boom cylinders
55
Holding valve for arm cylinder
HYDRAULIC SYSTEM
E215B-E245B
HOLDING VALVE FOR BOOM & ARM HYDRAULIC CIRCUIT
54
54
55
SM0079
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
6. COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS Blue Feed, drain circuit less than 0.44 MPa (64 psi) Green Return, make up circuit, 0.44~0.59 MPa (64~86 psi) Purple Secondary pilot pressure, (including proportional vlave) 0.59~5 MPa (86~725 psi) Red Primary pilot pressure, (including proportional vlave) 5 MPa (725 psi) Orange Main pump drive pressure, 5~34.3 MPa (725~4970 psi) Blue tone At valve operation Red valve When solenoid proportional valve (reducing) is operating Red solenoid In active and exciting Displaying the flow circuit and standby circuit when operating. Regarding the electrical symbols in this manual, refer to the electric circuit diagram.
HYDRAULIC SYSTEM
7. NEUTRAL CIRCUIT
7.3 PUMP POSITIVE FLOW CONTROL
This section describes the following. 7.1 Bypass cut valve and unload valve control 7.2 Safety lock lever and pilot circuit 7.3 Pump positive flow control 7.4 Pump P-Q (Pressure-Quantity) curve control
(1) Type: Electric flow controlled variable displacement pump.
7.1 OPERATION OF BY-PASS CUT VALVE AND UNLOADING VALVE HOUSED IN CONTROL VALVE
(3) Operation:
(1) By-pass cut valve On starting engine, P1 and P2 unloading proportional valves (PSV-D, PSV-B) output secondary pressure according to the command output by mechatro controller, and this pressure exerts on PBp1 and PBp2 ports, and consequently the by-pass cut spool is switched to CLOSE side. The by-pass cut spool is usually held on CLOSE side after the engine started. And it is switched to OPEN side only when failure occurred on pump proportional valve and mechatro controller. (2) Unloading valve On starting engine, like by-pass cut valve, the secondary pressures output by P1 and P2 unloading proportional valves (PSV-D, PSV-B) exert on PCb and PCa ports, consequently the P1 and P2 unloading valves are switched to OPEN side. 7.2 SAFETY LOCK LEVER AND PILOT CIRCUIT (1) Purpose: To protect attachment movement for safety.
from
unexpected
(2) Principle: Cut pressure source of pilot valve for operation. (3) Operation: If the safety lock lever (red) is pushed forward after the engine starts, the limit switch (SW-11) is turned on. The timer relay is actuated one second later which causes the solenoid (SV-4) of the solenoid valve block (13) to be energized and makes the pilot operating circuit to stand by.
T2-2-10
(2) Principle: The current command I to the pump’s solenoid proportional valve controls the delivery rate of the pump. 1) Flow rate rise operation (Eg. P1 pump) By operating any of control levers, the operating secondary pressure of pilot valve rises, and the rising pressure is transformed to the rise of output voltage corresponding to the pressure input by the low pressure sensor. Mechatro controller signalprocesses this change of voltage, resulting in rise of command current value I to the pump proportional solenoid valve and consequently the pump flow rate rises. This is called "Positive Control System". As the pump command current value rises, the secondary pressure of proportional solenoid valve also rises. On the regulator attached on the pump, the spool (652) through piston (643) is pushed leftward, and stops at the position where being in proportion to the force of pilot spring (646). The tank port connected to the large bore of servo piston (532) opens, and the piston moves leftward by delivery pressure P1 of the small bore resulting in the increase of tilt angle ( ). The servo piston (532) and spool (652) are connected to feedback lever (611). Therefore when servo piston moves leftward, the spool (652) also moves rightward by means of feedback lever. With this movement, the opening of spool sleeve closes gradually, and the servo piston stops at the position the opening closed completely. 2) Flow rate reduction operation As the current value I of mechtro controller reduces, the secondary pressure of solenoid proportional valve reduces, and 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.
The operation is maintained until the opening of spool sleeve is closed.
7.4 PUMP P-Q CURVE CONTROL OPERATION (1) Type: Electrical flow control type variable pump (2) Principle: Perform an operation of the value from pump high pressure sensor to P-Q curve control value, and send a command to the pump solenoid proportional valve. (3) Operation: The pump high pressure sensor converts the pressure to the output voltage corresponding to the pump delivery pressure. The mechatro controller converts the voltage output by the high pressure sensor to the P-Q curve control value. On the other hand, select the pump positive control command current value from the low pressure sensor in lower order, and the values are output to respective pump proportional valve as a command current. With this operation, the pump power is controlled so as not to be exceed the engine power, therefore engine dose not stall.
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 This section describes the following. 8.1 Travel forward pilot simultaneous operation circuit 8.2 2 speed travel solenoid command circuit and auto 1-speed return function 8.3 Travel main circuit 8.4 Travel motor function 8.1 TRAVEL FORWARD PILOT SIMULTANEOUS OPERATION CIRCUIT (1) Purpose: Light operating force and shockless operation (2) Mechatronics : 1) If the travel lever with damping mechanism is operated for travel right, left and forward motions, the secondary pilot proportional pressure comes out of the 3, 1 ports of P/V (10). The higher of the pressures is selected, comes out of the 6, 5 ports and acts upon the low pressure sensors (SE-9) (SE-10). 2) The pilot secondary pressure flows to PAr and PAL ports of the control valve (2), moves the travel spool, and switches the main circuit. 3) The low pressure sensor output voltage is input into mechatro controller. The mechatro controller performs signal processing and outputs current corresponding to the increase of flow rate to P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2), and at the same time the command current is output to P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B). 4) The secondary pressures output by P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2) exert on pump regulator, actuating the pump on the delivery flow rate increase side. 5) The secondary pressure delivered in P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B) is fed to PBp1, PCb, PBp2 and PCa ports provided in control valve (2). The secondary pressure from proportional valve which has exerted on PBp1 and PBp2 ports holds the by-pass cut spool on CLOSE 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
8.2 2-SPEED TRAVEL SOLENOID COMMAND CIRCUIT AND AUTO 1st SPEED RETURN FUNCTION 1) Purpose: Change travel motor speed with switch. (2) Principle: If the switch is turned, an electric signal is issued. It excites the 2-speed travel solenoid which in turn converts the primary pilot pressure and the self pressure to a tilting angle of the variable displacement motor. (3) Operation: If the rabbit marked switch on the gauge cluster is pressed, the solenoid (SV-3) of the proportional valve block (13) is excited and changes the proportional valve. Then the solenoid command pressure is issued from port A3, enters the Ps port of the travel motor (4), opens the oil passage to the 2nd speed select piston, and causes the motor to run in the 2nd speed tilting mode by its self pressure. However, when the main circuit pressure rises above 27.3 MPa (3960 psi) (E245B) and 28 MPa (4060 psi) (E215B), the motor’s self pressure pushes the 2nd speed select piston back to the 1st speed. 8.3 TRAVEL MAIN CIRCUIT (1) Operation: The delivery oil from Pump A1 and A2 ports by changing the travel spool with the operation of travel pilot flows into P1 port on the left side motor (4) and P2 port on the right side motor (4) through C,D ports of swivel joint (8) from AL, AR ports of C/V, and rotates the travel motor. 8.4 TRAVEL MOTOR FUNCTION (1) Function: 1) Prevents the motor from over running on a slope. 2) Check valve that prevents cavitation of the hydraulic motor. 3) Shockless relief valve and anti cavitation valve when inertia force stops. 4) High/Low 2 step speed change mechanism and auto 1st speed return at high load. 5) Travel parking brake.
HYDRAULIC SYSTEM
E215B-E245B
TRAVEL CIRCUIT: Travel 2nd speed, RH & LH simultaneous operation.
SM0082
T2-2-13
E215B-E245B
HYDRAULIC SYSTEM
9. BUCKET CIRCUIT This section describes the following. 9.1 9.2 9.3 9.4 9.5
Bucket digging pilot circuit Auto accel operation Flow control in the work mode Bucket digging travel priority main circuit Bucket spool stroke limiter
9.1 PILOT CIRCUIT FOR BUCKET DIGGING (1) Mechatronics : 1) When the operation for bucket digging is performed, the pilot proportional secondary pressure is delivered through port 1 of the right pilot V (9), flows to PAc port, and acts on the low pressure sensor (SE-1), and at the same time the bucket spool is switched. 2) The voltage output by low pressure sensor (SE-1) inputs in mechatro controller. The mechatro controller performs signal processing and outputs current corresponding to the increase of pump flow rate to pump proportional valves (PSV-P1) and (PSV-P2) on the P1 and P2 pump sides, and at the same time the command current is output to P1 unloading valve (PSV-D), P2 unloading valve (PSV-B) and travel priority proportional valve (PSV-C). In the following pages, the relation of operation of low pressure sensor to both the increase of pump flow rate and unloading proportional valve is the same. Therefore the explanation is omitted. 3) The secondary pressure output by P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2) exerts on pump regulator, actuating the pump onto the delivery flow increase side. 4) The secondary pressure delivered in P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B) is led to PBp1, PCb, PBp2 and PCa ports provided in control valve (2). The secondary pressure from proportional valve which has exerted on PBp1 and PBp2 ports holds the by-pass cut spool on CLOSE 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.
T2-2-14
5) The secondary pressure delivered in travel priority proportional valve (PSV-C) is led to PTb port provided in control valve (2) and shifts the travel priority valve one stage. 9.2 AUTO ACCELERATION OPERATION (1) Principle: Auto acceleration actuates according to signals from low pressure sensor. (2) Operation:
In the event where the sensor does not receive signal for 4 seconds or more even though the acceleration dial is set to MAX position, the engine speed should be raised to 1050 rpm. When the pressure 0.6MPa (87psi) is input to low pressure sensor in STD specification (travel, bucket, swing, arm), proportional voltage from low pressure sensor inputs in mechatro controller, and then the engine speed returns to the dial set position corresponding to the lever operation. 9.3 FLOW CONTROL IN THE WORK MODE (1) Principle: When the engine speed is intermediate speed or lower, command current value to have the pump delivery rate constant is output. (2) Operation: Even if the engine speed specified by acceleration potentiometer is low speed, as the delivery rate corresponds to the intermediate speed, the actuator moves earlier than the movement equivalent to the control lever angle rate in light load operation. 9.4 BUCKET DIGGING AND TRAVEL PRIORITY CONFLUENCE (CONFLUX) MAIN CIRCUIT (1) Operation: 1) The oil delivered through A1 port of P1 pump goes into P1 port of C/V (2), opens load check valve LCc through parallel circuit and enters in bucket spool. 2) On the other hand, the oil delivered through A2 port of P2 pump goes into P2 port of C/V (2), confluences with oil from P1 pump through travel priority valve, and goes into bucket spool. (Confluence of oil from 2 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
bucket spool and returns to tank circuit from Bc port of C/V (2). References: • In bucket dumping operation, the travel priority valve also switches like digging operation, resulting in confluence with travel straight. • When the bucket operation and other operation are simultaneously performed, the travel priority valve does not actuate, resulting in single flow of bucket circuit. 9.5 BUCKET SPOOL STROKE LIMITER (1) Purpose: To secure simultaneous operability of boom and arm on boosting up attachment pressure (Pump flow rate decreases.) and to prevent cavitations at low engine speed (2) Operation: On boosting up attachment pressure, pilot primary pressure exerts on PCc port of C/V(2) through attachment booster solenoid valve, operates stroke limiter of bucket spool, and throttle oil path of spool. As a result, P1 pump pressure increases, making the simultaneous operation of boom up and bucket digging possible. Even though the engine speed is low, similarly the cavitations can be prevented by actuating the stroke limiter.
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. 10.3 Boom down pilot circuit 10.4 Prevention of natural fall by lock valve and actuation at lowering 10.5 Constant recirculation function of boom down main circuit 10.3 BOOM DOWN PILOT CIRCUIT (1) Operation: 1) If the boom down operation is performed, the secondary pilot proportional pressure comes out of port 2 of the right pilot valve (9) and acts upon the low pressure sensor (SE4). At the same time, the pressure acts upon the PBb port of C/V (2). 2) The voltage output of the low pressure sensor (SE-4) enters the mechatro controller and processed in it. 3) Then, the proportionl secondary pressure fed into C/V (2) PBb port and branches off in two lines and switches boom spool and releases boom lock valve. 10.4 PREVENTION OF NATURAL FALL BY LOCK 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
10.5 CONSTANT RECIRCULATION FUNCTION OF BOOM DOWN MAIN CIRCUIT (1) Purpose: Prevention of cavitation during boom lowering motion. (2) Principle: The oil returning from the boom cylinder head (H) is recirculated to the rod (R). (3) Operation: When the oil is supplied to the boom cylinder rod (R) side during boom down operation, the boom moves faster than it should do in some cases by the self weight of the attachment. On that occasion, the circuit pressure on the rod (R) side is on the negative side. The oil supplied to the boom cylinder rod (R) flows into the A1 port of the P1 pump and the P1 port of C/V. The oil then passes through the boom spool and goes out of the Bb port. On that occasion, the oil returning from the head (H) goes through the recirculation path in the boom spool, pushes the check valve in the spool open, is recirculated to the Bb port and is supplied to the rod (R). When the (R) pressure is larger than the head (H) pressure, the check valve in spool closes. Thereupon, the recirculation is stopped.
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 This section describes the following operations. 11.1 Swing left pilot circuit 11.2 Swing auto parking brake 11.3 Swing main circuit 11.4 Swing motor circuit 11.1 PILOT CIRCUIT FOR LEFT SWING (1) Operation: 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
as the swing spool is shifted, the oil pushes the load check valve LCs open through the parallel circuit, enters the B port of the swing motor via the Bs port of C/V (2), and rotates the swing motor counterclockwise. 11.4 SWING MOTOR CIRCUIT (1) Anti cavitation circuit at swing deceleration (2) Shockless relief valve that prevents the swing motor from being reversed.
HYDRAULIC SYSTEM
E215B-E245B
SWING CIRCUIT: Swing operation (LH)
SM0086
T2-2-21
E215B-E245B
HYDRAULIC SYSTEM
12. ARM CIRCUIT This section describes the following operations. 12.1 Arm in, light-load operating pilot circuit 12.2 Arm in, light-load variable normal recirculation main circuit / internal conflux main circuit 12.1 ARM IN, LIGHT-LOAD OPERATING PILOT CIRCUIT (1) Purpose: Speed-up and Anticavitation when the arm is at light loaded. (2) Principle: The oil returning from the arm cylinder rod (R) is recirculated variably to the head (H) at arm 2 spool in C/V. (3) Operation: 1) When the arm in operation is performed, the secondary pilot proportional pressure gets out of port 4 of the left pilot valve (9) and acts upon the low pressure sensor (SE-7). At the same time, the pressure is branched off in two flows, acts upon the PAa1 port and the PLc2 port, changes over the arm spool and the arm lock valve CRar releases. 2) The output voltage by the low pressure sensor is input into mechatro controller, and is pilot signal-processed, and is output to P1, P2 pump proportional valve (PSV-P1), (PSV-P2) and arm 2 inverse proportional valve (PSV-A). 3) The secondary pressure from pilot proportional valve, which is reduced by arm 2 inverse proportional valve (PSV-A) switches arm 2 spool.
3) The return oil from arm cylinder (R) side flows in Ba port of C/V (2) and passes through the Ba port because the arm lock valve CRar is open, and is flowed into arm 2 spool through arm 1 spool. 4) Because arm 2 spool is switched to normal recirculation position, causing restriction of passage to tank, the return oil from arm cylinder (R) side flows into arm cylinder (H) side. • Because, at light load, the pressure in cylinder rod (R) side is higher than that in the head (H) side, it opens the check valve housed-in arm 2 spool and is recirculated in the head (H) side, resulting in the speed up of arm-in operation at light load. 5) Cavitations prevention control in arm-in operation. Command current is output to arm 2 solenoid proportional valve by signal processing of E/G speed and arm-in pilot pressure, accordingly the arm 2 spool is switched to neutral (cavitations prevention) position, resulting in cavitations prevention. Position of arm 2 spool Neutral position (Anticavitation position)
Normal recirculation position Recirculation
From arm out P/V From arm 2 inverse proportional valve SM0195
12.2 ARM-IN, LIGHT-LOAD VARIABLE NORMAL RECIRCULATION, INTERNAL CONFLUX MAIN CIRCUIT (1) Operation: 1) The P2 pump delivery oil flows in travel left section through P2 port of C/V (2) and is branched off in by-pass circuit and parallel circuit, but because arm 1 spool is switched, the delivery oil which goes through parallel circuit opens load check valve LCa and is flowed into arm 1 spool. 2) On the other hand, P1 pump delivery oil 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 check valve LCAT2, goes through arm 2 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
Reference: In light-load arm-in operation (normal recirculation, conflux), when the attachment to which the circuit in P1 pump side is applied is operated, the meter-in path of arm 2 spool is closed, resulting in single flow operation. Spool position at arm in, light load and combined operation (This position is not shown in hydraulic diagram) Neutral position
Arm 2 spool
Meter-in passage (Close)
Normal recirculation opsition SM0196
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. 12.3 Arm in, heavy load operating pilot circuit (recirculation cut) 12.4 Arm in, heavy load operating sequence confluxed main circuit
4) The return oil returns directly into tank circuit because arm 2 spool is switched to recirculation cut position. Position of arm 2 spool Neutral position
12.3 ARM IN, HEAVY LOAD OPERATING PILOT CIRCUIT (1) Operation: 1) 1)In arm-in operation, when the heavy loading is applied to arm and the P2 pump pressure increases to the set pressure, the 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
From arm out P/V
Recirculation cut position
From arm 2 inverse proportional valve SM0197
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. 12.5 Arm out pilot circuit 12.6 Arm out 2 pumps conflux main circuit 12.7 Natural fall protection with arm lock valve 12.5 ARM OUT PILOT CIRCUIT (1) Operation: 1) When the arm out operation is performed, the secondary pilot proportional pressure gets out of port 8 of the left pilot valve (9), and acts upon the low pressure sensor (SE8). At the same time, the oil is branched off in two flows and act upon the PBa1 and PBa2 ports of C/V (2). 2) The operating proportional secondary pressure flowed in PBa1 port of C/V (2) switches the arm 1 spool. 3) Then, the operating secondary pressure flowed in PBa2 port of C/V (2) switches the 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
12.7 NATURAL FALL PROTECTION WITH ARM LOCK VALVE (1) Purpose: To prevent the arm from falling naturally by the weight of the arm and bucket. (2) Principle: Complete seat of the return circuit against the arm spool of the arm cylinder (R) side circuit. (3) Operation: 1) When the secondary pressure for arm operation disappears and the arm cylinder stops, the pressure on the rod (R) side passes through the selector of the lock valve from the Ba port of C/V, acts the back pressure on the lock valve CRar and seats the lock valve. 2) Since the oil flow into the arm spool from the lock valve is shut off completely, natural fall of the arm due to oil leaks through the arm spool is prevented.
HYDRAULIC SYSTEM
E215B-E245B
ARM CIRCUIT: Arm out operation, Confluence function
SM0089
T2-2-27
E215B-E245B
HYDRAULIC SYSTEM
13. COMBINED CIRCUIT This section describes only the difference in combined operation. 13.1 Boom up / travel, pilot circuit 13.2 Boom up / travel, main circit 13.1 BOOM UP / TRAVEL, PILOT CIRCUIT (1) Operation: 1) The mechatro controller outputs command current to travel priority solenoid proportional valve (PSV-C) and to shortcircuit 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
because the travel straight spool is shifted and exerts on the right travel operation. (In travel straight operation, P2 pump delivery oil exerts on travel operation.) 4) However, a portion of the flow is led to the spool of short-circuit valve notch restriction. The speed of attachments like travel, boom, etc. is adjusted by the circuit of restriction.
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 and describes difference in combined operation. 13.3 Swing / Arm in light load, pilot circuit 13.4 Swing / Arm in, swing priority main circuit 13.3 SWING / ARM IN LIGHT LOAD, PILOT CIRCUIT (1) Operation: 1) On operating swing (left) and arm in motions simultaneously, mechatro controller outputs 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
Position of arm 2 spool
Position of forced recirculation Neutral position From arm out P/V
Meter-in passage (Close) From arm 2 inverse proportional valve
Arm 2 spool
Normal recirculation position SM0198
HYDRAULIC SYSTEM
E215B-E245B
COMBINED CIRCUIT: Swing / Arm in operation, swing priority function
SM0091
T2-2-31
E215B-E245B
HYDRAULIC SYSTEM
14. PRESSURE DRAINING (RELEASING) CIRCUIT This section describes the following operations. 14.1 Pressure releasing pilot circuit 14.2 Pressure releasing main circuit 14.1 PRESSURE RELEASING PILOT CIRCUIT (1) Purpose: To release the pressure in main circuit for piping repair works. (2) Principle: After the mode is switched to "Pressure Relief Mode" with switch on gauge cluster, mechatro controller outputs the following commands. 1) Minimum tilting command value to pump proportional valve (PSV-P1, PSV-P2). 2) Output "Pressure relief control speed command value" at engine governor motor (M2). 3) Stand-by command value to P1, P2 unloading proportional valves. How to switch to "Pressure release mode" 1) Select the service diagnosis mode 1. (Keeping pressing of the "BUZZER STOP SWITCH" [ ] on gauge cluster, turn the starter key ON.) 2) Select the service Adjustment Mode 1. (Under the condition that "Screen No.1" of "Service diagnosis mode 1" is indicated, keeping pressing of the "BUZZER STOP SWITCH", press the SELECT switch [ ] 3 times. When "LANGUAGE/LOGO", "ADJUSTING MODE 1" and "PRESET BY FACTORY" are displayed, press [ ] or [ ] switch, and highlight "ADJUSTING MODE 1", and then press "SELECT Switch" again.) 3) When "ADJUSTING MODE 1" screen is displayed, press [ ] or [ ] switch, several times and "DRAIN HYD. PRESS. OFF " screen appears. 4) Press "SELECT Switch" and highlight "OFF", and press [ ] switch to change to "DRAIN HYD. PRESS. ON", and then press " SELECT Switch" again. (3) Operation: 1) Pump proportional valve reduces the pump flow rate to the minimum. 2) Unloading proportional valves (PSV-D, PSV-B) output secondary pressure and the secondary pressure flows in PCb, PCa ports of C/V(2) and switches the P1, P2 unloading valves to OPEN position.
T2-2-32
14.2 PRESSURE RELEASING MAIN CIRCUIT (1) Operation: CAUTION: before to perform the hydraulic pressure releasing, make sure to place bucket on the ground. When the operating lever is shifted to neutral during engine running, "DRAINING HYD. PRESS." is displayed on the gauge cluster while the mode switch is changed to pressure relieving mode. In this time the intermittent buzzer sounds continuously. When right and left operating levers are operated 4 or 5 times to their full stroke, pressure is relieved. After draining pressure is completed, turn off the starter key and buzzer sound stops. If the pump pressure is determined to be more than 1 MPa (145 psi) by the output value of the high pressure sensor (SE 22, SE 23) (or the high pressure sensors are broken) "FAIL DRAIN HYD. PRESS" is displayed and the buzzer sounds continuously. In that case, also the buzzer is not stopped unless the engine key is turned to OFF. Repeat the pressure releasing procedure once again. (2) Hydraulics: If the Unloading valves are turned to the pressure release position, the oil delivered by each pump is unloaded to the tank passage. If the spools are switched by pilot operation, the remaining pressure from the actuators may be relieved to the tank circuit, i.e. the main circuit pressure may be released.
HYDRAULIC SYSTEM
E215B-E245B
PRESSURE DRAINING (RELEASING) CIRCUIT: at pressure release mode
651 652 611 643 646 532
SM0092
T2-2-33
E215B-E245B
T2-2-34
HYDRAULIC SYSTEM
ELECTRICAL SYSTEM
E215B-E245B
ELECTRICAL SYSTEM MAIN COMPONENTS ELECTRICAL SYSTEM (Overall system)
A
F B
E
E
C
SM0004
D A - Cab Control B - Mechatro Controller and Fuse&Relay box C - Batteries, Batteries Relay, Fuse link
D - Hydraulic System Electrical Components E - Engine Electrical Components F - Light, Horn, ect
T2-3-1
E215B-E245B
ELECTRICAL SYSTEM
A - CAB CONTROL Electrical components
10
1
2 16 3
4 14 5
13 12
6
11
7
8 15
9
1 - Cluster gauge 2 - Power Boost switch 3 - Starter switch 4 - Engine speed throttle 5 - Work lights switch 6 - Single/Double flow switch 7 - “Heavy Lift” switch (opt.) 8 - Load momentum switch (opt.)
9 - Cigarette lighter 10 - Hour meter 11 - Climate controls panel 12 - Quick coupling switch (opt.) 13 - Tuner 14 - Cab work lights switch (opt.) 15 - Parking brake release switch 16 - Horn switch
T2-3-2
ELECTRICAL SYSTEM
E215B-E245B
Cluster Gauge
SM0003
1 - Coolant temperature indicator 2 - Fuel level indicator 3 - Screen change button 4 - Select button 5 - Auto-Idle button 6 - Work Mode button
7 - Windshield washer button 8 - Wiper button 9 - Buzzer cut-off button 10 - Travel speed button 11 - Display
T2-3-3
E215B-E245B
ELECTRICAL SYSTEM
Cluster gauge wiring harness
10 12
14
VIEW I
15 16
8
7
6
13
5 4
17
3
19
10 a-a
1
20
2
9
b-b
DETAIL a-a
c-c
11 I
2
4
3
5
6
7 E
1
8 W
8
Br
18
VIEW E
DETAIL c-c DETAIL b-b 1 - Starter switch (SW-1) 2 - Engine speed throttle (SE-16) 3 - Work light switch (SW-55) 4 - Single/Double flow switch (SW-15) 5 - “Heavy Lift” switch (SW-35) (opt.) 6 - Over load alarm select switch (SW-12) (opt.) 7 - (opt.) 8 - Cigarette lighter (E-14) 9 - Cluster gauge (C-2) 10 - Starter switch (GND) (SW-1)
SM0098
11 - Wiper motor (M-3) 12 - 12 V socket (E-23) 13 - Speaker right (E-9) 14 - Connector for cab work light (SW-26) 15 - Connector for room light (L-5) 16 - Connector for wiper interlock switch (SW-19) 17 - Speaker left (E-8) 18 - Hour meter (E-3) 19 - Connector with “A” label (CN-5F) 20 - Connector with “B” label (CN-6F)
T2-3-4
ELECTRICAL SYSTEM
E215B-E245B
B - MECHATRO CONTROLLER AND FUSES&RELAY BOX
SM0010
1 - Mechatro Controller Unit (C-1) 2 - Fuse & Relay box (E-1) 3 - DC-DC Converter (E-22)
T2-3-5
E215B-E245B
ELECTRICAL SYSTEM
Fuse & Relay box FUSES
SM0008
FUSES BOX
FUSES BOX
FUSE No.
PROTECTED CIRCUIT
Rating (A)
FUSE No.
PROTECTED CIRCUIT
Rating (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) 2 - Wiper motor reversing relay (RLY 30) 3 - Cab working light relay (RLY 9) 4 - Cab working light relay (RLY 11) 5 - Working light relay (RLY 6) 6 - Alternator relay (RLY 28) 7 - Auto-Idle stop relay (RLY 24) 8 - Lever look relay (RLY 26) 9 - Auto-Idle stop relay (RLY 23) 10 - Engine emergency stop relay (RLY 25) 11 - Horn relay (RLY 5) 12 - Nibbler close relay (RLY 16) 13 - Reserve relay (RE-RLY 1) 14 - Reserve relay (RE-RLY 2) 15 - Wiper motor relay (RLY 31)
16 - Wiper motor relay (RLY 29) 17 - Discharge pressure relay (RLY 17) 18 - Grease (forward) relay (RLY 27) 19 - Grease (reverse) relay (RLY 35) 20 - Safety relay (RLY 4) 21 - Bucket control relay (RLY 10) 22 - Travel alarm relay (RLY 8) 23 - Revolution right relay (RLY 12) 24 - Nibbler open relay (RLY 15) 25 - Revolution left relay (RLY 13) 26 - Reserve relay (RE-RLY 5) 27 - Reserve relay (RE-RLY 6) 28 - Reserve relay (RE-RLY 4) 29 - Reserve relay (RE-RLY 3)
T2-3-7
E215B-E245B
ELECTRICAL SYSTEM
C - BATTERIES, BATTERIES RELAY, FUSES LINK
7
2
6 3 1
4 5
SM0005
1 - Batterie relay (R-1) 2 - Fuse Link 1, 2, 3, 4 (E-25) 3 - Starter motor relay (R-2) 4 - Fuel filter heater relay (R-40)
5 - Batteries (E-12) 6 - Pre-Heater relay (R-3) 7 - Fuse Link 5 (E-26)
Fuses located into radiators compartment Fuse No. FUSE 1
Protected circuit
Value (A)
Fuses powering (1 – 6)
60
FUSE 2
Fuses powering (17 - 32)
60
FUSE 3
Alternator
100
FUSE 4
Starter relay, fuel heater filter relay
60
FUSE 5
Fuses powering (10 - 15)
60
T2-3-8
ELECTRICAL SYSTEM
E215B-E245B
D – HYDRAULIC SYSTEM ELECTRICAL COMPONENTS
14
3
4
2
28 15
13
1 30 29 26
16
27
17 18 19
12 5
11
6
7
8
9 10
25
24
23
22
21
20 SM0006
1 - Extra valve selector press sensor (SE-29) (opt.) 2 - Pomp P2 proportional solenoid valve (PSV-P2) 3 - Pump P1 proportional solenoid valve (PSV-P1) 4 - Swing sensor (SE-5) 5 - Lever lock solenoid valve (SV-4) 6 - Power boost solenoid valve (SV-2) 7 - P2 Unload proportional solenoid valve (PSV-B) 8 - Travel priority prop. solenoid valve (PSV-C) 9 - P1 Unload proportional solenoid valve (PSV-D) 10 - Arm 2 inverse prop. solenoid valve (PSV-A) 11 - Two speed select solenoid valve (SV-3) 12 - Swing parking brake solenoid valve (SV-1) 13 - Short-circuit proportional solenoid valve (PSV-R) 14 - Extra dis-press solenoid valve (SV-11) (opt) 15 - Extra dis-press sensor (SE-28) (opt)
16 - P1 opt. sensor valve (SE-20) 17 - Travel right sensor (SE-9) 18 - Travel left sensor (SE-10) 19 - P2 Opt. sensor valve (SE-11) 20 - Bucket digging sensor (SE-1) 21 - Bucket dump sensor (SE-2) 22 - Boom raising sensor (SE-3) 23 - Boom lowering sensor (SE-4) 24 - Arm in sensor (SE-7) 25 - Arm out sensor (SE-8) 26 - Pump P1 sensor (SE-22) 27 - Pump P2 sensor (SE-23) 28 - Relief adjustment prop. solenoid valve 1 (PSV-E) 29 - Relief adjustment prop. solenoid valve 2 (PSV-I) 30 - Selector E&N solenoid valve (SV-13)
T2-3-9
E215B-E245B
ELECTRICAL SYSTEM
E – ENGINE ELECTRICAL COMPONENTS
15
18
1
17 19
13
2 4
14
16
12
10
9
3
8
1 - Air filter restriction switch (SW-8) 2 - Engine coolant level switch (SW-24) 3 - Stepping Motor (M-2) 4 - Starter motor assembly (M-1) 5 - Thermo-switch for heater (SW-52) 6 - Coolant thermo sensor (SE-14) 7 - Engine coolant temperature switch (SW-6) 8 - Alternator assembly (E-2) 9 - Engine revolution sensor (SE-13) 10 - Engine oil pressure switch (SW-7)
5
6-7
11
11 - Air compressor (E-21) 12 - Cold start air heater (E-12) 13 - Fuel filter heater (E-20) 14 - Engine stop solenoid (SV-15) 15 - Fuel sensor (SE-15) 16 - Engine oil level sensor (SE-12) 17 - Water separator restriction switch (SW-36) 18 - Water separator heater (E19) 19 - Fuel filter heater switch (E-20)
T2-3-10
SM0007
ELECTRICAL SYSTEM
E215B-E245B
F – ELECTRICAL COMPONENTS (Lights, Horns)
3
1
2
4
5
6 1 - Frame Working light (L-2 2 - Boom Working light left (L-1) 3 - Boom Working light right (L-6)
4 - Horn high (E5) 5 - Horn low (E6) 6 - Engine room light (L-11)
T2-3-11
SM0011
E215B-E245B
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM DIAGRAM ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 1) Item
Description
Code
1
Fuse box
E-1
2
Key starter switch
SW - 1
3
Fuse link box
E - 25
4
Auto-Idle stop relay 1
R - 23
5
Starter motor
M-1
6
Starter relay
R-2
7
Safety relay
R-4
8
Alternator relay
R - 28
9
Battery relay
R-1
10
Fuse link
E - 26
11
Auto-Idle stop relay 2
R - 24
12
Alternator
E-2
13
Reserve relay
RY - 29
14
Battery
E - 12
15
Engine emergency stop relay
R - 25
16
Mega fuse
E - 24
17
Fuel filter heater relay
R - 40
18
Grid heater relay
R-3
19
Water separator heater
E - 19
20
Fuel filter heater
E - 20
21
Grid heater
E - 21
22
Engine stop solenoid
SV - 15
23
Diode
D - 21
24
Diode
D - 30
25
Diode
D - 20
26
Diode
D - 19
27
Diode
D - 13
28
Diode
D - 14
29
Diode
D-9
30
Diode
D - 12
31
Diode
D - 11
32
Diode
D -18
33
Hour meter
E-3
34
KSB soleniod
---
35
Mechatro Controller
C-1
T2-3-12
ELECTRICAL SYSTEM
E215B-E245B
ELECTRICAL SYSTEM DIAGRAM (No. 1)
19 17
1
20 31 16
26
18
21
10 25 14 3 9 4
15
11
29
23
30
2
22
35
34
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
T2-3-14
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
ELECTRICAL SYSTEM
E215B-E245B
ELECTRICAL SYSTEM DIAGRAM (No. 2)
37
35
58 59 60 61
38
62
39
63
40
64
41
65
42
66
43
67
44 45 46 47 48 49 50 51 52 53
36
54
68
55
69 70
56
71 SM0094
57 T2-3-15
E215B-E245B
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 3) Item
T2-3-16
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
ELECTRICAL SYSTEM
E215B-E245B
ELECTRICAL SYSTEM DIAGRAM (No. 3)
35 93 94
72 73
95
82
74
81 75
83
96
88
76 84
85
97
86 77
79
78
87
80
89
90 98 91
99 100 101 102
92
SM0095
T2-3-17
E215B-E245B
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 4) Item
Description
Code
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
35
T2-3-18
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
-
ELECTRICAL SYSTEM
E215B-E245B
ELECTRICAL SYSTEM DIAGRAM (No. 4)
35
115 113 116 117
112 114 111 118
104
107
119
109 120
105 106
121 110
103
108
123
124
122
SM0096
T2-3-19
E215B-E245B
ELECTRICAL SYSTEM ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 5) Item 35
T2-3-20
Description
Code
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
-
ELECTRICAL SYSTEM
E215B-E245B
ELECTRICAL SYSTEM DIAGRAM (No. 5)
135
134
136 139 131 138 132
140 141
133 142 137
143 144
128
127 129
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
T2-3-24
SM0199
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 SM0255
T2-3-26
SM0199
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
4
To engine stop solenoid (SV-15)
T2-3-28
- The connector view on the cable are from “X” side SM0199
ELECTRICAL SYSTEM
E215B-E245B
ENGINE WIRING HARNESS (KSB & STOP)
SM0256
T2-3-29
E215B-E245B
T2-3-30
ELECTRICAL SYSTEM
COMPONENT OPERATION
M0103
COMPONENT OPERATION
E215B-E245B
SECTION AND GROUP CONTENTS Section 3
COMPONENT OPERATION
Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8
Hydraulic Pump Assy Pilot Valve Control Valve Swing Device Travel Device Swivel Joint Cylinders Air Conditioner system
SECTION 3
E215B-E245B
COMPONENT OPERATION
CONTENTS Group 1 - Hydraylic pump assy Outline .................................................... T3-1-1 General view and hydraulic ports ...... T3-1-1
Boost check valve (517)..................... T3-3-18 Hydraulic circuit diagram......................... T3-3-19 Operation ................................................ T3-3-20
Hydraulic circuit diagram .................. T3-1-2 Specifications .................................... T3-1-3
Group 4 - Swing device
Hydraulic pump ...................................... T3-1-4
Outline..................................................... T3-4-1
Operation .......................................... T3-1-7
General view ...................................... T3-4-1
Regulator ............................................... T3-1-9
Construction ............................................ T3-4-4
Construction....................................... T3-1-9
Swing motor ....................................... T3-4-4
Operation .......................................... T3-1-11
Swing reduction unit........................... T3-4-6
Adjusting the regulator ....................... T3-1-16
Hydraulic motor ....................................... T3-4-7
Causes of fault resulting from regulator ........................................ T3-1-18
Valve casing section ............................... T3-4-8
Control curve of pump............................. T3-1-19
Operation of relief valve ..................... T3-4-8 Brake section .......................................... T3-4-11 Swing reduction unit................................ T3-4-12
Group 2 - Pilot valve Pilot valve (ATT) ..................................... T3-2-1 Outline ............................................... T3-2-1 Construction....................................... T3-2-2 Operation ........................................... T3-2-3 Pilot valve (travel) ................................... T3-2-5 Outline ............................................... T3-2-5 Construction and operation................ T3-2-6
Group 5 - Travel device Outline..................................................... T3-5-1 Specifications..................................... T3-5-1 Hydraulic motor.................................. T3-5-2 Planetary gearbox.............................. T3-5-2 Ports E215B....................................... T3-5-2 Ports E245B....................................... T3-5-3 Hydraulic circuit E215B...................... T3-5-4
Group 3 - Control valve
Hydraulic circuit E245B...................... T3-5-4
Control valve ........................................... T3-3-1
Direction of rotation............................ T3-5-5
Control valve ports ............................. T3-3-3
Construction ............................................ T3-5-5
Specifications .................................... T3-3-4
Track drive E215B ............................. T3-5-5
Construction and operation................ T3-3-5
Hydraulic motor E215B ...................... T3-5-6
Main relief valve (601) ....................... T3-3-12
Brake.................................................. T3-5-6
Over load relief valve (602, 603, 605) T3-3-13
Hydraulic motor and track drive E245B ............................................ T3-5-7
Arm 2 spool (308) .............................. T3-3-14 Boom spool (301) .............................. T3-3-14 Lock valve selector (211) ................... T3-3-15 Bypass cut valve (606) ...................... T3-3-16 Swing shuttle valve cover (204) ......... T3-3-17
Hydraulic motor E245B ...................... T3-5-8
Group 6 - Swivel joint Outline..................................................... T3-6-1 Construction ............................................ T3-6-2 Operation ................................................ T3-6-3
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
Group 8 - Air conditioner system Basic system of air conditioner (HVAC air conditioner) ....................... T3-8-1 Air cycle................................................... T3-8-1 Auto air conditioner system outline ......... T3-8-2 Component and construction .................. T3-8-3 Operation ........................................... T3-8-7 Disassembly and assembly..................... T3-8-13 Precautions to be exercised in operation ........................................ T3-8-13 Disassembly and assembly of unit..... T3-8-14 Charging refrigerant ................................ T3-8-18 Precautions to be exercised in operation ........................................ T3-8-18 Operating procedure .......................... T3-8-19 Electric circuit .......................................... T3-8-23 Wiring diagram and connectors ......... T3-8-23 Structure and operation of each functional parts and the inspection .... T3-8-25 Troubleshooting ...................................... T3-8-28 Self diagnosis function on display of panel .................................................. T3-8-35 Explanation of monitor mode .................. T3-8-37
HYDRAULIC PUMP ASSY
E215B-E245B
OUTLINE General view and hydraulic ports
Dr
5
B3
3
a5
a3 PSV1
PSV2 A1
PH1 2 a3
4
PH2
PSV1
a4
PSV2
PH1
A2
a4
PH2 a1 a2 Dr3 B3
a5 A3 1
Dr
B1 SM0745
1Main pump assy 2Regulator assy (Q.ty 2) 3Gear pump assy (for pilot) Solenoid proportional reducing valve (Q.ty 2) 45PTO unit A1 - Delivery port SAE 6000 psi 1'' A2 - Delivery port SAE 6000 psi 1'' B1 - Suction port SAE 2500 psi 2 1/2'' Dr - Drain port G 3/4-20 PSV1 - Servo assist port G 1/4-13 PSV2 - Servo assist port G 1/4-13
PH1 PH2 a1 a2 a3 a4 a5 A3 B3 Dr3 -
T3-1-1
Pressure sensor port G 3/8-17 Pressure sensor port G 3/8-17 Gauge port G 1/4-15 Gauge port G 1/4-15 Gauge port G 1/4-15 Gauge port G 1/4-15 Gauge port G 1/4-14 Delivery port of gear pump G 1/2-19 Suction port of gear pump G 3/4-20.5 Drain port of gear pump G 3/8-15
E215B-E245B
HYDRAULIC PUMP ASSY
Hydraulic circuit diagram
4
4
2
2
1
3 SM0746
1234-
Main pump assy Regulator assy (Q.ty 2) Gear pump assy (for pilot) Solenoid proportional reducing valve (Q.ty 2)
T3-1-2
HYDRAULIC PUMP ASSY
E215B-E245B
Specifications
Main pump
Gear pump for pilot
Pump
Item
K3V112DTP1KMR-YTOK-HV
ZX10LPRZ7-07G
Type
Variable displacement plunger pump: regulator attached type
Fixed displacement type gear pump
110 x 2
10
2000
←
Max. displacement capacity
cm3
Revolution
rpm (Clockwise seen from shaft end)
Pressure
Rated Rated ATT boost
34.3
MPa
Max. flow
L/min
Max. input Power (at 2000 rpm) Max. input torque (at 1200 rpm)
220 x 2 at 7.8 MPa
20
kW
118
3.4
Nm
665
14.7
Model Regulator
Mass
5.0
37.8
KR3G-YTOK-HV
Control function
Electric flow control, positive flow control, total power control at emergency mode and power shift control
Others
With solenoid proportional reducing valve (KDRDE5K-31/30C50)
kg
143
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
886 717
953 806
(Three Bond N° 1305N) 724 789 532 A 214 548 531 702 792 534 535 732
901 808 954
717
151
152 211
261 406 824 774 111 B
B
127 123 710 212 401 251 490
271
153 156 157
468 728
313 124 710 116 467 466 312 885 314 141 727 725
271
113
05 04
401 406 407 414 466 467 468 490 531,532 806 808
M20 M8 M6 M10 PF 1/4 PF 3/8 PF 3/4 NPTF1/16 M24X2 M16 M20
Nm 430 29 12 57 36 74 170 8.8 240 130 240
546 725 727
407
325
A
B-B SM0747
111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 261 271 312
Drive shaft (F) Drive shaft (G) Gear #1 Roller bearing (Q.ty 2) Needle bearing (Q.ty 2) Bearing spacer (Q.ty 3) Cylinder block (Q.ty 2) Piston (Q.ty 18) Shoe (Q.ty 18) Retainer plate (Q.ty 2) Spherical bushing (Q.ty 2) Cylinder spring (Q.ty 18) Shoe plate (Q.ty 2) Swash plate (Q.ty 2) Tilting bushing (Q.ty 2) Swash plate support (Q.ty 2) Seal cover (F) Pump casing (Q.ty 2) Valve block
313 314 325 326 401 406 407 466 467 468 490 531 532 534 535 546 548 702 710
Valve plate (R) Valve plate (L) Sensor block Cover Socket bolt; M20X210 (Q.ty 8) Socket bolt; M8X20 (Q.ty 4) Socket bolt; M6X55 (Q.ty 3) VP plug; PF1/4 (Q.ty 2) VP plug; PF3/8 (Q.ty 2) VP plug; PF3/4 (Q.ty 4) VP plug; NPTF1/16 (Q.ty 4) Tilting pin; M24X2 (Q.ty 32) Servo piston M24×2 (Q.ty 2) Stopper (L) (Q.ty 2) Stopper (S) (Q.ty 2) Spacer (Q.ty 2) Feed back pin (Q.ty 2) O-ring; 1B G35 (Q.ty 2) O-ring; 1B G95 (Q.ty 2)
T3-1-4
717 724 725 727 728 732 774 789 792 806 808 824 885 886 901 953 954 04 05
O-ring; 1B G145 (Q.ty 4) O-ring; 1B P8 (Q.ty 16) O-ring; 1B P11 (Q.ty 9) O-ring; 1B P14 (Q.ty 3) O-ring; 1B P24 (Q.ty 4) O-ring; 1B P18 (Q.ty 2) Oil seal Back up ring; P18 (Q.ty 2) Back up ring; G35 (Q.ty 2) Nut; M16 (Q.ty 2) Nut; M20 (Q.ty 2) Snap ring (Q.ty 2) Valve plate pin (Q.ty 2) Spring pin (Q.ty 4) Eye bolt M10 (Q.ty 2) Socket screw; M16X35 (Q.ty 2) Set screw; M20 (Q.ty 2) Gear pump PTO unit
HYDRAULIC PUMP ASSY
E215B-E245B
GEAR PUMP (FOR PILOT)
361
700
433 354
434
351 353
B3
435 312 311
Dr4
a3
A3 728
710 732
312 433 434 435 466
M14 x 1.5 M8 M8 M10 G 1/4
310
308 309
307
434
Nm 29 17 17 33 16
850 355 466 725
SM0748
307 308 309 310 311 312 351 353 354 355 361 433 434 -
Poppet Seat Ring Spring Adjust screw Lock nut; M14×1.5 Gear case Drive gear Driven gear Filter Front case Flange socket; M8×40 (Q.ty 2) Flange socket; M8×55 (Q.ty 2)
435 466 700 710 725 728 732 850 a3 A3 B3 Dr4 -
T3-1-5
Flange socket; M10×35 (Q.ty 2) Vp plug; G1/4 (Q.ty 2) Ring O-Ring O-Ring O-Ring O-Ring Locking ring Gauge port; G1/4 16 Nm Delivery port; G3/8 34 Nm Suction port; G3/4 74 Nm Drain port; G3/8 34 Nm
E215B-E245B
HYDRAULIC PUMP ASSY
PTO GEAR CASE
711
468
125
118 11
262 728
117 414 126 128
825 710
10 12
435 886
826
SM0749
10 11 12 117 118 125 126 128 262 -
Idle shaft Gear case Pin 2nd gear 3rd gear Ball bearing (Q.ty 2) Roller bearing Bearing spacer (Q.ty 2) Cover
414 435 468 710 711 728 825 826 886 -
T3-1-6
Socket bolt; M10x20 (Q.ty 4) Flange socket; M10×20 (Q.ty 4) Vp plug: G3/4 O-Ring O-Ring O-Ring Snap ring Snap ring Pin (Q.ty 2)
HYDRAULIC PUMP ASSY
E215B-E245B
Operation The pump assy is equipped with two pumps arranged on the same axis that are connected with gear (116) and distribute the rotating power to the gear trains on a different axis. Thus the engine rotation is transmitted to front shaft (111) that drives the two pumps and, at the same time, drives the pilot gear pump arranged on another shaft. The pump assy consists largely of: - the rotary group, the main part of the pump that makes rotary on;
111
116
- the swash plate group that changes the delivery rate; - the valve block group that selects between oil suction and delivery; - the PTO group that transmits the drive power to the gear pump. 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) at its both ends. The shoe, which is caulked to the piston, forms a spherical joint and relieves it of thrust force that is generated by load pressure. Further, the piston is provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic balance.
The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the retainer plate and the spherical bushing, so that it moves smoothly over the shoe plate. The cylinder blocks (141) are also pressed against valve plates (313) or (314) by the action of cylinder spring (157).
111
312
141
211
151
153
156
314
124
124
313
116
157
152 SM0245
T3-1-7
E215B-E245B
HYDRAULIC PUMP ASSY
SWASH PLATE GROUP The swash plate group consists of swash plate (212), shoe plate (211), swash plate support (251), tilting bushing (214), tilting pin (531),and servo piston (532). The swash plate is the cylindrical part that is formed on the opposite side of the shoe sliding surface and is supported by the swash plate support. The hydraulic force controlled by the regulator flows into the hydraulic chamber that is provided on both sides of the servo piston. This moves the servo piston to the right and left. The result is that the swash plate swings on the swash plate support via the spherical part of the tilting pin and changes the tilting angle (a).
532 531
214
212
211
251 SM0246
VALVE BLOCK GROUP The valve block group consists of valve block (312), valve plates (313) (314), and valve plate pin (885). The valve plates having two crescent-shaped ports are installed to valve block (312) to feed oil and recycle it from cylinder block (141). The oil switched over by the valve plate is connected with the external pipe by way of the valve block.
313 312
111 885
141
PTO GROUP 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) 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 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 (zero tilting angle), the piston does not stroke i.e. delivers no oil. The shaft rotation is taken up by the 1st gear (116) 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. T3-1-8
314
116
SM0247
117
126
125
118
125
SM0248
HYDRAULIC PUMP ASSY
E215B-E245B
REGULATOR Construction
B
757
418
B- B
413
079
646 438
D
438 656
722
543
755
D
541 545
B
724
725
439
730
643 466 755 708
924 644 645 728
801
A -A
412
897 612
876 874
755 858 615
A
614 613 611 875
A
541 755
654 836 651 652 601 624
629
630 628 627 802
631 898 732 733 622 621 623
642
662 545 543
734 653 655 641 814
753 756
625
763 887 626
466
E
755
E E- E
D- D
496 SM0249
T3-1-9
E215B-E245B 412 413 418 438 439 466 496 541 543 545 601 611 612 613 614 615 621 622 623 624 625 626 627 628 629 630 631 641 642 643 644 645 646 651 -
Socket bolt; M8×50 (Q.ty 2) 29 Nm Socket bolt; M8×70 (Q.y 2) 29 Nm Socket bolt; M5×12 (Q.ty 2) 6.9 Nm Socket bolt; M6×20 (Q.ty 10) 12 Nm Socket bolt; M6×35 (Q.ty 3) 12 Nm Vp plug; G1/4 36 Nm Plug; NPTF1/16 (Q.ty 15) 8.8 Nm Seat Stopper 1 (Q.ty 2) Ball (Q.ty 2) Casing Feed back lever Lever 1 Lever 2 Fulcrum plug Adjusting plug Compensating piston Piston case Compensating rod (C) Spring seat Outer spring Inner spring (C) Adjusting stem (C) Adjusting screw (C) Cover Lock nut; M30×1.5 160 Nm Sleeve Pilot cover Spool Pilot piston (Q) Spring seat (Q) Adjusting stem Pilot spring Sleeve
HYDRAULIC PUMP ASSY 652 653 654 655 656 662 708 722 724 725 728 730 732 733 734 753 755 756 757 763 801 802 814 836 858 874 875 876 887 897 898 924 079 -
Spool Spring seat Return spring Set spring Block cover Spring O-Ring O-Ring (Q.ty 3) O-Ring (Q.ty 8) O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring (Q.ty 7) O-Ring O-Ring O-Ring Nut; M8 (Q.ty 3) 16 Nm Nut; M10 19 Nm Snap ring Snap ring Snap ring (Q.ty 2) Pin; Ø4×11.7L Pin; Ø4×8L (Q.ty 4) Pin; Ø5×8L (Q.ty 2) Pin Pin; Ø4×19L Pin; Ø8.5×10L Socket screw; M8×20 Solenoid proportional reducing valve
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
condition, because the power shift pressure is 0 MPa, the power control is not worked. With this mechanism, it is possible to obtain proper power for the working condition. This regulator is made up of the above two kinds of control system, but when both controls are actuated together, the low tilt angle (low delivery rate) command precede on mechanical operation described later.
Operation CONTROL FUNCTION Electric flow control • Positive flow control • Total horsepower control Emergency mode control • Hydraulic positive control • Hydraulic total horsepower control
POSITIVE FLOW CONTROL SUMMARY The regulator KR3G-YTOK for the in-line type axial piston pump K3V series is composed of the control mechanism as mentioned below:
As shown beside, the delivery rate Q of the pumps is controlled by the input current I (pilot pressure Pi).
Q
Electric flow control and positive flow control The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control (positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to attain optimum power according to the operating condition. Also, since the pump delivers only the necessary oil flow, the machine does not consume excessive power. Constant power control at emergency mode When the electromagnetic proportional pressurereducing valve cannot output the secondary pressure due to the trouble, the spool for emergency mode is switched automatically, and the control is switched from electric control to hydraulic control (emergency mode). In emergency mode, the power shift command pressure Pf shifts the power set value. The power shift pressure (secondary pressure of electromagnetic proportional pressure-reducing valve) is led to power control section of regulator on each pump through pump inside passage and shifts respective control to the same power set value. In the power shifted condition, as self pump delivery pressure Pd1 rises, the pump tilt angle (delivery rate) is automatically reduced; consequently the input torque is controlled to the constant value or less. (When the speed is constant, the input power is also constant.) This pump is controlled by Pd1 only regardless of another delivery pressure. Condition where the power is controlled, the regulator of each pump is controlled to the different tilt angle (delivery rate). Consequently in the condition where the power is controlled, the overloading of engine is automatically prevented regardless of the loading of pump 2. And in normal
T3-1-11
I
SM0250
E215B-E245B
HYDRAULIC PUMP ASSY
Flow rate increase As the command current value I rises, the secondary pressure P2 of electromagnetic proportional pressure-reducing valve rises, and by pressing pilot piston (643) in (A) direction it stops at the position the secondary pressure P2 balances the pilot spring force (646). The movement of pilot piston is transferred to lever 2 (613) through pin (875), and rotates at (B) fulcrum in arrow direction. Furthermore the lever 2 movement is transferred to feedback lever (611) through pin (897) and rotates at (C) fulcrum in the same arrow direction as (B). Consequently the spool (652) connected to feedback lever moves towards (D). When the spool moves towards (D), the port CL connected to tank port is open and the pressure in servo piston large bore diameter chamber is released, consequently the servo piston (532) moves towards (E) according to delivery pressure Pd1 in small bore diameter piston chamber, resulting in the rise of flow rate. Since the feed back lever is connected to the servo piston and spool, the feed back lever rotates at (F) fulcrums with the movement of the servo piston towards (E), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.
CL
652 B 876
D
F 897
875 611 643
A C 532
E
Psv A
Pd1
CL a3 B
T3-1-12
646 613
SM0895
HYDRAULIC PUMP ASSY
E215B-E245B
Flow rate decrease As the command current value I is reduced, the secondary pressure P2 of electromagnetic proportional pressure-reducing valve is reduced, and by pressing pilot piston (643) in (G) direction it stops at the position the pilot spring force (646) balances the secondary pressure P2. The movement of pilot piston is transferred to lever 2 (613) through pin (875), and rotates at (H) fulcrum in arrow direction. Furthermore the lever 2 movement is transferred to feedback lever (611) through pin (897) and rotates at (I) fulcrum in the same arrow direction as (H). Consequently the spool (652) connected to the feedback lever moves towards (J). When the spool moves towards (J), the delivery pressure Pd1 is led in servo piston large bore diameter chamber through spool and port CL. The servo piston small bore diameter chamber constantly receives delivery the pressure Pd1, consequently the servo piston moves towards (K) according to the difference of area resulting in the reduction of tilt angle, and finally the flow rate is reduced. Since the feed back lever is connected to servo piston and spool, the feed back lever rotates at (L) fulcrum with the movement of servo piston towards (K), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.
T3-1-13
613 CL
652
G 646 H 876
J
L 897
875 611 643
I
K
532 Psv A
Pd1
CL a3 B
SM0896
E215B-E245B
HYDRAULIC PUMP ASSY
POWER CONTROL (IN EMERGENCY MODE) When the load pressure rises, the pump tilt angle is reduced preventing the overloading of engine. The operation of power control is the same as the flow rate control, and is explained below.
Q
Overload prevention operation Because the delivery pressure Pd1 acts on the compensating rod stepped section with the rise of self pump delivery pressure Pd1 the compensating rod (623) is pushed towards (M), and moves to the position the delivery pressure Pd1 balances the spring force of outer spring (625) and inner spring (626). The movement of compensating rod is transferred to lever 1 (612) through pin (875), and rotates at (N) fulcrum in arrow direction. Furthermore the lever 1 (612) movement is transferred to feedback lever (611) through pin (897) and rotates at (O) fulcrum in the same arrow direction as (N). Consequently the spool (652) connected with feedback lever moves towards (P). When the spool moves towards (P), the delivery pressure Pd1 is led in servo piston large bore diameter chamber through spool and CL port. Since the delivery pressure Pd1 is constantly led to servo piston large bore diameter chamber, the servo piston moves towards (Q) according to the difference of area, resulting in the reduction of tilt angle, consequently the flow rate is also reduced. Since the feed back lever is connected with servo piston and spool, the feed back lever rotates at (R) fulcrum with the movement of the servo piston towards (Q), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.
Pd1
SM0897
625 897 896 R N 612 626 CL
G
652 H P
646
875 623 611
M
621 O
Q
532
Psv A
Pd1 CL a3 B
T3-1-14
SM0898
HYDRAULIC PUMP ASSY
E215B-E245B
Flow rate recovery operation Because the compensating rod (623) is pushed towards (S) with the force of outer spring (625) and inner spring (626) with reduction of self pump delivery pressure Pd1, and moves to the position the spring force of outer spring (625) and inner spring (626) balances the delivery pressure Pd1. The movement of compensating rod is transferred to lever 1 (612) through pin (875), and rotates at (T) fulcrum in arrow direction. Furthermore the lever 1 (612) movement is transferred to feedback lever (611) through pin (897) and rotates at (T) fulcrum in the same arrow direction as (N). Consequently the spool (652) connected to feedback lever moves towards (V). As the spool moves towards (V), CL port is open and connected to tank port, the pressure of servo piston large bore diameter chamber is released and the servo piston (532) moves towards (W) with delivery pressure Pd1 in small bore diameter chamber, and consequently the flow rate is raised. Since the feed back lever is connected to servo piston and spool, the feed back lever rotates at (X) fulcrum with the movement of the servo piston towards (W), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.
625 897 876 612 626 X T
S
CL
G
652 H J 875
V
623 611
621 U
W
532
Psv A
CL
Pd1
a3 B
Priority mechanism of low tilt angle (low flow rate) command As the said explanation, the tilting commands of flow rate control and power control are transferred to feedback lever (611) and spool (652) through the large bore section of lever 1 (612) and lever 2 (613), but because the pin (dia 5) is extruded in large bore (dia 9), pin (897) on the side where making tilt angle smaller contacts with it, consequently the bore (dia 9) of lever on the side where larger tilt angle command is given is free without contact with pin (897). In this mechanical selecting manner, the command on the side of low tilt angle of the flow rate control and power control has a priority.
T3-1-15
SM0899
E215B-E245B
HYDRAULIC PUMP ASSY
Power shift control The pump set power is controlled according to the movement of control by power shift pressure Pf. As power pressure Pf rises, the compensating rod (623) moves rightward through pin (898) and compensating piston (621). Consequently like the overloading prevention operation of power control, the pump tilt angle becomes smaller and the power setting value is reduced. Conversely, if the power shift pressure Pf is reduced, the power set value is raised. The power shift pressure Pf of this pump is ordinary set to 0 MPa, but in emergency mode, the power shift pressure Pf is raised to 4.9 MPa.
Q
Pd1
Adjusting the regulator The regulator may be adjusted in terms of maximum flow, minimum flow, horsepower (at back-up control) control characteristics, flow control characteristics using the adjust screw.
SM0900
Q
ADJUSTING THE MAXIMUM FLOW (See HYDRAULIC PUMP-construction) Adjust the maximum flow by loosening nut (808) and by tightening set screw (954) (or loosening it). Tightening set screw (954) decreases the delivery rate, as indicated. Only the maximum flow varies, but other control characteristics remain unchanged. Adjust screw No
954
No. of turns for tightening
1/4
Pilot pressure Pi (Input current I) Min. increase in delivery flow L/min
I (Pi) Q
No change 5.8
ADJUSTING THE MINIMUM FLOW (See HYDRAULIC PUMP-construction) Adjust the minimum flow by loosening nut (806) and by tightening socket screw (953) (or loosening it). Tightening socket screw increases the delivery rate, as indicated. Other control characteristics remain unchanged in the same way as maximum flow adjustment, care should be used of the fact that overtightening may increase a required power at the maximum delivery pressure (at relieving action). Adjust screw No No. of turns for tightening Pilot pressure Pi (Input current I) Min. increase in delivery flow L/min
953 1/4 No change 4.6
T3-1-16
I (Pi)
SM0996
HYDRAULIC PUMP ASSY
E215B-E245B
ADJUSTING THE INPUT HORSEPOWER (AT BACK-UP CONTROL) Since the regulator is of total horsepower control type, turn the adjust screws of both the front (No. 1) and rear (No. 2) pumps when changing horsepower set values. Adjust the horsepower settings of both pumps to a same level. The pressure change values by adjustment are based on two pumps pressurized at the same time, and the values will by halved when only one pump is loaded.
Q
Adjusting the Outer Spring (See REGULATORConstruction) (At emergency mode) Adjust it by loosening lock nut (630) and by tightening adjust screw (628) (or loosening it). Tightening the adjust screw shifts the control chart to the right and increases the input horsepower, as indicated. Since turning the adjust screw C (628) by N turns changes the setting of the inner spring (626), return the adjust screw C (627) by Nx1.48 turns at first. Adjust screw No.
1/4
Increase in delivery pressure MPa
2.06 50
Adjusting the Inner Spring (See REGULATORConstruction) (At emergency mode) Adjust it by loosening nut (802) and by adjust screw C (627) (or loosening it). Tightening the adjust screw increases the flow and then the input horsepower, as indicated. And the input torque raises. Adjust screw No.
627
No. of turns for tightening
1/4
Increase in flow L/min
12
Increase in input torque Nm
Pd1
628
No. of turns for tightening Increase in input torque
Q
58.7
T3-1-17
Pd1 SM0997
E215B-E245B ADJUSTING THE CHARACTERISTICS Construction)
HYDRAULIC PUMP ASSY FLOW CONTROL (See REGULATOR-
Adjust them by loosening nut (801) and socket bolt (924) (or loosening it). Socket bolt causes the control chart to move to the right as shown. Socket bolt raises the flow control start pilot pressure. And the delivery rate increases. Adjust screw No
924
No. of turns for tightening
1/4
Increase Pilot pressure Pi MPa
0.13
Decrease in delivery flow L/min
18.5
Causes of fault resulting from regulator
I (Pi)
When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter W2-2". WHEN THE ENGINE IS OVERLOADED Load every unit of pump, and check on pumps on the right and left sides for possible damages. When pumps on both sides are failed, check on them for the following failures 1), 2). When pump on the one side is failed, start checking from para. 3). 1.
Check that the power shift command current I is normal.
2.
The power shift pressure is low. • Check the dither of amp. • Replace solenoid proportional valve.
3.
Stick of compensating compensating rod • Disassemble and clean it.
4.
Stick of pin • Disassemble and clean it.
reducing
piston
and
THE MAX. FLOW RATE IS NOT DELIVERED 1.
Check that pilot differential pressure Pi is normal.
2.
Stick of pilot piston • Disassemble and clean it.
3.
Stick of spool • Disassemble and clean it.
NOTE: when the damage of part is severe, replace the part with new one.
T3-1-18
SM0998
HYDRAULIC PUMP ASSY
E215B-E245B
CONTROL CURVE OF PUMP
250
Q
2000min-1: (H mode) 1800min-1: (S mode)
200
[2]
[1]
150 Q [ L/min ]
[3]
100
50
Q (2000min-1)
0
5
10
15
20
250 718mA 220L
25
30
35
40 Pd [MPa]
[4] 91kW : At emergency mode
[1] 99 kW H mode at traveling or optional working [2] 83 kW H mode at operating attachment [3] 75 kW S mode at operating attachment
T3-1-19
Input revolution ;2000 min-1 Input horse power ;114 kW Input torque ;544 N.m
SM0999
E215B-E245B
HYDRAULIC PUMP ASSY
NOTE:
T3-1-20
PILOT VALVE
E215B-E245B
PILOT VALVE (ATT) OUTLINE 5-PF3/8 T=49.0 (36.1)
Single operating angle Single operating angle (Port 2, 4) (Port 1, 3) The adjust nut (opposing flats : 22) : Fix adjust nut (opposing flats : 22) when the lever is installed by means of spanner or the like. Then tighten the mating lock nut to 41 + 3 N.m (302.2 lbf.ft).
PF1/4 T=29.4 (21.7)
VIEW A
T=Tightening torque : N.m (lbf.ft)
PV48K2004
Model
Refer to the curve below
Operating torque
6.9 MPa (1000 psi)
Max. primary pressure
5.0 MPa (725 psi)
Primary pressure
20 L/min (5.3gal/min)
Rated flow
Approx. 1.9 kg (4.2 lbs)
Weight
A
PORT 1, 3
PORT 2, 4
3.0(2.2)
SINGLE OPERATING TORQUE
2.21(1.63)
(290)2.0
2.0(1.5)
SECONDARY PRESSURE
(145)1.0
1.0(0.74) 0.94(0.69)
(87)0.6
0
1.17 (0.86) 0.98 (0.72)
0 1.1 2 4 6 7 PUSH ROD STROKE (mm) 0
0
(464)3.2
(435)3.0
2.29(1.69)
2.0(1.5)
SECONDARY PRESSURE
(145)1.0
1.0(0.74)
(87)0.6
0
1.17 (0.86) 0.98 (0.72)
0
0 P
3.0(2.2)
SINGLE OPERATING TORQUE
(290)2.0
5 10 15 19 Operating angle (deg.)
1
4.0(3.0) Operation torque [N.m (lbf.ft)]
(464)3.2
(435)3.0
(580)4.0 Secondary pressure [MPa (psi)]
4.0(3.0) Operation torque [N.m (lbf.ft)]
Secondary pressure [MPa (psi)]
(580)4.0
1.1
2 4 6 8 PUSH ROD STROKE (mm) 5 10 15 20 Operating angle (deg.)
0.94(0.69)
9.4
0
25
T
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
PORT 2,4
PORT 1,3 SM0592
No.
Parts
101
Casing
151
Q.ty
Tightening torque Nm (lbf•ft)
No.
1
216-2
Parts Spring seat
Q.ty 2
Plate
1
**217
Washer 2 (Shim)
4
201-1 Spool
2
221
Spring
4
201-2 Spool
2
241-1
Spring
2
4
241-2
Spring
2
***301 Joint: M14
211
Plug
*212
Push rod
4
213
Seal
4
214
O-ring: 1B P20
216-1 Spring seat
4 2
302
Circular plate
****312 Adjust nut: M14 501
Boots
Note: * apply grease on top section; ** secondary pressure adjusting shim *** apply grease on rotating and sliding sections. Be careful the assembling drirection **** apply Loctite #277
T3-2-2
Tightening torque Nm (lbf•ft)
1
47.1 (34.7)
1 1 1
68.6 (50.6)
PILOT VALVE
E215B-E245B
OPERATION 1.
Lever in neutral (See Fig.SM0593) The action of spring (509) (for secondary pressure setting) that determines the output pressure of the pilot valve does not act upon spool (201). Therefore, spool (201) (for return) is pushed up by spring (221) [spring seat (216)]. The output ports (2, 4) connect with the T port. The result is that the output pressure is equal to the tank pressure.
216 509 221 201 PORT (2,4)
2.
When the pilot lever is tilted (See Fig.SM0594) When the lever is tilted and the push rod (511) strokes, the spool (201) [spring seat (216)] moves downward to make the port P to connect with the port 2, 4, with the result that the oil of the pilot pump flows to the port 2 ,4 to produce a pressure.
PORT (1,3)
SM0593
511
216
201 PORT (2,4)
PORT (1,3) SM0594
3.
Lever held (See Fig.SM0595) When the pressure at ports (2, 4) rises to a level equivalent to the action of spring (509) that is set by tilting the lever, the hydraulic pressure balances the spring action. When the pressure of ports (2, 4) rises above a set value, ports (2, 4) and the P port close while ports (2, 4) and the T port open. When the pressure at ports (2, 4) falls below a set value, ports (2, 4) and the P port open while ports (2, 4) and the T port close. Thus the secondary pressure is kept constant.
509
T PORT P PORT
PORT (2,4)
T3-2-3
PORT (1,3)
SM0595
E215B-E245B 4.
PILOT VALVE
Operation in the area where the tilting angle of the lever is large. (varies with the model) If the lever is inclined beyond a certain angle on certain models, the top end of the spool contacts the bottom of the bore of the push rod. This keeps the output pressure connected with the P port pressure. Furthermore, on a model in which a spring seat and a spring are built in the push rod, the bottom of the bore of the push rod contacts the spring if the lever is turned beyond a certain angle. This causes the secondary pressure gradient to change by the spring action. Thereafter, the bottom of the bore of the push rod contacts the top end of the spring seat, keeping the output pressure connected with the P port.
T3-2-4
PILOT VALVE
E215B-E245B
PILOT VALVE (TRAVEL) OUTLINE Outside view
Port size
Tightening torque Port name N.m (lbf.ft)
PF3/8
PF1/4
30 (22)
Function
1
LH travel forward port
2
LH travel reverse port
3
RH travel forward port
4
RH travel reverse port
T
Tank port
5
LH travel pressure sensor port
6
RH travel pressure sensor port
P
Pilot primary pressure port
16.7 (12.3)
SM0596
Specifications P
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 Hydraulic symbol
Performance characteristics Secondary pressure [MPa (psi)]
Secondary pressure
2.35 + 0.15 (340 + 22) 0.54 + 0.1 (78 + 15) 0 (4.7 + 0.5) 6.4 + 0.64 7.7 + 0.77 (5.7 + 0.6) 12.7 + 1.27 (9.4 + 0.9)
Operating torque
[N.m (lbf.ft)]
1 30' 2 30'
11 30' 12 30'
Pedal angle (degree)
Operating torque Control diagram
SM0598
T3-2-5
T
6
4 SM0597
E215B-E245B
PILOT VALVE
CONSTRUCTION AND OPERATION 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)
1
5 3 8
3 11
10 12
4 10 2 9
9 7
6
2 control ports 1-3
P line
control ports 2-4 T line SM0599
T3-2-6
CONTROL VALVE
E215B-E245B
CONTROL VALVE CONTROL VALVE OUTSIDE VIEW (1/2) PBa2
PAo PAa2
PBp1 PBp2 PBp1 PBp2
Arm 2 Bucket Boom
(P4)
(P3)
Travel right Travel priority
PAa2
Option
PBo PBo PAc
PAa1
Arm 1 PAa
PAb
Swing PCa
PBr
P2 unload (T3)
PTb
PBL
Travel left
PBo
VIEW A
A
CT1 T2 PAL
PCb USE FOR YN30V00101 F1
PAr
XAb
PB1 PBs
PBb PCc
PTb
P1 unload Travel priority PBr PAb
PL CMR1 CMR2 Br 1
Bb (ROD)
PBa1 Pss
PAc
Ac
CP1
MU
PBa2
PAo
PAa2
Ab (HEAD)
LCb CRb Bc
(HEAD)
PCb
Ar
(ROD)
LCc PCAP2 LCAT2
Travel right Boom PBc
PAr PBb PC
Bucket Arm 2
PBa2
PBp1 PBp2 (P3)
(P2)
T3-3-1
SM0824
E215B-E245B
CONTROL VALVE
CONTROL VALVE OUTSIDE VIEW (2/2) PTb
PBL
CT2
P2
CP2 CT1 P1
PAL
Pcb
T1
PAL
PBs
Travel left
AL CP2
Boom conflux As
Swing
PAo
Arm 1
PLc2
CRa Ba
Option
(ROD) Ao
LCs
P2 unload PCa
Aa (HEAD)
Bo
PCa
PAr
PB1 PBs
PAs
PBb PCc
PBa1 Pss
PAa1
LCa LCo
PAL
PCb
PBL
Bs
CCb
Pss PBa1
BL
USE FOR YN30V00101 F1
PB1
T2 CT2
PBo
MU
PBa2
PAo
PBp1 PBp2 (P2) SM0825
T3-3-2
CONTROL VALVE
E215B-E245B
CONTROL VALVE PORTS Port size
Tightening torque
Ports
PF3/4
150~180 N•m (111~133 lbf•ft)
MU (T3)
PF1/2 PF3/8
PF1/4
98~120 N•m (72~89 lbf•ft) 69~78 N•m (51~58 lbf•ft)
34~39 N•m (25~29 lbf•ft)
83~110N•m (61~81 lbf•ft)
Pluged
(P3)
Pluged
(P4)
Pluged
PAa1
Arm 1 (in) pilot port
PBa1
Arm 1 (out) pilot port
PAb
Boom (up) pilot port
PBb
Boom (down) pilot port
PAc
Bucket (digging) pilot port
PBc
Bucket (dump) pilot port
PAL
Travel left (forward) pilot port
PBL
Travel left (reverse) pilot port
PAr
Travel right (forward) pilot port
PBr
Travel right (reverse) pilot port
PAs
Swing (right) pilot port
PBs
Swing (left) pilot port
PAa2
Arm 2 (in) pilot port
PBa2
Arm 2 (out) pilot port
PAo
Option pilot port
PBo
Option pilot port
DR
Drain port
Pss
Swing pilot high pressure select port
PLc2
Lock valve select pilot port
PBp1
Bypass cut valve (P1 side) pilot port
PBp2
Bypass cut valve (P2 side) pilot port
PL
M12
Description
Attachment boost port
PB1
Boom (up) conflux pilot port
PTb
Travel priority pilot port
PCa
Unload valve (P2 side) pilot port
PCb
Unload valve (P1 side) pilot port
PCc
Bucket (digging) stroke limiter pilot port
P1
Pump port (P1 side)
P2
Pump port (P2 side)
T1
Tank port 1
T2
Tank port 2
T3-3-3
E215B-E245B
CONTROL VALVE
Port size
Tightening torque
Ports
M12
83~110N•m (61~81 lbf•ft)
P1
Pump port (P1 side)
P2
Pump port (P2 side)
T1
Tank port 1
T2
Tank port 2
Ar
Right travel motor port (forward)
Br
Right travel motor port (reverse)
AL
Left travel motor port (forward)
M10
49~65 N•m (36~48 lbf•ft)
Description
BL
Left travel motor port (reverse)
As
Swing motor port (right)
Bs
Swing motor port (left)
Ab
Boom cylinder head side port (up)
Bb
Boom cylinder rod side port (down)
Aa
Arm cylinder head side port (in)
Ba
Arm cylinder rod side port (out)
Ac
Bucket cylinder head side port (digging)
Bc
Bucket cylinder rod side port (dump)
Ao
Optional pilot port
Bo
Optional pilot port
SPECIFICATIONS Item Model
Specifications 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)] When power boost pressure
Std 34.3 (4970) [at 70×2L/min (18.5×2gal/min)] 37.8 (5480) [at 60×2L/min (15.9×2gal/min)]
Overload relief valve set pressure (Boom head, Bucket head, Arm rod) [MPa (psi)]
39.7 (5760) [at 30L/min (8gal/min)]
Overload relief valve set pressure (Boom rod, Bucket rod, Arm head) [MPa (psi)]
37.8 (5480) [at 30L/min (8gal/min)]
T3-3-4
CONTROL VALVE
E215B-E245B
CONSTRUCTION AND OPERATION Construction Control valve (1/6) PBa2
PAo
PBp1 PBp2 PBp1 PBp2
(P4) (P4)
(P3) (P3)
PAa2
PBo
A
B
273x10
T2
H P1 unload
PCb
(Travel priotity)
Travel right
USE FOR YN30V00101F1
C
PAL
H
Travel left
PAr
PB1
D
Boom conflux (P2 unload)
C
D
PBs
Boom
Swing
E
PBb
PCc
E
Pss
PBa1
Bucket
Arm 1
F
F
PAo PA
PBa2
Arm 2
273x10
Option
MU
G
G K
PBp1
PBp2
K
(P3)
B
A
T3-3-5
SM0826
E215B-E245B
CONTROL VALVE
Control valve (2/6)
J 164
154
101 P2
T2
T1
JJ
PBL
YT1
PAL
PAs
YS1
PBs
PCa
P2-20
YBG1
PB1
Pss PAa1
YA1
PBa1
PBo
YP1
PAo
SECTION A-A
(P4)
163
162 163 169
155 162
154
164
P1
102
973
973 PCb
P1-20
PTb
973
973 YT1
PAr
YB1
PBr
PBb
973 PAb
973
973
PBc PCc YK1
PAc
974
973 PBa2
YAG 1
PAa2
974 (P3) SM0532
162
162
169
155
T3-3-6
163
162
SECTION B-B
CONTROL VALVE
E215B-E245B
Control valve (3/6) 202 333 331 336 329 327
P1 unload
Travel left
PCb
201 333 331
PAL
336
601 331 261 309
324
MR
323 PL
159
AL
512
511 521
522 CP2
552 562 562
551 164 162
CMR2
CMR1
BL
552 522 512 307 261 331 327 329 336 331 333 202 201 333 331 336 324 323
163
264 205
PBL
SECTION C-C
PTb
Travel priority
Travel right
Boom conflux
PAr
202 333 331
PB1
339 326 325 331 261
331 261 306 161 163 511 521 551 164 163 161
331 261 306 163 162
CCb Ar
CP1
511 521 551 164 305 551 164
Br
310 164 (T3)
264
PBr
205 SECTION D-D
SM0533
PCa
P2 unload
T3-3-7
154 261 331 327 329 336 331 333 202
E215B-E245B
CONTROL VALVE
Control valve (4/6) Swing 203 333 331 603 211 279 x 3 331 215
Boom
AbR
XAb
204
PBs
336
333 Pss
331
322 321
336 322
266
321
261
331 261 303
160 514 524 556 164 511 521 551 164
161 As
CRb
162 163 511 523
Ab
LCs
LCb
Bb
556 164 162
Bs
161 301 264 602
266 264 206
PAb
205
160
BbR
PAs
SECTION E-E
551 164 209 216 333 331 336 322 321 602
Bucket PCc
Arm 1 PBa1
PBc BaR BcR
331 261 304
CRar
Bc
511 521 551 164
Ba LCc
LCa
201 333 331 336 322 321 603 171 331 261 211 160 514 524 556 164 511 521 551 164
Ac
162
Aa
302 161 264
264 603 205
PAc AcR
PAa1
SECTION F-F
T3-3-8
AaR
205 605
SM0534
CONTROL VALVE
E215B-E245B
Control valve (5/6)
Arm 2
201 333 331 340 328 321
PBa2
Option
201
PAo
333 331 336 324
331 261
AoR
308
323 604 331
MU
162 162 162 511 521 551 164 515 521
261 311 Ao
511 521
LCAT2 LCo
551 164
LCAP2
551 164
Bo
162 161
604
BoR
264 PAa2
205
264
PBo
205
SECTION G-G
T2
161 P1
511
T1
521 CT1
163 163
551
162 511
164
P2
521 CT2
551 164 SECTION H-H
T3-3-9
SM0535
E215B-E245B
CONTROL VALVE
Control valve (6/6) 207
266
160 278 x 5
264
264 528 527
T2 517
T1
518
SECTION J-J
PBp1
PBp2
606 606
163
SM0536
SECTION K-K
T3-3-10
CONTROL VALVE
Tightening torque N•m (lbf•ft)
No.
Parts Name
Q.ty
Tightening torque N•m (lbf•ft)
E215B-E245B
No.
Parts Name
Q.ty
101 Casing A
1
321 Spring
102 Casing B
1
322 Spring
4
3
323 Spring
3
220~250 (162~184) 154 Plug PF3/4
5
110~130 (81~96)
155 Plug PF1/2
2
324 Spring
3
20~24 (15~18)
159 Plug PT1/4
1
325 Spring
1
7.8~9.8
160 Plug PT1/16
5
326 Spring
1
161 O-ring
7
327 Spring
3
162 O-ring
15
328 Spring
1
163 O-ring
11
329 Spring
3
164 O-ring
19
331 Spring seat
24
333 Spacer bolt
12
169 O-ring 9.8~14 (7.2~13)
2
171 Socket bolt
336 Stopper
10
201 Cover
5
339 Stopper
1
202 Cover
4
340 Stopper
1
203 Cover
1
511 Poppet
11
204 Cover
1
205 Cover
7
512 Poppet
2
1
514 Poppet
2
1
515 Poppet
1
209 Cover
1
517 Boost check valve
1
211 Lock valve selector sub
2
518 Poppet
1
212 Plate
1
521 Spring
11
206 Cover Back pressure 207 valve cover 9.8~14 (7.2~13)
16~18 Loctite #262
check
213 Plate
1
522 Spring
2
215 Boom dowering valve
1
523 Spring
1
216 Piston
1
524 Spring
2
261 O-ring
12
527 Spring
1
264 O-ring
10
266 O-ring
4
528 Spring
1
25~34 (18~25)
273 Socket bolt
40
98~120 (72~89)
274 Socket bolt
4
98~120 (72~89
275 Socket bolt
4
25~34 (18~25)
278 Socket bolt
5
9.8~14 (7.2~13)
279 Socket bolt
3
301 Boom spool sub
1
302 Arm 1 spool 303 Swing spool
230~260 (170~192) 551 Plug 130~150 (96~111)
13
552 Plug
2
230~260 (170~192) 556 Plug
3
562 O-ring
2
69~78 (51~58)
601 Main relief valve
1
1
69~78 (51~58)
602 Over load relief valve
2
1
69~78 (51~58)
603 Over load relief valve
3
304 Bucket spool
1
69~78 (51~58)
604
305 Boom conflux spool
1
69~78 (51~58)
605 Over load relief valve
1
306 Travel spool
2
98~120 (72~89)
606 By-pass cut valve
2
307 Travel priority spool
1
140~180 (103~133) 973 Socket bolt
8
308 Arm 2 spool sub
1
140~180 (103~133) 974 Socket bolt
2
309 P1 unload spool
1
310 P2 unload spool
1
311 Option spool
1
T3-3-11
Plug assy for relief valve hole
2
E215B-E245B
CONTROL VALVE
Main relief valve (601)
123
512
124
125
521
561
541
121
562
122
611
103
663
621
664
104
163
661
614
673
613
652
671 SM0827
Main relief valve (Two step relief) Tightening torque N•m (lbf•ft)
No.
69~78 (51~58)
103
Plug; M27
1
562
Back up ring
1
104
Adjust screw
1
611
Poppet
1
121
C-ring
1
613
Stopper
1
122
Spacer
1
614
Piston
1
123
C-ring
1
621
Spring
1
124
Filter stopper
1
652
Adjust screw
1
125
Filter
1
661
O-ring
1
163
O-ring
1
663
O-ring
1
512
Plunger
1
664
O-ring
1
521
Spring
1
28~31 (21~23)
671
Lock nut; M14
1
541
Seat
1
46~52 (34~38)
673
Lock nut; M24
1
561
O-ring
1
Parts
Q’ty
Tightening torque N•m (lbf•ft)
T3-3-12
No.
Parts
Q’ty
1
CONTROL VALVE
E215B-E245B
Over load relief valve (602, 603, 605)
301
564
563
511
521 123
124
161
562
125
522
611
561
101
621
671
102
541
162
661 612
651 SM0828
Over load relief valve Tightening torque N•m (lbf•ft)
No.
69~78 (51~58)
101
Body; M27
1
541
Seat
1
69~78 (51~58)
102
Plug; M27
1
561
O-ring
1
161
O-ring
1
562
Backup ring
1
162
O-ring
1
563
O-ring
1
123
C-ring
1
564
Backup ring
1
124
Filter stopper
1
611
Poppet
1
125
Filter
1
612
Spring seat
1
301
Piston
1
621
Spring
1
511
Plunger
1
651
Adjust screw
1
521
Spring
1
661
O-ring
1
522
Spring
1
671
Lock nut; M14
1
Parts
Q’ty
Tightening torque N•m (lbf•ft)
28~31 (21~23)
T3-3-13
No.
Parts
Q’ty
E215B-E245B
CONTROL VALVE
Arm 2 spool (308)
351
371
361
340 319
308
317
340
361
371
350 SM0829
Arm 2 spool Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
308
Spool
1
16~18 (33~35) Loctite #638
350
Plug
1
317
Plunger
1
16~18 (33~35) Loctite #638
351
Plug
1
319
Plunger
1
361
O-ring
2
340
Spring
2
371
Backup ring
2
Boom spool (301)
301
317
340
361
371
350 SM0830
Boom spool Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
16~18 (12~13) Loctite #638
350
Plug
1
Parts
Q’ty
301
Spool
1
317
Plunger
1
361
O-ring
1
340
Spring
1
371
Buckup ring
1
T3-3-14
CONTROL VALVE
E215B-E245B
Lock valve selector (211)
101 164
171
201
321
PLc
166
A
541
B
Dr
167
511
161 SM0831
Lock valve selector Tightening torque N•m (lbf•ft)
Q’ty
Tightening torque N•m (lbf•ft)
No.
Casing
1
10~14 (7.4~10.3)
171
Socket bolt
3
161
O-ring
4
49~59 (36~44)
201
Plug
1
164
O-ring
1
321
Spring
1
166
O-ring
1
511
Spool
1
167
O-ring
1
541
Sleeve
1
No. 101
Parts
T3-3-15
Parts
Q’ty
E215B-E245B
CONTROL VALVE
Bypass cut valve (606)
302
301
402
401
Pi
P
T
Dr
201
202
101
102
SM0832
Bypass cut valve Tightening torque N•m (lbf•ft) 98~120 (72~89)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
101
Plug
1
301
Plunger
1
102
O-ring
1
302
Spring
1
201
Poppet
1
401
Plug
1
202
Spring
1
402
O-ring
1
69~78 (51~58)
T3-3-16
CONTROL VALVE
E215B-E245B
Swing shuttle valve cover (204)
PBs
555
Pss
SECTION B-B
A 166
542
541
PBs
A
G1/4
G3/8
B
B Pss
554
202
PAs
SECTION A-A
SM0833
Swing shuttle valve cover Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
166
O-ring
1
542
Seat
1
202
Cover
1
25~29 (18~21)
554
Plug
1
541
Steel ball
1
7.9~9.8 (5.9~7.2)
555
Plug
1
T3-3-17
E215B-E245B
CONTROL VALVE
Boost check valve (517)
104
107
102
101 SM0834
Boost check valve Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
20~29 (15~21) Loctite #262
104
Plug
1
107
Spring
1
101
Poppet
1
102
Poppet
1
T3-3-18
Parts
Q’ty
CONTROL VALVE
E215B-E245B
HYDRAULIC CIRCUIT DIAGRAM
1 2
12
3
11 10 9
4
8
5
6
7
SM0835
123456-
Travel priority P1 Unload Travel right Boom Bucket Arm 2
789101112-
T3-3-19
Option Arm 1 Swing P2 Unload Boom conflux Travel left
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) Pss
606
517
52
306 YP1
YS1
YA1
YT1
YBG1
T1
P2
P1 P1-20
YT1
YB1
YK1
YAG1
P2-20
309 55
310
606 (*)
(D)
SM0836
In neutral position (*) Connected to low pressure circuit of P2 side casing
T3-3-20
CONTROL VALVE 2.
E215B-E245B
Actuation in travel operation a) In travel independent operation On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed into travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left motor. The pilot pressure enters ports PAr and PAL, and the right and left travel spools (306) move rightward the force of springs (323) (324) and the secondary pressure of solenoid proportional valves [X1] and [X2] acts on ports PCb and PCa and switches unloading spools (309) (310). The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows into main circuit, and flows through between the perimeter of right travel spool (306) and casing and is fed into A side of right travel motor through port AR. The hydraulic oil delivered by hydraulic pump P2 flows through between the perimeter of left travel spool (306) and casing and is fed into A side of left travel motor through port AL similarly to the stream of hydraulic oil delivered by hydraulic pump P1. But in the meantime, the return oil from the B sides of left and right travel operations passes through between the perimeter of right and left travel spools (306) and casing through ports Br and BL and flows into low pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank through tank port T1. On traveling reverse (at the time when the pilot pressure actuates on ports PBr and PBL of control valve), the actuation is similar to that in forward travel operation. Left travel motor
A
B
AL 324
323
BL CP2
306
PBL
PAL
SM0837
In left reverse travel (at PBL is pressurized)
T3-3-21
E215B-E245B
CONTROL VALVE
b) In travel priority operation When actuator other than travel operation and the travel operation are operated simultaneously in the said item a) "In travel independent operation" the pilot signal from the outside acts on port PTb and the travel straight spool (307) moves upward. With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B and into main passage, and is used for right and left travel operations as hydraulic oil realizing the actuator and travel simultaneous operation. (Travel priority function) At circuit (I) position, a part of hydraulic oil delivered by hydraulic oil P1 passes through circular notch on travel priority spool (307) and enters from P1 to B enabling the hydraulic oil to be supplied from actuator side to travel side. And at circuit (II) position, the circular notch on travel priority spool (307) closes and the pump line on the travel sides is independent from pump line on actuator.
CMR2
P2
B CMR1
CMR2
CMR1
P1
P2
B P1
A
A
307
307
327
327
329
329
PTb
PTb P2 P1
P2 P1 PTb
Dr
PTb
Dr B
Dr
Dr
A B
A SM0838
Circuit (I)
Circuit (II) A - to each actuator B - to travel right Movement of travel priority spool
T3-3-22
CONTROL VALVE 3.
E215B-E245B
Actuation in bucket operation a) In bucket digging operation On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward 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). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac). In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1. And when the flow rate of hydraulic oil delivered by hydraulic pump P1 with engine running in low idling is low, the pilot signal from the outside enters port PCc and piston (216) moves rightward. With this actuation, the maximum leftward stroke of bucket spool (304) is limited, consequently the area of passage between the perimeter of bucket spool (304) and casing minimizes. Consequently the flow rate of return oil from bucket cylinder rod side (R) reduces and bucket cylinder moving speed is limited preventing cavitation which may be occurred on bucket cylinder head side (H). (Stroke limiter ON)
216
53
PAc
PCc
PBc
Bc 322
321
304
(D)
511
(R)
Ac
LCc
(H)
In bucket digging operation (Stroke limiter ON)
T3-3-23
SM0839
E215B-E245B
CONTROL VALVE
b) In bucket dumping operation On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves rightward 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). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder rod side (R) through port (Bc). In the meantime, the return oil from bucket cylinder head side (H) passes through between the perimeter of bucket spool (304) and casing and flows through low pressure circuit (D), and returns to the hydraulic tank through tank port T1. The return oil does not pass through boost check valve (517). Downstream of boost check valve
53
(D*)
216
PAc PCc PBc
Bc 322
321
304
Ac
LCc
511
(R)
(H)
(D*) Downstream of boost check valve In bucket dumping operation
T3-3-24
SM0840
CONTROL VALVE 4.
E215B-E245B
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.
301
(D)
(R)
(R)
(H)
(H)
Bb
514
511
53 LCb
Ab
(A)
321
322
CRb
PAb
PBb
SM0841
(A): BH chamber In boom up operation (Boom spool)
T3-3-25
E215B-E245B
CONTROL VALVE
b) In boom up conflux operation The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter of boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and confluents the hydraulic oil from the hydraulic pump P1 side.
PB1
326
325 511
CCb
(B)
56
305
SM0842
(B): Conflux passage to Ab port of P1 casing
In boom up conflux operation (Boom conflux spool)
T3-3-26
CONTROL VALVE
E215B-E245B
c) In boom down operation On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward against the force of springs (321) (322) and the secondary pressure of solenoid proportional valve [X1] acts on PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is switched, and the poppet (514) is released because the spring chamber of lock valve poppet CRb (514) is connected to the drain circuit. The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and 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 is supplied to boom cylinder rod side (R) through port (Bb). In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab). Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool (301) is released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH chamber and passes through between the perimeter of boom spool (301) and casing, and flows through low pressure circuit (D) and boost check valve (517), and the returns to the hydraulic tank through tank port T1. And a part of the return oil flows into the inside of boom spool (301) through circular notch of boom spool (301). Since the return oil contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes through inside passage of boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and flows through the circular notch, and then supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation function)
301
317
(R)
(R)
(H)
(H)
53 Bb
LCb
Ab
(A)
514
511
321
322
CRb
PBb
PAb
(D) (A): BH Chamber
In boom down operation
T3-3-27
SM0843
E215B-E245B 5.
CONTROL VALVE
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 PAa1
PBa1
P1 (D')
Arm 1 RR
RH
(D')
HH
52
(D')
LCAP2
(D)
P1
PAa2
PBa2 Dr
Dr
Arm 2 PBa2
LCAT2
PAa2
(F)
Ba (ROD)
Aa (HEAD) (G)
53 MU AP2
328
321
308
511
LCAT2 LCAP2
515
(F): To arm 1 spool (G): To pilot cut valve In arm out operation
T3-3-28
SM0844
CONTROL VALVE
E215B-E245B
b) In arm in operation (At light load: arm recirculation function) On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302) moves leftward 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, since the spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet CRar (514) is connected to the drain circuit and the retention of poppet (514) is released. And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308) moves leftward 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). But in light load operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in the position of circuit (I). The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into port (Aa) 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 also the oil from parallel passage (53) 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 from U-shaped passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic oil from hydraulic pump P2 side. The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa). In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR), but because arm 2 spool (308) does not connect to low pressure passage (D) at circuit (I), the entire flow rate flows into arm 1 spool (302). The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing, and flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool (308) passes through check valve (317) and flows into casing inside passage (HH) and the supplied to arm cylinder head side (H) again. (Arm recirculation function) And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319), and flows through boost check valve (517) through load pressure circuit (D) and returns to the hydraulic tank through tank port T1.
T3-3-29
E215B-E245B
CONTROL VALVE
(R) 322
321
211
(AR) 514
(H) 302
511 LCa Ba
CRar
Aa
56
PBa1
PAa1 Arm 1
(D') (D)
RR
Arm 2
HH
RH
52 (a)
PBa2
PAa2
[XR]
53 MU
LCAT2 328
321
308
319
LCAP2
(D) 511
515
317
P1 LCAT2
(D')
LCAP2
(D)
P1 PBa2 Dr
PAa2 Dr
Circuit (I)
(F) Aa (Head)
Ba (Rod) (G)
(F): To arm 1 spool (G): To pilot cut valve
In arm in operation (At light load: arm recirculation function)
T3-3-30
SM0845
CONTROL VALVE
E215B-E245B
c) In arm in operation (In heavy load operation) The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but in heavy load operation (work required large power); the function causes the power loss. This control valve selects the presence of recirculation function in light and heavy load operation with solenoid proportional valve [XR]. (Variable recirculation function) The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the same as that in light load operation, differs from that of return oil. In heavy load operation, solenoid proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low pressure passage (D) at circuit (II), almost all the return oil passes through between the perimeter of arm 2 spool (308) and casing and flows through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through tank port T1. The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head side (H) is higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside passage (HH), but flows through check valve (319) and passes through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through port T1.
322 321 211 (AR) 514
(H)
(R)
302 CRar 511 LCa Ba
Aa
Circuit (II) 56
PBa1
PAa1
P1 (D')
Arm 1
(D)
(D') (D) RR 52
Arm 2
RH
LCAP2 P1 PBa2 Dr
PAa2 Dr
HH
(a)
PAa2 Ba [XR] (Rod)
PBa2 53
MU
LCAT2
(F) Aa(Head)
(G)
LCAT2 LCAP2 328
321
308
319 (D) 511
515
317
(F): To arm 1 spool (G): To pilot cut valve
In arm in operation (In heavy load operation)
T3-3-31
SM0846
E215B-E245B 6.
CONTROL VALVE
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 (D)
As
LCs 56
511 B
(D)
303
321
322
A
Swing motor Swing operation
T3-3-32
SM0847
CONTROL VALVE 7.
E215B-E245B
Spool actuation for operation in option This spool is used to control the attachment in option like Nibbler (Crusher), etc. When the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters ports PAo, and option spool (311) moves against the force of springs (323) (324), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and opens load check valve LCo (511), and flows through between the perimeter of option spool (311) and casing through U-shaped passage and is supplied to actuator for attachment through port (Ao). In the meantime, the return oil from actuator for attachment swing passes through between the perimeter of option spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. The operation where the pilot pressure acts on PBo port is the same as the above. * The oil passage is branched toward the end side of control valve at the mid course from option spool (311) to port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of control valve, this oil passage is used as passage to connect to N&B selector valve.
324
323
604
511
311
LCo
Ao
AoR
Bo
(O) BoR 56 PBo
PAo
(D) Spool actuation for operation in option
T3-3-33
SM0848
E215B-E245B 8.
CONTROL VALVE
Lock valve operation The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R) and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding pressure caused by each cylinder. a) At boom spool neutral position (Arm spool makes the same operation.) When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the left side as shown in the figure. At this position, passages Sa and Sb are connected each other at the inside of bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of lock valve poppet, the holding pressure receiving from boom cylinder head side (H) passes from passage Sa to bushing (541) spool (511) and is connected through passage Sb, consequently the lock valve poppet (514) is kept pressed the lower side as shown in the figure and restricts the leaking to the minimum.
RH
1
514
BH
Sb
Dr
PLc
511
541
2
CRb Ab
(a)
PLc Sa Sb
A
A
(b) Dr
321
SECTION A-A
Sa
321
322
PBb
Dr
301
(D)
1. Return oil from boom cylinder head 2. Lock valve selector
Lock valve operation (At boom spool neutral position)
T3-3-34
SM0849
CONTROL VALVE
E215B-E245B
b) In boom down operation (In arm in operation) Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511) moves rightward as shown in the figure. After the spool (511) was moved, orifice (a) of bushing (541) first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving from boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514). And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR through spring chamber (321). With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of bushing (541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet (514) down as shown in the figure is released. And since lock valve poppet (514) receives holding pressure from boom cylinder head side (H) to the pressure receiving section in ring type which is made up of guide diameter and seat diameter of lock valve poppet (514), lock valve poppet (514) is pushed upward and is open. The said operation, in boom down operation, is performed before making the opening (meter out opening) which is used to return the return oil from the boom cylinder head side of boom spool (301) to the tank open, the operation has no effect on the operability of boom down operation. In case of arm-in operation, the operation is the same.
RH
1
514
BH
Sb
PLc
Dr
541
2
CRb
(a)
Ab
511
(b)
PLc Sa Sb
A
A
321 Dr
SECTION A-A Sa 321
322
PBb
Dr
301
(D)
1. Return oil from boom cylinder head 2. Lock valve selector
Lock valve selector operation (At boom down operation)
T3-3-35
SM0850
E215B-E245B 9.
CONTROL VALVE
By-pass cut valve This by-pass cut valve is located on the most downstream of center by-pass passage (52) on P1 side and center by-pass passage (55) on P2 side. And this by-pass cut valve controls the flow rate of hydraulic oil from each center by-pass passage to low pressure passage (D). a) In normal operation On starting the engine, the secondary pressure of solenoid proportional valves [X1] and [X2] act on pilot ports PBp1 and PBp2 of by-pass cut valve (606). This secondary pressure is the same as that actting on pilot port PCb of P1 unloading spool (309) and pilot port PCa of P2 unloading spool (310). The following explains the by-pass cut valve on P1 side, the operation of by-pass cut valve on P2 side is the same. The secondary pressure of solenoid proportional valve [X1] enters PBp1 and plunger (301) moves downward against the force of spring (302). The taper section at the top end of plunger (301) is seated on the seat of plug (101), shutting off the spring chamber of poppet (201) and spring chamber (b) of plug (101). The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are disconnected, spring chamber (a) of poppet (201) is the same pressure as center by-pass passage (52) and poppet (201) is pushed the seat section of casing shutting off center by-pass passage (52) and low pressure passage (D). Consequently, in normal operation, center by-pass passage (52) is always disconnected from low pressure passage (D) and the hydraulic oil delivered by hydraulic pump P1 does not flow through center by-pass passage (52), but returns to the hydraulic tank through P1 unloading spool (309).
[X1] PBp1
301
302
(C)
(b)
Dr
101
201
(a)
(D) 52
SM0969
By-pass cut valve (In normal operation)
T3-3-36
CONTROL VALVE
E215B-E245B
b) At the time when failure occurred When the electric system is failed and consequently the secondary pressure of solenoid proportional valves [X1] and [X2] is not produced, plunger (301) is moved upward by the force of spring (302). Since the taper section at the top end of plunger (301) is lifted up from the seat section of plug (101), spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other. The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other, the hydraulic oil in spring chamber (a) of poppet (201) passes through from seat section of plug (101) to spring chamber (b) and flows into passage (Dr) through passage (c). Consequently the pressure in spring chamber (a) of poppet (201) lowers, poppet (201) receives the pressure of center by-pass passage (52) and is lifted up against the force of spring (202), and the hydraulic oil from center by-pass passage (52) flows into low pressure passage (D) through poppet (201) of by-pass cut valve (606). Therefore when the electric system is failed, P1 unloading spool (309) is shifted to the neutral position and the passage to low pressure passage (D) is cut off, but because center by-pass passage (52) is connected to low pressure passage (D) through by-pass cut valve (606), the abnormal rise of the pump pressure is prevented.
PBp1
301
302
(C)
(b)
Dr
101
201
(a)
(D)
202
52
SM0970
By-pass cut valve (In condition of failure)
T3-3-37
E215B-E245B
CONTROL VALVE
10. Boost check valve, By-pass check valve a) Boost check valve The boost check valve is located between low pressure passage (D) and tank port T1 and generates boost pressure necessary for the low pressure passage. a. In normal operation The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against the force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the pressure generated by spring (527) is used as the boost pressure for the low pressure passage. But the return oil used for the arm out and bucket dumping operation does not pass through boost check valve (517), but returns from low pressure passage (D’) to hydraulic tank through tank port T1. b. In make up operation When supplying to make up the flow rate through low pressure passage (D) after the swing operation is suspended, if the hydraulic oil quantity in low pressure passage (D) is not enough, the deficient hydraulic oil is made up from hydraulic tank into low pressure passage (D). When the deficient hydraulic oil in low pressure passage (D) is not sufficient, the pressure of low pressure passage (D) is lowered. If the pressure of low pressure passage (D) is lowered to the pressure at tank port T1, poppet (102) housed in boost check valve (517) receives the pressure at tank port T1 on the receiving section in ring type which is made up of guide diameter and seat diameter of poppet (102), and is pushed upward and opens, and the hydraulic oil flows from the hydraulic tank to low pressure passage (D) to make up the deficient flow rate.
527 528 (D')
T2 T1
518
102
517
(D)
1
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
b) By-pass check valve Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass check valve actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure, and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected from possible damage. When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve (518) is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly returns to the hydraulic tank through tank port T2.
527
528 (D') T2
518 T1
102
(D)
517
By-pass check valve operation
T3-3-39
SM0992
E215B-E245B
CONTROL VALVE
11. Emergency manual valve for leaving attachment Needle valve (Emergency manual valve for lowering attachment) is equipped internally between Ab port of boom cylinder head side and boom lock valve. For safety, this valve lowers risen attachment to the ground, if the machine stops with engine trouble. Only in case that the boom is lowering, the pressure in the cylinder of attachment can be released by operating arm or bucket control lever. a) Functional explanation In normal cases, the needle valve was blocked completely to prevent pressure leak of boom circuit. a. Lowering of boom Loosen lock nut at first and loosen the needle valve to the end of contact. IMPORTANT: needle valve is provided the mechanism of stopper against falling out. But the mechanism might cause break by undue force. The oil of boom cylinder (1) head side (H) flows into drain passage (4) through orifice, and boom lowers slowly. The time of boom lowering to the ground takes about 4 to 8 minutes in accordance with machine position and holding pressure b. Function of actuator Oil pressure of XAb port is reduced by releasing holding pressure of boom cylinder head side to drain passage (4) through orifice. Operation of actuator with pilot control valve is possible by leading medium pressure via orifice from XAb port to shuttle valve (7). In this function, this leading of medium pressure ensures primary pressure of remote control (source of pressure). This function ensures that the cylinder movement of boom, arm, bucket and others can be actuated only downward by self weight. Consequently the releasing of pressure becomes possible. But after attachment is lowered to the ground by lowering boom, holding pressure disappears, and remote control, via pilot valve, becomes impossible. c. Boom cylinder with holding valve If the boom cylinder has holding valve, loosen above-mentioned needle valve together with port relief valve of holding valve, and boom cylinder starts boom lowering. Spool of holding valve moves to open side by back pressure of port relief valve, and holding pressure of boom cylinder is led to “Emergency manual valve for lowering attachment”, operation of actuator by pilot valve is possibile.
T3-3-40
CONTROL VALVE
E215B-E245B
Emergency manual valve for lowering attachment operation
(R)
1 (H)
2
Ab
3 4 6 5
XAb
7
8 9 12345-
Boom cylinder head side Control valve Hydraulic oil tank Drain passage Needle valve
SM0993
6789-
T3-3-41
Lock nut Shuttle valve To lever lock solenoid valve To control pilot valve
E215B-E245B
CONTROL VALVE
NOTE:
T3-3-42
SWING DEVICE
E215B-E245B
OUTLINE General view
PB
M
L
THREAD FOR EYE BOLT 2-M10 DEPTH 18
B
RELIEF VALVE (B PORT SIDE)
(SH)
IP PG RELIEF VALVE (A PORT SIDE)
A
DB PA
Symbol
SM0570
Port name
Port size
Tightening torque Nm (lbf•ft)
A, B
Main port
PF 3/4
167 (123)
DB
Drain port
PF 3/8
74 (55)
M
Make-up port
PF 3/4
167 (123)
Pressure measuring port
PF 1/4
36 (27)
Parking brake release port
PF 1/4
36 (27)
L
Gear oil level gauge
PF 1/2
65 (48)
IP
Gear oil filling port
PF 3/4
98 (72)
PA, PB PG
T3-4-1
E215B-E245B
SWING DEVICE
PB
ANTI-REACTION
PA VALVE BLOCK DB
M
A,(B)
PG
IP FILLING PORT PT3/4
Grease fitting
SM0571
PG DB
M
PB
PA
B
A Hydraulic diagram
T3-4-2
SM0572
SWING DEVICE
E215B-E245B
Hydraulic motor
Specification
Antireaction valve block
Model
M5X130CHB–10A–41C/295
Type
Swash-plate type, fixed-displacement plunger motor
Displacement
cm3
129.2
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
Type Mass
Hydraulic motor assy mass
2KAR6P72/240-712 kg
2.5
kg
51.5
Speed reduction type
Planetary 2-stage
Reduction unit
Reduction ratio
Total mass
15.38
Lubicate oil Lubicate oil volume
Gear oil SAE90 (API class GL–4 grade) L
Grease
3.0 Extreme pressure lithium base # 2 grease
Grease volume
kg
Approx. 1.0
Mass
kg
145
kg
Approx. 197
T3-4-3
E215B-E245B
SWING DEVICE
CONSTRUCTION Swing motor
993 VALVE CASING SECTION
702 712
ANTI CAVITATION PLUNGER
Arrangement of brake spring
351 355
051 RELIEF VALVE
469 488
051-1 ANTI-REACTION VALVE BLOCK
401
052 151 303 162 171 161 985
163
712
A
985
444
984
131
451
A
472
390 391 VIEW I
702 707 706 100 980 743 742 111
400-1 400-2
121 994
123 122
114 124 443
491
052
400 SECTION A-A
301
101 SM0573
T3-4-4
SWING DEVICE
E215B-E245B
Tightening
No.
051
Parts
Relief valve; M33-P1,5
051-1 O-ring; 1B G30
Q.ty
2
torque Nm (lbf•ft) 177 (130)
Tightening
No.
400
Parts
Anti-reaction valve; M22-P1.5
Q.ty
2
2
400-1 O-ring; 1B P20
2
400-2 Backup ring
2
torque Nm (lbf•ft) 69 (51)
052
Anti-reaction valve sub
1
100
Casing for anti-reaction valve
1
401
Socket bolt; M20×45
4
101
Drive shaft
1
443
Roller bearing
1
111
Cylinder
1
444
Roller bearing
1
114
Spring plate
1
451
Pin
2
121
Piston
9
469
ROMH plug; M30-P1,5
2
122
Shoe
9
472
O-ring; W1516,WG40
1
123
Set place
1
488
O-ring; 1B P28
2
124
Shoe plate
1
491
Oil seal
1
131
Valve plate
1
702
Brake piston
1
151
Plug; PF1/4
2
706
O-ring; W1516,WG38
1
161
O-ring; 1B P11
2
707
O-ring; W1516,WG41
1
162
O-ring; 1B P12
2
712
Brake spring
18
163
O-ring; 1B P6
2
742
Friction plate
3
171
Socket bolt; M8×55
4
743
Separator plate
4
301
Casing
1
980
Plug; PF1/4
1
0.9 (0.66)
303
Valve casing
1
984
Plug; PF3/8
1
1.7 (1.2)
351
Plunger
2
985
Plug; PF3/4
3
4.4 (3.2)
355
Spring
2
993
Plug; PT1/2
1
65 (48)
390
Name plate
1
994
Plug; PT3/4
1
98 (72)
391
Rivet
2
36 (27)
29 (21)
T3-4-5
431 (318)
334 (246)
E215B-E245B
SWING DEVICE
Swing reduction unit Be careful about installation direction of retaining ring. Caulk these 2 places Apply Three Bond #1360 with punch. or equivalent. 23 OIL FILLING PORT PT3/4 LEVEL PORT PT1/2 19 2
Apply Loctite #515.
28
15
16 3 SURFACE OF Be careful about LUBE OIL 15 installation direction of spring pin. 18 VIEW (II) (4 places) 5
6 7 4 8 Apply Loctite #515.
17
Be careful about installation direction 20 of retaining ring. 10 Apply Loctite #515. 12
18
Drive this spring pin 22 into 1mm lower than the surface of spider. 9 25 26
31 Install the filling port of this fitting toward motor side.
24 13
32
27 Apply seal tape or Loctite #577.
Fill up this space with grease. 11 30 21 1
SM0574
Tightening
No.
Parts
Q.ty
torque Nm (lbf•ft)
Tightening
No.
Parts
Q.ty
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
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
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
torque Nm (lbf•ft)
181 (134)
69.1 (51)
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 pressure acts upon piston (121) and creates force F in the axial direction. The force F may be divided into force F1 vertical to shoe plate (124) via shoe (122) and force F2 at right angles with the shaft. 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. 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 reversed, the drive shaft rotates in the opposite direction. Theoretical output torque T can be given by the following equation.
T=
Cylinder block (111) F2
F1 F
Drive shaft (101)
Shoe plate (122)
Shoe (122)
Valve plate (131)
Piston (121)
SM0575
PXq 2X
Low pressure oil
p: Effective differential pressure MPa q: Displacement per revolution cc/rev
OUTLET
High pressure oil
INLET
(a)
SM0576
T3-4-7
E215B-E245B
SWING DEVICE
VALVE CASING SECTION Operation of anti-cavitation check plunger Since the system using this type of motor is not equipped with a valve having a counterbalance function, the motor is rotated beyond the oil feed rate in some cases. The system has check plunger (351) and sucks in deficient oil, in order to prevent cavitation from occurring due to oil deficiency.
351
M port
Operation of relief valve 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 hydraulic pressure that is determined by the product of the pressure-receiving area A1 of plunger (301) and the pressure P balances the hydraulic pressure that is determined by the product of the pressure-receiving area A2 of 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 spring (321) increases by this movement of the piston. As the result, the relief pressure P is raised and controlled in the pressure boost time t1 from P1 till Ps. 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. If the P port of the relief valve is pressurized, pressure is built up in chamber g via the restrictor m of plunger (301). The hydraulic pressure acting on plunger (301) increases and when it balances the load Fsp of spring (321), the relief valve performs relieving action by the pressure P1. This relationship is expressed as: P1×A1=Fsp1+Pg1×A2 where Fsp1: primary set load value of spring (321).
T3-4-8
(Make-up port)
DIRECTIONAL VALVE SM0577
Chamber h Orifice m
Spring (321)
Piston 1 (302)
P
Pressure receiving area A1
R Plunger (301)
Chamber g A3 A2 A4 Orifice n SM0578
Orifice m
Spring (321)
Chamber h Pin (303) Piston 1 (302)
P R Plunger (301)
Orifice n
Chamber g SM0579
SWING DEVICE b) Condition shown in Fig.SM0580. The pressure of chamber g acts upon the pressure-receiving area A3-A4 of piston 1 (302). When the hydraulic pressure rises above the load of spring (321), the piston 1 begins to move to the left. On that occasion, since the machine turns to the left while discharging the oil of chamber h arranged between piston 1 and adjust plug (401) into chamber g via orifice n provided in piston 1 (302), chamber h serves as a dumping chamber. The load of the spring increases slowly till piston 1 reaches the end of the adjust plug. The relief pressure P rises smoothly.
E215B-E245B
Orifice m
Chamber h Pin (303) Piston 1 (302)
P R Plunger (301)
Orifice n
Chamber g SM0580
Orifice m
c) Condition shown in Fig.SM0581 The machine does not travel to the left further when piston 1 (302) arrives at the end of adjust plug (401). Therefore, the relief valve keeps its normal relieving action whereby the relief pressure is held at P2. In the processes a. to c. above, the relief pressure changes as shown in Fig.SM0582.
Spring (321)
Spring (321)
Pin (303)
Piston 1 (302)
P R Plunger (301)
Orifice n
Chamber g SM0581
2.
Function when the relief valve pressure is reduced. Let us consider the pressure of the P port is reduced. When the pressure at port P is reduced to zero, the pressure of chamber g falls to the tank pressure level. The result is that the plunger (301) which is now open moves to the left and is seated on seat (341). At the same time, the piston 1 (302) moves to the right by the action of spring (321) and returns to the condition of Fig.SM0580. SM0582
T3-4-9
E215B-E245B 3.
SWING DEVICE
Operation of anti-reaction valve a) Neutral condition Fig.SM0583 illustrates the relationship between the neutral condition of the antireaction valve and the hydraulic circuits. Now, let us consider a braking condition in which brake pressure generates on the AM port side. b) When brake pressure occurs: If pressure (P) generates at the AM port, it passes through the passage L, the hole on the shaft of seat (313) and the passage m of plunger (311) and is led to the n chamber. When the pressure P rises above a value (Ps) set by spring (321), plunger (311) compresses spring (321) and shifts it to the left. Seat (313) compresses weak spring (322) as pushed by plunger (311) and moves to the left. c) At anti-reaction action When inertia load stops moving (point Y Fig. SM0587), brake pressure (P) tries to fall. When P
ANTI REACTION VALVE ANTI REACTION VALVE SM0583
L
k 322
313
321
311
m
SM0584
n
P=PS L
322
313 p
321
311
321
311
SM0585
t
P
r
g
P
SM0586
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 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 casing (301) via separator plate (743) and brake piston (702) by the action of brake spring (712), frictional force is created between friction plate (742) and casing (301) and between separator plate (743) and brake piston (702). The frictional force bounds the drive shaft to brake the motor. In the meantime, when brake release pressure applied to the oil chamber formed between brake 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
712
702 712
743
702
742
111
301
743
742
301
101 SM0588
E215B-E245B
SWING DEVICE
SWING REDUCTION UNIT Operation The swing reduction unit is used to reduce the rotating speed which is transmitted by the hydraulic motor and to convert it to the strong turning force (torque). This swing speed reduction unit is equipped with planetary speed reducing mechanism. The planetary mechanism is made up of sun gear, planetary pinion, planetary shaft, spider and ring gear, as shown in in Fig.SM0589. 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). 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 the involute spline, and transmits the power to the 2nd stage planetary mechanism. For the operation of the 2nd stage planetary, the power is transmitted to sun gear (4) → planetary pinion (5) → spider (8) similarly to the 1st stage. The #2 spider (8) is linked with pinion shaft (1) by the involute spline, and pinion shaft (1) is engaged with the swing gear fixed on the undercarriage (lower frame) and rotates.
Ring gear (Fixed)
Planetary shaft
Spider Sun gear
Planetary pinion
SM0589
Swing motor 3
2 6
7 4 8 13 5
10
11
1
SM0590
T3-4-12
TRAVEL DEVICE
E215B-E245B
OUTLINE Characteristics
Item
E215B
Reduction gear unit
E245B
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
low speed
129.3 cm3/rev
181.3 cm3/rev
220 L/min
246 L/min
high speed
38949 Nm
42827 Nm
low speed
24469 Nm
25600 Nm
static
32060 Nm
25000 Nm
dynamic
26707 Nm
20900 Nm
Displacement Max. flow Max. gearbox output torque
Parking brake torque Min. pressure parking brake release Relief valve set pressure
11 bar cracking
311 bar at 1.2 L/min
total flow
353 bar at 40 L/min
Mass
235 kg
T3-5-1
262 kg
E215B-E245B
TRAVEL DEVICE
Hydraulic motor
Planetary gearbox
Two speed hydraulic motor (axial piston swash plate type) containing: - Integrated counterbalance valve;
Planetary gearbox, 3 stages, rotating housing type. The track drive is suitable to be used as track drive for crawled machines equipped with open loop hydraulic circuit.
- Crossover relief valve wich contains a shock absorber to smoooth acceleration and stopping; - Integrated flushing valve (only E215B); - Negative multidisc parking brake built-in directly driven from ythe motor oil pressure (no additional hose is required); - Double speed function, allowing the motor to be set to a fast or slow speed.
Ports E215B
SM0551
1
M22x1,5
Oil filling and level plugs
2
M22x1,5
Oil draining plug
P1
PF 1”
P2
PF 1”
T
PF 1/2”
Drain ports
Ps
PF 1/4”
2 speed control port
Tin
PF 1/4”
Oil motor filling port
Pm1
PF 1/4”
Pm2
PF 1/4”
Pp
PF 1/4”
Service ports
Pressure gauge ports
T3-5-2
TRAVEL DEVICE
E215B-E245B
Ports E245B
Ps
P1 T
Pm1
A
Tin Pm2 Pp
P2 1
A
3
2 1
PF 3/4”
Oil filling plug
2
PF 3/4”
Oil draining plug
3
PF 3/4”
Oil level plug
P1
PF 1”
P2
PF 1”
T
PF 1/2”
Drain ports
Ps
PF 1/4”
2 speed control port
Tin
PF 1/4”
Oil motor filling port
Pm1
PF 1/4”
Pm2
PF 1/4”
Pp
PF 1/4”
Service ports
Pressure gauge ports
T3-5-3
SM0552
E215B-E245B
TRAVEL DEVICE
Hydraulic circuit E215B
Ps
Pm2
T P2
P1 Pp Pm1
SM0553
Hydraulic circuit E245B
Ps
Pm2
T
P2 P1
R/G
Pp Pm1
Tin
T3-5-4
SM0554
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
Oil inlet port
Oil outlet port
Direction of rotation
P1
P2
Clockwise
P2
P1
Counterclockwise
COSTRUCTION Track drive E215B
1 2
SM0556
1- Hydraulic motor 2- Reduction stages
T3-5-5
E215B-E245B
TRAVEL DEVICE
Hydraulic motor E215B
2 1
3 4
7
6 1234567-
5
SM0557
Hydraulic motor base plate Motor shaft, Cylinder block Brake unit Brake valve Relief valve assy Flushing valve Two speed spool
MOTOR DRAIN PRESSURE (E215B-E245B) Continuous running
Less than 2 bar
Max. intermittent
Less than 5 bar
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
Hydraulic motor and track drive E245B
SM0558
T3-5-7
E215B-E245B
TRAVEL DEVICE
Hydraulic motor E245B
SM0559
T3-5-8
TRAVEL DEVICE 1- Flange 2- Base plate 3- (Spool) Plunger 4- Check valve 5- Spring (Q.ty 2) 6- Plug (Q.ty 2) 7- O-Ring (Q.ty 2) 8- Spring seat(Q.ty 2) 9- Spring (Q.ty 2) 10- Spring seat (Q.ty 2) 11- Cap (Q.ty 2) 12- O-Ring (Q.ty 2) 13- Socket bolt (Q.ty 8) 14- O-Ring (Q.ty 2) 15- Plug (Q.ty 2) 17- Relief valve assy (Q.ty 2) 18- Plug (Q.ty 8) 19- Spool A: 2-speed change over 20- Spool C 21- Spring 22- Plug 23- O-Ring (Q.ty 2) 24- Spring guide 25- Plug 26- Washer 28- Orifice 29- Orifice (Q.ty 3) 30- Orifice (Q.ty 2) 31- Plug (Q.ty 4) 32- O-Ring (Q.ty 4) 33- Ball (Q.ty 2) 34- Spring (Q.ty 2) 36- Shaft 37- Cylinder Block 38- Piston assy (Q.ty 9) 39- Plate 40- Holder 41- O-Ring 42- Sede molla 43- Spring 44- Collar 45- Pin (Q.ty 3) 46- Plate (swash plate) 47- Ball (Q.ty 2) 48- Piston assy (Q.ty 2) 49- Ball bearing 50- Ball bearing 51- Pin
52- Socket bolt (Q.ty 10) 53- Oil seal 54- Disk plate (Q.ty 3) 55- Friction plate (Q.ty 2) 56- Brake piston 57- O-Ring 58- O-Ring 59- Spring (Q.ty 6) 60- Pin (Q.ty 4) 61- Spring (Q.ty 2) 62- Valve plate 63- O-Ring (Q.ty 4) 64- O-Ring 65- Name plate 66- Rivet (Q.ty 2) 67- Plug (Q.ty 2) 68- Plug 69- Plug 70- Floating seal (Q.ty 2) 71- Angular bearing (Q.ty 2) 72- Housing (ring gear) 73- Shim 74- Holder B 75- Washer (Q.ty 8) 76- Socket bolt (Q.ty 8) 77- Thrust plate (Q.ty 4) 78- Inner race (Q.ty 4) 79- Needle bearing (Q.ty 4) 80- Planetary gear B 81- Thrust plate (Q.ty 4) 82- Socket bolt (Q.ty 4) 83- Sun gear B 84- Snap ring 85- Holder A 86- Thrust plate (Q.ty 3) 87- Inner race (Q.ty 3) 88- Needle bearing (Q.ty 3) 89- Planetary gear A 90- Thrust plate (Q.ty 3) 91- Thrust plate 92- Capscrew (Q.ty 3) 93- Drive gear 94- Thrust plate 95- Cover 96- Bolt (Q.ty 16) 97- Plug (Q.ty 3) 98- O-Ring (Q.ty 3) 99- Pin (Q.ty 4)
T3-5-9
E215B-E245B
E215B-E245B
TRAVEL DEVICE
NOTE:
T3-5-10
SWIVEL JOINT
E215B-E245B
OUTLINE General view Y
C D A F
E
B D
VIEW Y
C B A
E
VIEW Z
Z
SM0568
Specifications High pressure ports A,B,C,D
Low pressure ports E
Low pressure ports F
Working pressure
34.3 MPa
Max. impact pressure
51.5 MPa
Rated flow
255 L/min
Working pressure
0.49 MPa
Rated flow
50 L/min
Working pressure
5 MPa
Rated flow
30 L/min 15 min-1
Revolution
Ports size
A,B,C,D (body)
PF 1
A,B,C,D (stem)
PF 3/4
E
PF 1/2
F
PF 1/4
Length (height)
368 mm
Weight
24.5 kg
T3-6-1
E215B-E245B
SWIVEL JOINT
CONSTRUCTION
Y E 2 H
C
13 D
H 6
A
1
E
B D VIEW Y
C B
12 F
A
5 7
9
3
E
E
SECTION HH
8
4 SM0569
123456-
Body Stem Thrust plate Cover Seal (Q.ty 5) Seal
7- O-Ring 8- Capscrew; M8x20 (Q.ty 2) 30.4 Nm 9- Capscrew; M8x30 (Q.ty 3) 30.4 Nm 12- Plug 13- O-Ring (Q.ty 2)
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
gth
e
nd
xte
e ully
F
lly Fu
en dl
rac
ret
gth
en
l ted
B A
Part No. and Manufacturing No. Stamp position
SM0560
Specifications
Cylinder bore Rod Dia.
Stroke
Center distance of pins Full extend B / Full retract A
(mm)
(mm)
(mm)
Boom
Ø 120 / Ø 85
1345
3200 / 1855
With cushion on rod side
176
Arm
Ø 135 / Ø 95
1558
3637 / 2079
With cushion on both sides
255
Bucket
Ø 120 / Ø 80
1080
2684 / 1604
With cushion on rod side
153
Positioning
Ø 145 / Ø 90
992
2662 / 1670
Without cushion
220
Use
T3-7-1
Cushion
Dry weight (kg)
E215B-E245B
CYLINDERS
CONSTRUCTION Boom cylinder 27
26
12
24
25
0 105 -0.5
0 105 -0.5
B
28
PT 1/4
28 SLIT
GREEN
With hole (1 place)
BLACK
DETAIL B
DETAIL 6
9
8
7
6
4
5
3
11
10
2
1
13
14
C
DETAIL C
15
17
16
18
19
20
Orientation of cut off part of cushion bearing (13)
21
22
23
SLIT
SM0561
1- Cylinder tube 2- Piston rod 3- Rod cover 4- Bushing 5- Snap ring 6- Buffer ring 7- U-Ring 8- Backup ring 9- Wiper ring 10- O-Ring 11- Backup ring 12- Socket bolt; M16 × 75 (Q.ty 12) 267 Nm 13- Cushion bearing 14- Cushion seal 15- Piston
16- Seal ring 17- Backup ring (Q.ty 2) 18- Slide ring (Q.ty 2) 19- Slide ring (Q.ty 2) 20- Spessore 21- Piston nut; M62 ×3 7280 Nm 22- Set screw; M12 56.9 ± 10.7 Nm 23- Steel ball 24- Pin bushing (Q.ty 2) 25- Wiper ring (Q.ty 2) 26- Pin bushing (Q.ty 2) 27- Wiper ring (Q.ty 2) 28- Grease fitting; M10 x 1 (Q.ty 2)
T3-7-2
CYLINDERS
E215B-E245B
Arm cylinder
27
12
26
26
27
0 120 -0.5
0 120 -0.5
B
PT 1/4
PS 1/8 SLIT
GREEN
With hole (1 place)
BLACK
DETAIL 6
9
8
3
7 6
DETAIL B
4
5
11
10
2
1
13
14
DETAIL C
15
16
17
18
19
20, 21 25
23
C
22
24
SLIT
Orientation of cut off part of cushion bearing (13)
SM0562
1- Cylinder tube 2- Piston rod 3- Rod cover 4- Bushing 5- Snap ring 6- Buffer ring 7- U-Ring 8- Backup ring 9- Wiper ring 10- O-Ring 11- Backup ring 12- Socket bolt; M18 × 80 (Q.ty 12) 367 Nm 13- Cushion bearing 14- Cushion seal
15- Piston 16- Seal ring 17- Backup ring (Q.ty 2) 18- Slide ring (Q.ty 2) 19- Slide ring (Q.ty 2) 20- Set screw; M12 56.9 ± 10.7 Nm 21- Steel ball 22- Cushion bearing 23- Cushion seal 24- Stopper (Q.ty 2) 25- Snap ring 26- Pin bushing (Q.ty 4) 27- Wiper ring (Q.ty 4)
T3-7-3
E215B-E245B
CYLINDERS
Bucket cylinder
25
24
12
24
25
0 107 -0.5
0 107 -0.5
B
27
26
SLIT
GREEN
With hole (1 place)
BLACK
DETAIL 6
9
8
7 6
3
DETAIL C
DETAIL B
4
5
10
11
2
1
13
14
15
16
C
17
18
19
20
21
22 23
SLIT
Orientation of cut off part of cushion bearing (13)
SM0563
1- Cylinder tube 2- Piston rod 3- Rod cover 4- Bushing 5- Snap ring 6- Buffer ring 7- U-Ring 8- Backup ring 9- Wiper ring 10- O-Ring 11- Backup ring 12- Socket bolt; M16 × 75 (Q.ty 12) 267 Nm 13- Cushion bearing 14- Cushion seal
15- Piston 16- Seal ring 17- Backup ring (Q.ty 2) 18- Slide ring (Q.ty 2) 19- Slide ring (Q.ty 2) 20- Shim 21- Piston nut; M62 × 3 7280 Nm 22- Set screw; M12 56.9 ± 10.7 Nm 23- Steel ball 24- Pin bushing (Q.ty 4) 25- Wiper ring (Q.ty 4) 26- Grease fitting; M10x1 27- Grease fitting; M10x1
T3-7-4
CYLINDERS
E215B-E245B
Positioning
23
12
22
22
23
0 128 -0.5
0 123 -0.5
B
PT 1/4
24
GREEN
SLIT
With hole (1 place)
BLACK
DETAIL B
DETAIL 6
9
8
7 6
3
4
5
10
11
2
DETAIL C
13
1
14
15
16
17
18
19
20 21
C
SM0564
1- Cylinder tube 2- Piston rod 3- Rod cover 4- Bushing 5- Snap ring 6- Buffer ring 7- U-Ring 8- Backup ring 9- Wiper ring 10- O-Ring 11- Backup ring 12- Socket bolt; M20 × 80 (Q.ty 12) 520 Nm 13- Piston 14- Seal ring
15- Backup ring (Q.ty 2) 16- Slide ring (Q.ty 2) 17- Slide ring (Q.ty 2) 18- Shim 19- Piston nut; M62 × 3 7280 Nm 20- Set screw; M12 56.9 ± 10.7 Nm 21- Steel ball 22- Pin bushing (Q.ty 4) 23- Wiper ring (Q.ty 4) 24- Grease fitting; M10x1
T3-7-5
E215B-E245B
CYLINDERS
Hydraulic cylinder construction (for boom, arm and bucket cylinders) By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (2) that takes out the motion of pistons reciprocating in the cylinder tube assy, and cylinder head (3) that serves as both a lid and a guide. Cylinder tube assy (1) is equipped with a pin mount (clevis) that connects piston rod assy (2) with other parts. In addition to these main components, seal ring (16) and back-up ring (17) are located between cylinder tube assy (1) and piston rod assy (2); buffer ring (6), U ring (7) back-up ring (8) and wiper ring (9) are located between piston rod assy (2) and cylinder head (3); and an O-ring (10) and a back-up ring (11) are placed between cylinder tube assy (1) and cylinder head (3).
Operation If pressurized oil is fed alternatively to the oil inlet and outlet provided in the cylinder, force acts on the piston which in turn causes the piston rod (2) to extend and retract.
CUSHION RING (13)
CHAMBER “A” TANK
PATH (B)
PISTON (15) ROD (2)
Operation of cylinder with cushion
ROD SIDE
HEAD SIDE
CUSHION ON ROD SIDE The cushion mechanism is provided to prevent the generation of shock when the moving speed of piston (15) is not reduced and strikes cylinder head (3). An oil in chamber "A" returns to the tank by passing through paths "B" at a fixed flow rate in a intermediate stroke state of pressing bottom side. Next, in a state of just before stroke end, cushion ring (13) plunges into path "B". At this time, an oil in chamber "A" passes clearance "D" and mouth gap "C", an oil flow volume returning to tank suddenly drops and the piston part movement slows down.
CYLINDER HEAD (3) CUSHION STROKE
SM0565
CLEARANCE “D”
TANK
MOUTH GAP “C”
SM0566
T3-7-6
CYLINDERS
E215B-E245B
CUSHION ON HEAD SIDE This construction is similar to the one of cushion on rod side. In a state of intermediate stroke pressing rod side, an oil in chamber "A" returns to tank by passing through path "B" at a fixed flow rate. Next, in a state of just before stroke end, cushion bearing (23) plunges into path "B". At this time, an oil in chamber "A" path clearance "D" and cushion seal (24) are mouth gap "C", an oil flow volume returning to tank suddenly drops and the piston part movement slows down.
CUSHION SEAL (24) PATH “B”
TANK
CUSHION BEARING (23)
CLEARANCE “D” CHAMBER “A” SM0567
T3-7-7
E215B-E245B
CYLINDERS
NOTE:
T3-7-8
AIR CONDITIONER SYSTEM
E215B-E245B
BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) 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
AUTO AIR CONDITIONER SYSTEM OUTLINE
AIR CONDITIONER CONTROL PANEL
25.0℃
COMPRESSOR
COMPRESSOR DRIVE SOURCE
SOLAR RADIATION SENSOR
REFRIGERANT PRESSURE SWITCH
AIR MIXED DAMPER SIGNAL AIR-CON AIR OUTLET SWITCHING SIGNAL
BLOWER REVOLUTION SIGNAL
CONTROLLER INNER AIR SENSOR
EVAPORATION SENSOR
INNER AIR AND OUTER AIR SWITCHING SIGNAL
MOTOR ACTUATOR
VENT
OUTER AIR INTAKE INNER AIR
MOTOR ACTUATOR
AIR CONDITIONER UNIT
FACE
FOOT
MOTOR BLOWER ACTUATOR CONTROLLER
SM0024
T3-8-2
AIR CONDITIONER SYSTEM
E215B-E245B
COMPONENT AND CONSTRUCTION COMPONENT
27
30
33
27-1 40
32 39
27-6 27-3
27-5
27-2 35 35-6
35-7
35-1 35-5
35-2
35-8
34
35-9
35-10
SM0025
Air conditioner group
No.
Parts
Q.ty
No.
Parts
Q.ty
No.
Parts
Q.ty
27
Air conditioner assy
1
32
Compressor
1
35-6
D hose
1
27-1
Air conditioner unit
1
33
Pulley
1
35-7
L hose
1
27-2
Hose
2
34
Condenser
1
35-8
L hose: Ø 15.5
1
27-3
Clamp
2
35
Air dryer assy
1
35-9
S tube: Ø 16
1
27-5
Filter
1
35-1
Receiver dryer
1
35-10 L tube: Ø 8.5
27-6
Tube assy
1
35-2
Bracket
1
39
Filter
1
30
Panel assy
1
35-5
S hose: Ø 24.5
1
40
Solar radiation sensor
1
T3-8-3
1
E215B-E245B
AIR CONDITIONER SYSTEM
CONSTRUCTION (1) Air conditioner unit 49
48
6 47
46 44 42
31
31
41
50
3
45
F
1
1 43
1
G
32
1
28
39
1
37
38
B
36 27 H
9 40 A
I 2
33
SM0022
Air conditioner unit (1/2)
T3-8-4
AIR CONDITIONER SYSTEM
1
1 1
31
E215B-E245B
14
16
5
15
31
1
3
1
61
1
F
1
C D
4
7 G
1
1 1 26
20
13
59 29
11 21
22
H
23 1
24
B
1
8
60
D
17
18 A
I C
10
31
19
12 3 31
1 25 52
SM0021
Air conditioner unit (2/2)
T3-8-5
E215B-E245B
No.
AIR CONDITIONER SYSTEM
Q.ty
No.
Q.ty
No.
Parts
Q.ty
1
Screw M5×16
Parts
23
19
Relay
Parts
2
40
KK-box lower packing
1
2
Main harness
1
20
Evaporator
1
41
Vent lever
1
3
MA air mix
3
21
Expansion valve
1
42
Face lever
1
4
Blower controller
1
22
O-ring
1
43
Foot joint lever
1
5
Upper casing
1
23
O-ring
1
44
MA mode lever
1
6
Air mix door
1
24
Screw M5×40
2
45
Foot lever
1
7
Air mix lever
1
25
Thermistor
1
46
Face lever cam
1
8
Lower casing
1
26
Thermistor holder
1
47
Vent lever cam
1
9
Air mix door sub
1
27
Heater core
1
48
Face rod
1
10
Air mix lever sub
1
28
Pipe holder
1
49
Vent rod
1
11
Blower
1
29
Thermistor
1
50
Foot rod
1
12
Lever MA air mix
1
31
Screw M4×30
9
52
Inner air filter
1
13
Intake door
1
32
Upper casing
1
55
Screw M6×25
10
14
MA intake lever
1
33
Lower casing
1
56
Screw M8×25
10
15
Intake lever
1
36
Foot door
1
59
Evaporator packing
1
16
Intake rod
1
37
Vent door
1
60
Casing packing A
1
17
Air mix rod
1
38
Face door
1
61
Casing packing B
1
18
Air mix rod sub
1
39
KK box upper packing
1
Receiver dryer 1 - Pressure switch 2 - Sight glass 3 - Desiccant 4 - Suction pipe 5 - Filter 6 - Receiver tank A - Refrigerant INLET B - Refrigerant OUTLET
A
2
B
2 -M6 1
3 4 5
6
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 through the cooling circuit changes its phases from liquid to gas and vice versa during which process heat is transferred from the low temperature part (compartment) to the high temperature part (outside of the vehicle).
HFC-134a (R134a) CH2FCF3
Chemical formula Molecular weight
102.03
Boiling point
–26.19 °C
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 are available, but the following requirements are needed for use in such applications: • Latent heat of vaporization (heat of vaporization) is large. • It is easy to liquefy (condense). (It does not require very high pressure for condensation.) • 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 R134a refrigerant that is used in this machine.
Density of saturated liquid (25 °C)
CHARACTERISTICS OF REFRIGERANT In general, the fluid (general term of gas and liquid) has the following qualities: 1.
As a gas under certain pressure is cooled down, it begins to condensate at a certain temperature to take a liquid state. The temperature at which condensation begins is unique to each substance (fluid) at a given pressure. The temperature determined by a given pressure is called saturation temperature.
T3-8-7
Specific volume vapor (25 °C)
of
saturated
Latent heat of vaporization (0 °C) Flammability
1206 kg/m3 0.0310 m3/kg 197.5 kJ/kg Non flammable
Ozone destruction coefficient
0
P (MPa)
R134a
4
3 LIQUID
2
GAS 1
0
15 18
35
50
T (°C) SM0038
E215B-E245B 2.
AIR CONDITIONER SYSTEM
Inversely to 1. above, the pressure at which a gas condenses for a temperature is determined. This pressure is called saturation pressure. Figure beside illustrates the relationships between the saturation temperature and the saturation pressure in the case of refrigerant R134a used in the air-conditioner. At the temperature and the pressure on the lower righthand side of the curve in figure, the refrigerant take a gaseous state, while at the temperature and the pressure on the upper lefthand side of the curve, the refrigerant takes a liquid state. Let us think of a case where an air-conditioner is operated in the midst of summer. As the refrigerant evaporates, it absorbs evaporation heat from the air of the compartment. In order to cool the inside of the compartment down to 25 °C, the refrigerant must transform (evaporate) from a liquid to a gaseous state at a lower temperature. It can be seen from the figure that R134a under a pressure above the atmospheric pressure is capable of cooling the inside of the compartment sufficiently. (If a refrigerant that requires a pressure below the atmospheric pressure to cool it to a required temperature is used, air is mixed into the circuits, thereby deteriorating the performance of the cooling unit.) In the process in which gaseous refrigerant is brought back to a liquid state, the refrigerant is cooled and condensed by the outer air exceeding 35 °C. Accordingly the refrigerant is capable of condensing at a pressure exceeding 1 Mpa, as seen from the figure.
1 2
3
9
6 4
5
7
8
SM0039
1 - Inside of the compartment (cab) 2 - Evaporator 3 - Blower 4 - Compressor 5 - Cooling fan 6 - Inside of engine room 7 - Condenser 8 - Receiver dryer 9 - Expansion valve
Cooling circuit The figure illustrates the cooling circuit of the car airconditioner. 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 15 °C. For that purpose, it can be seen from the figure that the pressure of the refrigerant in the evaporator must be less than 0.51 MPa.
Furthermore, the cooling effect deteriorates unless the feed rate of the refrigerant is controlled so that all of the refrigerant supplied to the evaporator vaporizes and turns into dry vapor.
T3-8-8
AIR CONDITIONER SYSTEM
E215B-E245B
Consequently, the cooling circuit is so constructed that the evaporator can cool down an object (air in this case) sufficiently (i.e. so as to decrease the pressure in the evaporator) and that an adequate amount of refrigerant can be fed to the evaporator. The feed rate of the refrigerant is controlled by the expansion valve, but the pressure in the evaporator is held low by the throttling action of the expansion valve and the suction action of the compressor. The compressor acts as a pump that allows the refrigerant to circulate. The compressive action of the compressor and the heat exchange (heat radiation) action of the condenser transform the refrigerant in a dry vapor state back to a liquid state. Component parts EVAPORATOR The evaporator is an important heat exchanger that absorbs the heat of the compartment air (object) by 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. 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. 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 of the refrigerant of the evaporator. Accordingly, reducing the pressure drop is one element that makes the evaporator attain its full performances. EXPANSION VALVE
1
2
3
4 SM0026
1 - Evaporator 2 - O-ring 3 - Expansion valve 4 - Socket bolt M5 x 40
In order for the evaporator to fulfill its performances, a proper amount of low-pressure low-temperature liquid refrigerant must be fed to the evaporator. If the feed rate is too low, the refrigerant completes vaporization early in the evaporator which results in deterioration of the cooling effect. If the feed rate is too high, unvaporized liquid refrigerant returns to the compressor (liquid back). This not only deteriorates the cooling effect, but also damages the compressor valves.
T3-8-9
E215B-E245B
AIR CONDITIONER SYSTEM
The expansion valve feeds the flowing highpressure high-temperature liquid refrigerant to the evaporator as low-pressure low-temperature liquid refrigerant (damp vapor of low dryness). The expansion valve controls the feed rate of the refrigerant at the same time. The figure beside shows how the block type expansion valve is constructed. The temperature sensing part is provided in the shaft of the expansion valve to directly detect the refrigerant temperature at the outlet of the evaporator. The diaphragm contains R134a in saturated state. The pressure in the diaphragm changes according to the temperature detected by the sensor. The change in the pressure causes the force acting upon the diaphragm to vary accordingly. The high-pressure high-temperature liquid refrigerant that is fed from the receiver side reduces the pressure abruptly as it passes through the valve (throttling action). On that occasion, part of the refrigerant evaporates by the very heat of the refrigerant and cooled off. The result is that lowpressure low-temperature damp refrigerant vapor is fed to the evaporator. The opening of the valve is determined by the equilibrium between the pressure (low) of the evaporator side, the action of the adjust spring and the pressing force of the diaphragm (the temperature of the refrigerant at the outlet of the evaporator to be sensed by the thermowell). The feed rate is controlled automatically so that under the pressure in the evaporator, the refrigerant is properly overheated (3 ~ 8 degrees) and goes out of the evaporator. This action is carried out by sensing the refrigerant temperature at the outlet of the evaporator as against the inlet pressure of the evaporator and consequently controlling the feed rate of the refrigerant. This means that if the refrigerant pressure drop in the evaporator is excessive, it is difficult to control the overheating or the feed rate of the refrigerant. For this reason, the smaller the pressure drop of the evaporator, the better. The expansion valve senses the pressure and the temperature at the outlet of the evaporator and controls the overheating of the refrigerant and the refrigerant supply to the evaporator more securely. The air-conditioner of this machine adopts a block type expansion valve.
1
2 3 4
5 6 7 SM0040
1 - Diaphragm 2 - Evaporator side 3 - Refrigerant outlet 4 - Shaft 5 - Refrigerant inlet 6 - Ball valve 7 - Spring
T3-8-10
SM0041
AIR CONDITIONER SYSTEM
E215B-E245B
COMPRESSOR The compressor performs the following three functions in the cooling circuit: 1. Suction action 2. Pumping action 3. Compressive action 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.
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 pressure increases. For instance, it becomes possible to cool down the refrigerant by the use of an outer air of 35 °C and liquefy it. The compressive action of the compressor works to turn low pressure vaporized refrigerant to high pressure vapor refrigerant. The condenser then serves to cool down the refrigerant. However, since the compressive action takes place only for a short period, the refrigerant hardly exchanges heat with outer air. That is to say, it takes a near form of thermally insulated compression, so that the refrigerant discharged by the compressor turns into high-temperature high-pressure vapor and is delivered to the condenser.
1
2
3
SM0042
1 - D Hose 2 - S Hose 3 - Compressor
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.
2.
3.
Receiver Tank On the air-conditioner, the revolution of the compressor varies greatly which causes the proper flow of refrigerant in the cooling circuit to 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 extra amount of refrigerant to be used for filling balance and supplement small amounts of leakage of the refrigerant through penetration into rubber hoses.
1
2 3
4
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 the circuit as the water freezes in the expansion valve. It is desirable that the amount of water mixed in the refrigerant should be held below a concentration of 30ppm. The air-conditioner uses a molecular sieve as desiccant suited for the circuit, in order to absorb water content that intrudes into the circuit when the dryer is installed or when refrigerant is charged.
6
Sight Glass This is a inspection window with which the refrigerant level in the circuit is determined, the only means of confirming the inside of the circuit visually.
8
4.
Filter
5.
Pressure Switch This machine employs pressure switches of high/low pressure type. The pressure switch protects the circuit by cutting off the power supply to the compressor when high pressure increases abnormally high (more than 3.14 MPa). The pressure switch also detects the leakage of refrigerant by cutting the power supply to the compressor when the pressure of the circuit falls below 0.196 MPa.
5
7
SM0043
1 - Refrigerant inlet 2 - Sight glass 3 - Refrigerant outlet 4 - Pressure switch 5 - Desiccant 6 - Suction pipe 7 - Filter 8 - Receiver tank
T3-8-12
AIR CONDITIONER SYSTEM
E215B-E245B
DISASSEMBLY AND ASSEMBLY PRECAUTIONS TO BE EXERCISED IN OPERATION 1.
Special Refrigerator Oil This air-conditioner uses special refrigerator oil SP20 for use with new refrigerant R134a. Oils other than SP20 may not be used. Since SP20 tends to absorb moisture and may corrode paint and resin, the following points must be noted: 1) Do not keep open all pipe connections on a new compressor and the component parts of the installed refrigeration circuit (Remove valves and caps at the pipe openings of the compressor, just before connecting pipes. If you have removed a 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 SP20 has adhered to such surfaces, wipe it off immediately.
2.
3.
The receiver dryer is filled with desiccant to absorb moisture in the circuit. Therefore, remove the valve at the pipe port immediately before connecting pipes. Tightening Torque 1) Pipe Joints When connecting pipe joints, coat the O-ring with special oil (SP20) and fasten to the tightening torque indicated in the table, using a double spanner. 2) Screws and Bolts Fasten to the tightening torque indicated in the table
4.
5.
6.
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 service life will occur. If the oil volume is large, the cooling ability will be deteriorated. Once the air-conditioner is operated, part of the oil is dispersed in the refrigeration circuit. Therefore, when replacing the parts in right Table, adjust the oil level to that of table. Before performing operation, stop the engine and turn off all power supplies to the equipment related to the air-conditioner. After the operation is over, confirm that all faults have been repaired completely, by operating the air-conditioner.
Unit: N·m (lbf·ft) TIGHTENING TORQUE
PIPE FASTENING PART D hose and compressor (M8 bolt)
19.6~24.5 (14~18)
D hose and condenser
19.6~24.5 (14~18)
L hose and condenser
11.8~14.7 (8.7~11)
L hose and receiver dyer (M6 bolt)
7.8~11.8 (5.8~8.7)
L hose and air-conditioner unit
11.8~14.7 (8.7~11)
S hose and air-conditioner unit
29.4~34.3 (22~25)
Expansion valve
1.96~2.45 (1.4~1.8)
Unit: N·m (lbf·ft) TIGHTENING TORQUE
SCREW SIZE N4, T4 machine screw, M4
0.78~1.18 (0.58~0.87
N5, T5 machine screw, M5
1.96~2.45 (1.4~1.8)
M6 (mounting part of L hose joint)
7.85~11.8 (5.8~8.7)
M6 (except mounting part of L hose joint)
9.8~11.8 (7.2~8.7)
M8 (mounting part of S,D hose joints)
19.6~24.5 (14~18)
M8 (mounting part of A/C unit)
9.8~11.8 (7.2~8.7)
M8 (other than those mentioned above)
11.8~15.7 (8.7~12)
M10
39.2~53.9 (29~40)
REPLACED PARTS
AMOUNT TO BE FILLED IN
EVAPORATOR
40 cc (2.4cu·in)
CONDENSER
40 cc (2.4cu·in)
COMPRESSOR
Drain out the volume of oil left in the compressor to be replaced, from the new compressor.
RECEIVER DRYER
20 cc (1.2cu·in)
HOSES
20 cc (1.2cu·in)
T3-8-13
E215B-E245B
AIR CONDITIONER SYSTEM
DISASSEMBLY AND ASSEMBLY OF UNIT 1.
Removing inner air filter Slide the inner air filter (1) leftward and remove it from the unit (2).
2
7
1 SM0027
2.
3.
Removing selector box Remove 6 plus screws (3), remove connector (4) connected to the mode actuator (5) on mode selector box (6), and separate the mode selector box from the unit (2).
3
5
Removing main harness Pull out 3 harness clamps (7) from the unit (2), and disconnect all connected connectors and remove harness (8) on the body from the unit (2).
8
4 6
2
SM0028
4.
Removing upper unit case 1) Remove air MIX rod (9) and air MIX rod sub (10) from air MIX lever (11). 2) Remove 12 plus screws (12) which are used to install the upper and lower unit casings (2a). Pull out the upper unit casing (2b) upward giving attention to the thermistor harness so as not to be caught by the casing.
11
12
2b 10 9
2a
T3-8-14
SM0029
AIR CONDITIONER SYSTEM
E215B-E245B
5. Replacing blower controller 1) Remove 2 plus screws (14) and remove the blower controller (15) from the upper unit casing (2b). 2) Install new blower controller by the reverse procedure of removal.
2b
* Do not disassemble the blower controller.
14
15 SM0030
6.
Removing heater core 1) After draining the coolant, remove heater hos e from the heater core (16). 2) Remove 1 plus screw (17), and remove pipe clam (18) which is used to secure the heater core and then remove the heater core (16) from the lower unit casing (2a). 3) Install it by the reverse procedure of removal.
7.
16
17 18 20
19
Replacing blower motor 1) Disconnect connector which is connected to the blower motor and remove the blower motor (19) from the lower unit casing (2a). * Do not remove the fan from the blower motor.
2a
SM0031
2) Install it by the reverse procedure of removal.
8.
Replacing evaporator and expansion valve 1) Take the evaporator (20) with expansion valve off from the lower casing. 2) Remove evaporator sensor (21) with sensor holder (22) from the removed evaporator (20). 3) Insert the sensor holder into the new evaporator at the position shown in Fig. SM0032 and install the evaporator sensor (21) again. A - 11th rows of fin
20
22 105mm (4.1 inch)
21
A
SM0032
T3-8-15
E215B-E245B
AIR CONDITIONER SYSTEM
4) Remove 2 socket bolts M5×40 (23) with Allen wrench (4 mm) and remove the expansion valve from the evaporator (20). 5) Fit O-ring (24) (NF O-ring 5/8 and 1/2 one each) to new evaporator.
20 A
* When assembling again, fit O-ring paying attention so as not to be caught with others. (Socket bolt M5×40 (2 pcs.) Tightening torque: 6.9N•m (5.1lbf•ft)
24
* Do not apply undue force to pipe of evaporator outlet. This undue stress causes the leak of refrigerant from "A" part of evaporator. Moreover, when tube assembly (27-6) (see Pag. T3-8-3 Fig. SM0025) connected with expansion valve (25) is disconnected from expansion valve, similar careful work is necessary. 9.
25
23
Replacing motor actuator
SM0033
1) Replacing mode actuator a) Remove connector (26) connected to the motor actuator (27). b) Remove FACE rod (28) and VENT rod (29) which is used to connect MA mode lever (30) and mode cam from the holder. c) Remove 3 plus screws (31) and remove the motor actuator (27) with lever MA mode from the unit. d) Remove the lever MA mode from the removed motor actuator, and install it on new motor actuator by the reverse procedure of removal. 2) Replacing air mixing actuator a) Remove connector (32) connected to the motor actuator. b) Remove rod air MIX (33) which is used to connect the motor actuator (27) and the lever MA air MIX. c) Remove 3 plus screws (34) and remove the motor actuator (35) with MA lever air MIX (36) from the unit. d) Remove the MA lever air MIX from the removed motor actuator, and install it on new motor actuator by the reverse procedure of removal.
29 28 30 31 27
SM0034
33
36
32
34
T3-8-16
26
35
SM0035
AIR CONDITIONER SYSTEM 3) Replacing inner and outer air switching actuator a) Disconnect connector (37) connected to the motor actuator (38). b) Remove intake rod (39) from MA intake lever (40). c) Remove 3 plus screws and remove the motor actuator (38) with MA intake lever (40) from the unit. d) Remove the MA intake lever (40) from the removed motor actuator, and install it on new motor actuator by the reverse procedure of removal.
E215B-E245B
40
39
41
37
38
T3-8-17
SM0036
E215B-E245B
AIR CONDITIONER SYSTEM
CHARGING REFRIGERANT PRECAUTIONS TO BE EXERCISED IN OPERATION 1.
Always assign a person in charge of handling refrigerant. Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person familiar with how work is done for handling refrigerant. WARNING • •
2.
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.) Storage and Transportation 1) Keep the service can (hereinafter called can) less than 40°C (104°F). Since high pressure gas of R134a is filled in the can in a saturated liguefied state, the pressure in the can increases sharply as temperature rises. The can may blast as the result. It is for this reason why the can temperature must be kept below 40°C (104°F). 2) For storage, choose a cold dark place not exposed to direct sunlight. 3) If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes the inside pressure to rise and may cause the can to blow out. Do not bring the can close to a fire. 4) The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the compartment. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous temperature level. Do not bring the can into the compartment. Also, the inside of the trunk room may rise to a dangerous temperature level even in the summer time. Use sufficient care, therefore, taking the above into account. 5) Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate. - Do not drop or knock on the can. - When transporting, loading or unloading cans and packages containing cans, do not throw or drop them. 6) Store cans beyond the reach of children.
3.
Charging 1) When warming the can in which refrigerant is charged, do not fail to open the service can valve and the low pressure valve of the gauge manifold and warm the can in warm water of 40°C (104°F or below (to an extent that you do not feel hot when you put your hand in the water.) If the can is put in hot water or heated by a direct fire, the pressure of the can may rise sharply, thereby blowing off the can. 2) When charging refrigerant while running the engine, do not open the high pressure valve (HI) of the gauge manifold in any case.
4.
Others Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to enter the air-conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the components of the air-conditioner correctly and speedily. Pay full attention to the entry of water and dust.
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 requires a "vacuum generation procedure" and a "gas charging procedure". - The "vacuum generation procedure" consists in removing moisture from the air conditioner circuit. In the event even a small quantity of moisture remains in the system, it would freeze in the small orifices of the expansion valve when in operation. This causes a clogging of the circuit or the formation of rust, with a series of operational troubles. prior to filling the circuit with refrigerant, apply the vacuum and cause the boiling and vaporisation of the moisture. In this manner, moisture is eliminated from the system.
- The "gas charging procedure" consists in the filing the circuit with refrigerant, after applying a vacuum. the filling of the gas is not only depending upon the cooling performance of the air conditioner, but it influences also the useful working life of the circuit components. An excessive overloading increases considerably the pressure of the system and damages the cooling performance. On the contrary, a too low charging, results in an insufficient circulation of lubricant oil in the compressor, causing the wear of the moving parts of the compressor. WARNING 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.
Vacuum making operatio
More than 30 min. Begin vacuum making Lower than -750m mHg
Refrigerant filling operation
Leave it as it is, for five minutes.
Stop vacuum making
Check air-tightness
Fill in refrigerant
Check for gas leak
Fill in refrigerant
Gauge indicates abnormality Charge refrigerant gas to a gauge pressure of 0.1 MPa
Check and correct joints
SM0194
T3-8-19
E215B-E245B
AIR CONDITIONER SYSTEM
PROCEDURE FOR THE GENERATION OF VACUUM 1.
Close high pressure valve (3) and low pressure valve (1) on gauge manifold (2).
2.
Connect the red charging pipe (5) and the blue one (6) to compressor service valves (8) "D" and "S" as described in the figure.
2
WARNING Never exchange by mistake the high pressure pipe with the low pressure pipe when connecting them. Install the pipe firmly until a click noise is heard. 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, mini-valve (9) of the compressor fails to open. 3.
1
3
6
5 4
D
S 8
Connect the central valve of the gauge manifold with charging pipe (4) of the vacuum pump (7).
7 SM0016
IMPORTANT: some types of manifold are not equipped with an open/close valve in the central part. 4.
Open high pressure valve (3) and low pressure valve (1) of gauge manifold (2).
5.
Start the vacuum pump and let it operate 30 minutes to generate the vacuum.
6.
At the end of the vacuum phase for the prescribed time (vacuum value: lower than 750 mm Hg) close the high pressure valve (3) and the low pressure valve (1) of the gauge manifold (2).
7.
Cut-off the vacuum pump.
8.
With the high pressure valve (3) and the low pressure valve (1) closed, check, after five minutes, that the pressure gauge dial does not return to zero.
NOTE: in the event the pressure gauge moves toward zero, this indicates the presence of a leakage. Tighten again the connecting joints and apply the vacuum again, verifying that there are no further leakages.
T3-8-20
D
S
8
9 SM0017
AIR CONDITIONER SYSTEM
E215B-E245B
PROCEDURE FOR THE CHARGING OF THE GAS 1.
2.
After applying the vacuum repeatedly, exchange charging pipe (4) of the gauge manifold (2), from the vacuum pump to the service can (9).
2 11
Open the valve of service can (10). Close the high and low pressure valves of the gauge manifold. Press central bleeding valve (11) of the side service opening on the low pressure side of the gauge manifold using a screwdriver in order to let out the air in the charging pipe by the pressure of the refrigerant. Proceed with this operation until a whistle is heard coming from the bleeder.
4 10 9 SM0018
3.
Open high pressure valve (3) of the gauge manifold and charge the refrigerant to a pressure of 0.1 MPa. Once the charge is completed, close high pressure valve (3) of the gauge manifold and service valve (10).
3
1
D
WARNING Never start operating the compressor during this work. The starting of the compressor causes the blowing of the service can. 4.
Check that there are no leakages of gas in the cycle, using a gas leakage tester. Retighten and eliminate all points of leakage.
IMPORTANT: to check for gas leakages, always use a tester for R134a. Do not use one for flon gas service as it provides poor sensitivity. 5.
Make sure that high pressure valve (3) and low pressure valve (1) of the manifold and service valve can (10) are closed.
6.
Start the engine running it at 1500 ± 100 rpm and open fully the door and windows of the cab.
7.
Activate the air conditioner, setting it at maximum ventilation speed and at lowest temperature.
8.
During the charging of the gas, set the discharge pressure of the compressor to 1.4 ~ 1.6 MPa.
T3-8-21
10 S SM0019
E215B-E245B 9.
AIR CONDITIONER SYSTEM
Open low pressure valve (1) of the gauge manifold and service valve can (10) and fill with refrigerant until all air bubbles in sight window (12) of the dryer disappear. Total quantity of gas to be charged: 900 ± 50 g.
01
10. Once the refrigerant change operation is terminated, close low pressure valve (1) of the gauge manifold and the service valve can (10).
CAUTION Do not open the high pressure valve of the manifold under any circumstance nor place the service can upside down.
R0115
11. The level of refrigerant is correct only once the air conditioner is activated and through the inspection sight window, just a few air bubbles are seen and, afterward, a white colour slightly milky is seen.
IMPORTANT: when the air conditioner operates with an insufficient quantity of refrigerant, this has a negative effect on the compressor; on the contrary, when the refrigerant is charged with an excessive quantity, the cooling performance is lost. Also, the pressure of the system increases abnormally.
12. Disassemble the manifold disconnecting the charging pipes from the compressor, as indicated here below. a. Press the quick release coupling of the charging pipe on the low pressure side against the service valve of the compressor so that the refrigerant doers not escape leaking when loosening the connection. As soon as the nut has been removed, disconnect the charging pipe from the service valve. b. Wait for the pressure in the high pressure site to decrease, indicated on the pressure gauge, to a value of 1.0 MPa. c. Disconnect the red charging pipe from the high pressure side, in the same manner as described for the low pressure.
A: Appropriate quantity of refrigerant B: The system is overloaded C: Insufficient quantity of refrigerant
T3-8-22
AIR CONDITIONER SYSTEM
E215B-E245B
ELECTRIC CIRCUIT WIRING DIAGRAM AND CONNECTORS Wiring Diagram
1
(A)(B)
2 (C) 12
(R)
3
(N)
155(BR)
(D)
150(BP) FUSE 20A
15
4
85E(WB)
(E)
18(RG)
13
25(WG)
FUSE 5A
26(RL)
FUSE 15A
5
E24(B)
FUSE 5A
(Q)
(M) FUSE BOX
(P)
(F)
(L)
6
11 (K) 14
(G)
10
7 9 (J)
(H)
8 SM0044
(I) 1 - CCU(Operation Panel + Controller) 2 - Evaporator Sensor 3 - Air Inlet Sensor 4 - Solar radiation Sensor 5 - Motor Actuator (for air mix) 6 - Motor Actuator (for Mode) 7 - Motor Actuator (Rec/Fresh) 8 - Compressor Relay
9 - Blower AMP 10 - Blower Motor 11 - Blower Off Relay 12 - Pressure Switch 13 - Main Key Switch 14 - Compressor 15 - Light Switch
T3-8-23
E215B-E245B
AIR CONDITIONER SYSTEM
Connectors
(B)
(A)
JAE HOUSING : IL-AG5-22D-S3C1 TERMINAL : IL-AG5-C1-5000
(C)
MAKER : YAZAKI CORP. HOUSING No. : 7123-2228 TERMINAL : 17111
(F)
JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000
(G)
(I)
MAKER : YAZAKI CORP. HOUSING No. : 7123-2249 TERMINAL : 17111
(J)
(L)
MAKER : YAZAKI CORP. HOUSING No. : 7123-2249 TERMINAL : 17111
(D)
MAKER : YAZAKI CORP. HOUSING No. : 7123-2228 TERMINAL : 17111
JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000
MAKER : YAZAKI CORP. HOUSING No. : 7123-2237 TERMINAL : 17111
(M) MAKER : YAZAKI CORP.
HOUSING No. : 7122-6060 REAR HOLDER : 7157-6260-30 TERMINAL : 7114-2871
JAE HOUSING : IL-AG5-14D-S3C1 TERMINAL : IL-AG5-C1-5000
(E)
NIPPON AMP KK 174056-2 TERMINAL : 175062-1
(H)
JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000
(K)
MAKER : YAZAKI CORP. HOUSING No. : 7123-6020 TERMINAL : 7116-2871
(N) MAKER : YAZAKI CORP.
HOUSING No. : 7123-6060-40 TERMINAL : 7116-2871 26
25 85E
150 E24 18
(P)
(Q)
MAKER : YAZAKI CORP. 7120-8019 CP3.96MA
NIPPON AMP KK 170889-1 170003-5
(R)
MAKER : SUMITOMO HOUSING No. : 6189-0094 HARNESS SEAL : 7160-8234 TERMINAL : 1500-0110 150 155
SM0045
JAE : JAPAN AVIATION ELECTRONICS INDUSTRY, LTD.
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
STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION 1.
Control panel and control unit The control unit is integrated into control panel, and processes the signal input by each sensor, etc. and the signal input by each switch through control panel with the function of the built-in micro computer, and comprehensively controls each actuator (Inner and outer air flow select, air mix), fan motor and compressor on the output side. And the self-diagnosis performance is provided to facilitate the trouble shooting.
2.
Blower controller (TKS-B215A1) The power transistor shifts the fan motor into variable speed with base current from the control unit. TERMINAL NO. 1
2
+ TESTER
+
SM0047
CONTINUITY
B
3 -
CONTINUED (4.7 k ±5%)
+
NOT CONTINUED
-
CONTINUED (DIODE PARALLEL AND FORWARD DIRECTION FLOW)
Lg
L
In normal operation 1) Disconnect the connector of blower amplifier. 2) Check continuity between terminals on the blower amplifier side.
㨫 㨫
* The installing position is provided on the left side of air-con unit. SM0048
T3-8-25
E215B-E245B 3.
AIR CONDITIONER SYSTEM
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. When the blower OFF relay turns on, the source voltage is supplied to the blower motor and the blower motor starts running.
A A
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 12: Not continued 4.
Air mix actuator Air mix actuator is installed at the center of aircon 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 determined through the temperature control switch, the control unit reads the level of potentiometer of the actuator, and determines the rotating direction of motor in either normal rotation or reverse rotation. Then as the motor rotates, the contact point is moved, and when the contact point is detached or the output signal of control unit turns OFF, the motor stops rotating.
T3-8-26
CONTROL AMPLIFIER
MOTOR ACTUATOR
LIMITER COOL POTENTIO 5V POTENTIO POTENTIO GND
HOT
SM0050
AIR CONDITIONER SYSTEM 5.
6.
The actuator for inner and outer The actuator for inner and outer air flow select is installed on the blower intake unit, and opens and closes inner and outer air damper through the link. The actuator for inner and outer air flow select contains position detection switch which is switched with the movement of shaft of the actuator. When the inner and outer damper position is set by the inner and outer switch on the control panel, the control unit reads the signal of the position detection switch in the actuator and determines the rotation direction of motor in either normal rotation or reverse rotation. Then as the motor rotates, the position detection switch also rotates and makes it stop at the set position of the inner and outer air damper. Evaporator sensor This sensor is used to control the evaporator outlet temperature with the compressor ONOFF to protect the evaporator from freezing, and this evaporator sensor functions as a sensor of this control. •
7.
AMPLIFIER
E215B-E245B
MOTOR ACTUATOR
INNER AIR SIDE OUTER AIR SIDE LIMITER
SM0051
Evaporator sensor inspecting items (Specification) Terminal resistance: at 0 degree C: 7.2 k at 25 degree C: 2.2k
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.
SM0052
SPECIFICATION OF DUAL PRESSURE SWITCH
0.02MPa(2.9psi)
0.59MPa(86psi) SM0053
ON OFF
3.14MPa 0.20MPa (LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
8.
Solar radiation sensor This solar radiation sensor, which is used to correct the solar radiation to the auto air conditioner detects the strength and solar orientation of sunbeam after transforming them into current by means of photo diode. Inspection: Check for the continuity between terminals. SM0054
T3-8-27
E215B-E245B
AIR CONDITIONER SYSTEM
TROUBLESHOOTING Note : M/A is motor actuator * is any of the numbers 0 ~ 9
Air temperature does not fall.
If AUTO switch or A/C switch is pushed, "HL.E" is indicated on the set temp. display of the panel. NO
YES • Connector for air mix M/A is disconnected or in poor contact. • Air mix M/A is failed. • Main harness shows poor continuity.
"HL.*" is shown on the set temp. display of the panel NO
YES
A snow mark ( ) on the panel is flashing.
A snow mark ( panel is flashing. NO
) on
Inspect and correct or replace parts.
YES
• Inner air sensor or harness is disconnected or shorted • Inner air sensor connector is disconnected or in poor contact. See section monitor mode.
• Both inner air sensor and evaporation sensor are disconnected or shorted. • Controller failed. See section monitor mode.
Inspect and correct or replace parts. A NO Blowout temp. falls if temp. is set at 18.0 °C (64.4 °F) (COOLMAX) and the blowout mode is changed to vent mode. NO Air mix damper is in COOLMAX.
NO
YES • Evaporation sensor connector is disconnected or in poor contact. • Evaporation sensor is disconnected or shorted.
YES
Inspect and correct or replace parts.
Cool air flowing into inner air sensor
Inspect and correct or replace parts.
YES
If M/A is at stop halfway, eliminate cause, correct and measure operating force. (less than 14.7N: OK)
NO Turn compressor clutch on and off. Inspect and correct electric circuits. Refer to Troubleshooting for refrigeration cycle. NO
Controller is faulty or inner air sensor is faulty.
Inspect and replace.
YES
• Inspect, correct or replace M/A lever link. • After cleaning lever link, apply grease.
M/A failed or controller is out of order. Replace.
T3-8-28
YES Inspect duct or eliminate cause for cool air intrusion.
AIR CONDITIONER SYSTEM
E215B-E245B
Air temperature does not rise.
Note : * is any of the numbers 0 ~ 9
HL.E is shown on the set temp. display of the panel. NO
YES • Connector for air mix M/A is disconnected or in poor contact. • Air mix M/A is failed. • Main harness shows poor continuity.
"HL.*" is shown on the set temp. display of the panel. NO
YES
• Inner air sensor or harness is disconnected or shorted • Inner air sensor connector is disconnected or in poor contact.
Inspect and correct or replace parts.
See section monitor mode. 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 Air mix damper is in HOT MAX
NO
YES Warm air is flowing into inner air sensor.
YES
If M/A action is at stop, eliminate cause, correct and measure operating force. (less than 14.7N: OK)
NO
YES
Inspect warm water piping. Controller or inner air sensor is out of order.
Inspect and replace. NO • Inspect, correct or replace M/A lever link. • Clean lever link and apply grease.
YES M/A failed or controller is out of order. Replace.
T3-8-29
Inspect duct or eliminate causes for warm air entry.
E215B-E245B
AIR CONDITIONER SYSTEM
Blower motor does not run.
Note 1)
At air flow HI, battery voltage acts across both terminals (+) and (-) of blower motor. NO
YES Blower motor fails.
Battery voltage acts across red (+) and body of blower motor. NO Note 2)
YES
Inspect blower motor relay. Blower motor rotates if white / red wire and red wire of blower motor relay are direct connected.
Replace. Approx. 10V acts across light green wire and grounding of blower amplifier.
NO NO
YES
YES
Controller is out of order. Replace.
Wire harness is faulty. Inspect and correct or replace.
NO Eliminate cause and replace blower amplifier.
Battery voltage acts across white / red wire and body of blower motor relay. NO Inspect and repair harness or replace.
Remove blower amplifier and check for continuity across light green wire and black wires; you get continuity. YES Inspect and repair harness.
YES Blower turns if orange wire of blower motor relay is connected with ground. NO Replace relay.
YES Inspect and correct harness or replace controller.
Note 1) Measure with connector set. Note 2) Always turn off air-conditioner, starter key switch and light switch before work.
T3-8-30
AIR CONDITIONER SYSTEM
E215B-E245B
Blower motor speed does not change.
CASE (1) "HL.*" is shown on the set temp. display of the panel. NO Replace blower controller.
amplifier
Note) * is any of the numbers 0 ~ 9.
YES • Inner air sensor or harness is disconnected or shorted. • Inner air sensor connector is disconnected or in poor contact. See section monitor mode.
Inspect and correct or replace parts.
CASE (2) Does not blower motor speed change because the setting mode is other face NO Is door or front window open? NO The limiting or control operation is actuated by door switch or front window switch
YES See CASE (1).
T3-8-31
YES See CASE (1).
E215B-E245B
AIR CONDITIONER SYSTEM
Magnet clutch does not engage.
Snow mark ( ) lights if A/C switch is pressed. NO
YES Voltage acts upon clutch.
Snow mark ( ) flickers and E is shown on panel display.
NO
To A On page T8-3-28.
Voltage is applied to pressure switch harness. NO
Pressure switch is faulty or refrigerant gas is under charged or overcharged. Refer to troubleshooting for refrigeration cycle.
YES
Inspect clutch fuses.
Clutch faulty.
YES
Voltage acts across white / green wire and Ground (Black) connector connected to excavator. NO
YES
Inspect air-conditioner harness. No fault. NO
YES
Replace harness.
Replace controller.
Inner air and outer air do not change
Inner / outer air mode display on operation panel is flickering. NO
YES
M/A lever includes foreign matter or is broken. NO M/A failed
Connector of inner/outer air M/A is disconnected or in poor contact. Or M/A failed or main harness failed.
YES Remove foreign matter and replace parts.
Replace
T3-8-32
Inspect or replace.
AIR CONDITIONER SYSTEM
E215B-E245B
Modes do not change.
Mode display (Mark of person) on operating panel is flickering. NO
YES
M/A rod does not disengage. NO
Mode M/A connector is disconnected or in poor contact or M/A failed or main harness is faulty.
YES
Repair.
Each damper lever does not disengage. NO Repair.
Inspect or replace.
YES When rod is removed and cam is operated by hand, it is heavy. (more than 19.6N.). NO
M/A or controller is out of order. Replace.
YES • Cam or damper shaft includes foreign matter or is broken • Erroneous motion occurs due to dirty grease. • Remove foreign matter or replace parts. • Clean cam and apply new grease.
T3-8-33
E215B-E245B
AIR CONDITIONER SYSTEM
Trouble with refrigeration cycle.
Both high and low pressures are lower. Air bubbles are seen in sight glass. NO
YES
Cooling does not work if run at high speed. NO
Oil comes out from piping and parts.
YES
NO
YES
Expansion valve is clogged or maladjusted.
Expansion valve is frozen or intruded by water.
Natural leak from hose.
Adjust or replace expansion valve.
After making vacuum, refill refrigerant and replace receiver.
Charge gas.
Gas leaks from pipe joints and parts. Retighten parts.
or
replace
Low pressure is higher. 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.
Replace expansion valve.
Replace compressor
High pressure is lower.
Air bubbles are seen in sight glass. NO High pressure gets lower slowly.
YES Condenser is fouled or clogged. YES
High pressure circuit before receiver is clogged up.
Remove clogging replace parts.
Clean condenser.
or
NO Air bubbles are hard to go out even if water is poured on condenser.
Air is mixed. Make vacuum and refill refrigerant.
T3-8-34
AIR CONDITIONER SYSTEM
E215B-E245B
SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL The failure of motor actuator and each sensor can be identified on the display of panel. POSITION OF INDICATION FOR FAILURE.
SM0055
The error is indicated on 3 digits segment. EXPLANATION OF INDICATION FOR FAILURE. Failure of Motor Actuator 1.
HL.E is indicated on 3 digits segment.
Check harness or connector to motor actuator for the air mix damper for disconnection.
SM0056
2.
MODE
is flickering.
Check harness or connector to motor actuator for the air outlet damper for disconnection.
SM0057
3.
R/F
is flickering.
SM0058
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 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.
Check the inner air sensor or the harness for disconnection and short circuit, and also connectors for disconnection.
SM0059
(* is any of the numbers 0 to 9.) 2.
**E and
mark are flickering. (** is displayed leaving the present set temperature value.)
Check evaporator sensor or the harness for disconnection and short circuit, and also connectors for disconnection.
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.
Communication error of control amplifier and panel 1.
E is indicated on the only use segment of display.
Check the harness of control amplifier and panel for disconnection, and connectors for poor connection.
SM0061
T3-8-36
AIR CONDITIONER SYSTEM
E215B-E245B
EXPLANATION OF MONITOR MODE When error “failure of sensors” is displayed, the monitor mode is available to identify the sensor condition (disconnection, short circuit). 1.
Position of monitor mode indication
SM0062
3 DIGITS SEGMENT
2.
SEGMENT FOR ONLY MONITOR INDICATION
Operation of monitor mode
A
B
C
E
D
SM0063
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. SEGMENT ASSIGNMENT LIST 0
INNER AIR SENSOR
1
EVAPORATOR SENSOR
2
SOLAR RADIATION SENSOR
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 3.
AIR CONDITIONER SYSTEM
Contents of monitor mode display Refer to the list of segment display exclusively used for monitor and the list of segments in three digits. 1. Example 1 When the segment exclusively used for monitor indicates 0 (displays the inner air sensor condition), since the segment indicates 3F, the sensor is in normal operating condition according to the list of 3 segments. --> The inner air sensor is in normal operating condition. SM0065
2. Example 2 When the segment exclusively used for monitor indicates 1 (displays the evaporator sensor condition), since the segment indicates 00, the sensor is in disconnection condition according to the list of 3 segments. --> The evaporator sensor is in disconnection condition. SM0066
3. Example 3
SM0067
4.
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 condition.
List of 3 segments SECOND SEGMENT INNER AIR SENSOR DISCONNECTION EVAPORATOR SENSOR DISCONNECTION
THIRD SEGMENT
SOLAR RADIATION SENSOR SHORT-CIRCUITING
EACH SENSOR IS NORMAL
SOLAR RADIATION SENSOR 5V SIDE SHORT-CIRCUITING INNER AIR SENSOR SHORT-CIRCUITING EVAPORATOR SENSOR SHORT-CIRCUITING SM0068
T3-8-38
OPERATIONAL PERFORMANCE TEST
M0103
OPERATIONAL PERFORMANCE TEST
E215B-E245B
SECTION AND GROUP CONTENTS Section 4
OPERATIONAL PERFORMANCE TEST
Group 1 Group 2 Group 3 Group 4
Introduction Standard Performances Test Procedures Mechatro Controller
SECTION 4
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
Group 2 - Standard Performances Performance Inspection Standard Table.................................................. T4-2-1
Group 3 - Test Procedures Measurement of engine speed ............... T4-3-1 Measurement of hydraulic pressure........ T4-3-2 Measuring travel performances .............. T4-3-7 Measuring swing performances .............. T4-3-11 Measuring attachment operating performances ..................................... T4-3-15 Measuring performances of swing bearing............................................... T4-3-17
Group 4 - Mechatro Controller Engine control input/output ..................... T4-4-1 Engine control ......................................... T4-4-2 Engine control equipment ....................... T4-4-3 Adjustment of mechatro controller output (A-B-C adjustment) ............................ T4-4-4
E215B-E245B
INTRODUCTION
E215B-E245B
HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED Application
Cautions to be Exercised at Judgment
WHEN THE MACHINE IS NEW
EVALUATION OF MEASURED DATA
Confirm that the performances are in accordance with standard specifications as compared to the performance standards. AT SPECIFIC SELF INSPECTION (RULE BY COUNTRY)
Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors are to be evaluated. Determine generally at what levels measured values are located, instead of determining whether or not values fall within or run out of the reference values.
Use the data for the criterion, for the purpose of correction, adjustment and replacement.
DETERMINING CORRECTION, ADJUSTMENT OR REPLACEMENT
WHEN PERFORMANCES ARE DETERIORATED
Machine performances deteriorate with time as parts wear and some deteriorated performances may be restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the operating hours, kind of work and circumstances in which the machine is placed, and condition the machine performances to its most desirable levels.
Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for safety and economical considerations. WHEN MAIN COMPONENTS ARE REPLACED For example, use data to restore performances of pumps and others.
Other Cautions to be Exercised
Terminology
PARTS LIABLE TO DEGRADE
STANDARD VALUES Values to be used to condition or assemble a new machine. Where special notes are not given, these values represent standard specifications (machine with standard attachments and standard shoes). REFERENCE VALUES FOR REMEDY Values at which readjustment is required. In order to ensure performance and safety it is strictly prohibited to use the machine over the specified values. SERVICE LIMIT This is the limit value at which reconditioning is impossible without replacement of parts. If the value is expected to exceed the service limit before next inspection and correction are performed, replace the parts immediately. The operation over the specified values causes increase of damage and requires the down time of machine, and also causes safety problems.
Rubber products, such as, hydraulic hoses, ORings, and oil seals deteriorate with time; replace them at regular intervals or at overhauls. PARTS REQUIRING REGULAR REPLACEMENT Out of critical hoses that are necessary to secure safety, we designate Very Important Parts (V.I.P) and recommend that they should be replaced regularly. INSPECTION AND REPLACEMENT OF OILS AND GREASES In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as well.
T4-1-1
E215B-E245B
INTRODUCTION
PREPARATION FOR PERFORMANCE TESTS Observe the following rules in order to carry out performance tests accurately and safely. 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.
3.
SM1231
If required, rope off the test area and provide signboards to keep unauthorized personnel away.
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 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.
Make precise measurement 1.
Accurately calibrate test instruments advance to obtain correct data.
in
2.
Carry out tests under the exact test conditions prescribed for each test item.
3.
Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary.
T4-1-2
SM1232
STANDARD PERFORMANCES
E215B-E245B
PERFORMANCE INSPECTION STANDARD TABLE
NOTE: unless otherwise specified, measure it on "H" mode.
Measuring Position
Inspection Item
Standard Value
Unit
Adjusting Point
Hydraulic oil in tank
NAS 9 or less
Class
-
Sampling
Tank surface
50 ± 5
-
Radiator surface
75 ± 15
Atmospheric temp 50 °C ~ -10 °C
Position
Cleanliness of hydraulic oil
Water temperature
H mode Hi idle Measure the engine speed at multi display on the gauge cluster, or measure with diesel speed meter
Auto-Idle B mode Hi idle
ATT Travel
Power boost
Bucket
Arm
Swing
Travel
RH
LH
P1
a1
P2
a2
P1
a1
P2
a2
H
a1
R H R H R LH RH Forward Reverse Forward Reverse
Main pump
Main relief valve pressure
Full throttle (Hi Idle)
1050 ± 50 2000 ± 50
1800 ± 50
Boom
Over load relief valve pressure
2000 ± 50
S mode Hi idle a5
PF 1/4
a1
Adjustment not required Perform all measurement with the air-conditioner “OFF”
PR1
HI idle
34.3 +0.7
MR1
Boom up
37.8 +1.0
MR1
-0
-0,5
-0.5
39.7 +0 -5.9
OR3
Boom up
37.8 +0
OR4
Boom down
39.7
OR1
Bucket digging
OR2
Bucket dump
OR7
Arm in
OR8
Arm out
OR5
Swing LH
OR6
Swing RH
37.8
-4.0 +0 -5.9 +0 -4.0 +0 -4.0
39.8 +0
-5.9
a2
+6.0 29.0 +0
a1
34.3 +0,7
a2
34.3 +0,7
T4-2-1
min-1
5.0 +0,5
37.8 a2
-
Low throttle
2000 ± 50
G pump
°C
1000 ± 50
A mode Hi idle
Pilot primary pressure circuit
High pressure circuit
Port
H mode Lo idle Engine speed
Std. Measuring condition
Hydraulic oil temperature
Size
Measuring Condition
-0,5
-0,5
MPa
Simultaneous Operation of travel RH and LH
E215B-E245B
STANDARD PERFORMANCES
Inspection Item
Standard value
Sprocket revolution (RH, LH) E215B
1st speed
32~28
2nd speed
50~45
Sprocket revolution (RH, LH) E245B
1st speed
28~24
2
nd
45~40
speed
Operating speeds
Arm Operating time of cylinder
Positioner Swing speed Travel speed E215B Travel speed E245B
Performance
Bucket
In
3.0~3.6
Out
2.3~2.9
Digging
2.2~2.8
Dumping
1.7~2.3
In
2.9~3.5
Out
4.1~4.7
RH - LH
4.2~5.4
st
1 speed
Iron shoe
25.2~28.2
2nd speed
Iron shoe
16.9~18.9
1st speed
Iron shoe
29.5~32.5
Iron shoe
18.5~21.5
2
nd
speed
Amount of travel deviation
2nd speed
Parking brake drift
15° Gradient
Performance of Swing brake
Neutral position after 180° full speed swing
Swing parking brake drift
ATT amount of drift
Measuring condition
Unit min-1
min-1
s
(At no load)
s / 3 rev
0~240
mm / 20 m
0
mm / 5 min
55~75
degree
15° Gradient
0
mm
Tip of the bucket tooth
80
Boom cylinder
7
Arm cylinder
6
-
-
Amount of horizontal play at the bucket tooth
30~50
mm / 5 min
mm
NOTE: over load relief valves OR1~OR8 described in advance correspond to the following operations. 1.
Bucket digging
5.
Swing left
2.
Bucket dump
6.
Swing right
3.
Boom up
7.
Arm in
4.
Boom down
8.
Arm out
T4-2-2
(At no load)
(8) (5)
(4) (6) (1)
(7)
(2) (3)
TEST PROCEDURES
E215B-E245B
MEASUREMENT OF ENGINE SPEED Warming up of engine Start engine to raise the coolant temperature of engine to 60 to 90°C (140 to 194°F) at surface of radiator upper tank. The E/G coolant tem-perature gauge is used to measure. The range in white color shows the temperature of approx. 65 to 105°C (149 to 221°F), so confirm that the pointer indicates the temperature within the white range. SM0600
Engine speed measured value through service diagnosis 1.
Turn "ON" the starter switch with the buzzer stop switch pressed.
2.
A program No. and an actual engine revolution are displayed as the No.2 Item.
3.
The screen advances like No.2, No.3....each time the "Wiper switch" on the gauge cluster is pushed.
4.
The screen returns like No.45, No.44....each time the "Washer switch" is pushed.
5.
The display does not disappear unless the starter switch is turned to"OFF".
GAUGE CLUSTER
BUZZER STOP SWITCH WASHER SWITCH
WIPER SWITCH SCREEN CHANGE SWITCH
NO.2 ENG G-3 SPEED SET MEAS G-5 ENG PRS. WATER TEMP MODE H-1 ACCEL VOLT. POS. G-1 MOTOR STEP POS. COIL A COIL B G-2 LIMIT SW.
SM0851
1000 1000 LIVE 20 °C OFF H 0.3 V 0% 30 0% 1.5 A 1.5 A OFF SM0852
T4-3-1
E215B-E245B
TEST PROCEDURES
MEASUREMENT OF HYDRAULIC PRESSURE Preparing to measure hydraulic pressure HYDRAULIC EQUIPMENT 6.9 MPa (1000psi) pressure gauge: 1unit 49 MPa (7100psi) pressure gauge: 2 units Pressure measuring equipment and instrument for analysis: 1 set
a5 B3 Dr3
A3
MEASURING CLEANLINESS OF HYDRAULIC OIL A2 (A1)
PSV2
WARNING After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and measure with the instrument for analysis. If the measured value is higher than the standard value, replace the return filter or change the hydraulic oil.
Place to install pressure gauge MAIN CIRCUIT After releasing the pressure in hydraulic oil tank and system, replace plugs PF1/4 of main pump gauge ports (a1) (a2) with plugs for pressure measurement, and attach pressure gauge 49 MPa (7100 psi). 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
(PSV1)
a1
a2
SM0853
TEST PROCEDURES
E215B-E245B
Pressure adjustment position MAIN CONTROL VALVE Relief valve position on main control valve.
ARM (R) OR8
PLUG FOR OPTIONAL RELIEF
FRONT MACHINE
USE FOR YN30V00101 F1
MAIN RELIEF (ATT & TRAVEL)
BOOM (H) OR3
BUCKET (R) OR2
View from the top of the machine
BOOM (R) OR4
SM0854
BUCKET (H) OR1
MACHINE FRONT
ARM (H) OR7 View from the bottom of the machine
T4-3-3
PLUG FOR OPTIONAL RELIEF SM0855
E215B-E245B
TEST PROCEDURES
PILOT RELIEF VALVE The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.
B3
A3
PR1
SWING OVER LOAD RELIEF The swing motor is equipped with plugs PA, PB for pressure measurement, but the measurement is carried out using gauge ports (a1) and (a2).
a5
Dr3
SM0856
SWING RIGHT OVERLOAD RELIEF OR6
SWING LEFT OVERLOAD RELIEF OR5
(A)
(B)
PB
PA
SM0857
a5 B3 Dr3
A3
A2 (A1)
PSV2 (PSV1)
a1
T4-3-4
a2
SM0853
TEST PROCEDURES
E215B-E245B
Procedure for adjusting relief valve PILOT RELIEF VALVE Adjust it with adjust screw (311). : 24 mm : 29.4 N•m (22 lbf•ft) : 6 mm No. of turns of adjust screw
Pressure change MPa (psi)
1 turn
Approx. 2.1 (305)
311 LOCK NUT HEX24 SM0858
2-STAGE MAIN RELIEF VALVE (Commom for travel and ATT sections) Start from the boosting side, first. Loosen nut (1), adjust the pressure with adjusting screw (2) and tighten nut (1) after completion of the adjustment on the boosting side. Then, loosen nut (3), adjust the pressure on the standard side with adjusting screw (4) and tighten nut (3) after completion of the adjustment.
1
2
4 3
: 32 mm : 27.4~31.4 N•m (20~23 lbf•ft)
SM0859
: 22 mm : 27.4~31.4 N•m (20~23 lbf•ft) : 19 mm Adjust screw : 6 mm
No. of turns of adjust screw
Pressure change MPa (psi)
Boosting side 1 turn
Approx. 17.6 (2560)
STD side 1 turn
Approx. 17.6 (2560)
OVER LOAD RELIEF VALVE (Boom, bucket, arm sections) Loosen lock nut (1) and adjust it with adjust screw (2). : 22 mm : 27.4~31.4 N•m (20~23 lbf•ft) : 6 mm No. of turns of adjust screw
Pressure change MPa (psi)
1 turn
Approx. 17.7 (2560)
2
1 SM0860
T4-3-5
E215B-E245B
TEST PROCEDURES
OVER LOAD RELIEF VALVE (SWING) When the adjustment of pressure is required, loosen lock nut (1) and adjust the pressure with cap (2).
1
2
: 30, 38 mm : 118 N•m (87 lbf•ft) : 12 mm
3
R
No. of turns of adjust screw
Pressure change MPa (psi)
1 turn
Approx. 10 (1450)
SM0861
OVER LOAD RELIEF VALVE (TRAVEL) This valve was adjusted by valve maker. When adjustment is required, loosen nut (1) and adjust the pressure with adjusting screw (2).
1
: 17 mm : 6 mm 2 SM0862
T4-3-6
TEST PROCEDURES
E215B-E245B
MEASURING TRAVEL PERFORMANCES 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. 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 Engine revolution: 2-speed travel switch:
SM0863
REFLECTION PANEL
Hi idle 1st speed and 2nd speed Right and left
Measuring points: Method, example 1: Measure revolution with a stroboscope Method, example 2: Measure the revolutions per minute visually.
SM0864
E215B Unit: min-1
Sprocket revolution Measurement item H mode 1st speed RH& LH H mode 2nd speed
Standard value
Reference value for remedy
Service limit
32~28
25.2~22.8
20.4 or less
50~45
39~35.3
32.5 or less
E245B Unit: min-1
Sprocket revolution Measurement item H mode 1st speed RH& LH H mode 2nd speed
Standard value
Reference value for remedy
Service limit
28~24
22~19
17 or less
45~40
34~31
29 or less
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 Engine revolution: Hi idle.
Approx. 30~40 cm
PREPARATION
SM0865
1.
Straight course more than 30m (108ft).
2.
Travel position in which the bottom of the bucket is lifted by about 30cm (1ft).
MEASUREMENT 1.
2.
Measure the max. deviation distance of the circular arc in the 20m (66ft) length, excluding the preliminary run of 3~5m (10~16ft). Operate the travel lever at the same time.
Travel deviation
A 20m
Unit: mm (in)/20m (66ft)
Measuring position
Standard value
Reference value for remedy
Service limit
A
240 (9.45) or less
480 (18.9)
720 (28.4)
SM0866
T4-3-8
TEST PROCEDURES
E215B-E245B
Performances of parking brake 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 that it makes an angle more than 15 degree. Hang a perpendicular in parallel with the guide frame rib on the track frame and put a mark (matching mark) on the shoe plate.
15 degree slope
SM0867
MEASUREMENT Five minutes after the engine stops, measure the movement distance of the matching mark. Parking brake
Units: mm (in)/5 min
Measuring position
Standard value
Reference value for remedy
Service limit
C
0
1 (0.04)
2 (0.08) GUIDE FRAME
C
ANGLE METER
SM0868
T4-3-9
E215B-E245B
TEST PROCEDURES
Drain rate of travel motor PURPOSE To measure the drain rate of the travel motor and to confirm the performances of the travel motor. CONDITIONS Hydraulic oil temperature: Engine revolution:
45~55°C (113~131°F) Hi idle
PREPARATION 1.
Place a stopper under the RH and LH travel sprockets.
2.
Stop the engine and release pressure from the hydraulic circuit.
3.
Connect a hose with the drain port of the travel motor and take drain in a container.
MEASUREMENT AT TRAVEL LOCK
90 o 10 (3.54") (0.394")
FORWARD o 22 PIPE (0.866") RIB "A"
40 (1.57") 150 (5.91")
STOPPER "B"
ROTARY DIRECTION
o 80 (3.15") SM0869
WARNING Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in some cases. 1.
Start the engine and relieve pressure at the full stroke of the travel lever.
2.
Measure the drain rate for 30 seconds of relieving.
Drain rate of travel motor E215B Unit: (gal) L/30 s
Drain rate of travel motor Measuring position
Standard value
Reference value for remedy
Service limit
Drain rate
9 (2.4)
16 (4.2)
23 (6.1)
E245B Unit: (gal) L/30 s
Drain rate of travel motor Measuring position
Standard value
Reference value for remedy
Service limit
Drain rate
7 (1.6)
14 (3.5
21 (4.6)
T4-3-10
SM0870
TEST PROCEDURES
E215B-E245B
MEASURING SWING PERFORMANCES 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: Firm, level ground Engine revolution:
45~55°C (113~131°F) 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. MEASUREMENT AT TRAVEL LOCK Swing the machine by bringing the swing lever to its full stroke. Measure the time required to make two turns after one turn of preliminary run and calculate the time required for one turn.
Swing speed
Unit : sec/rev
Measuring position
Standard value
Reference value for remedy
Service limit
Swing speed at min. reach
4.2~5.4
5.4~6.9
7.2~
T4-3-11
SM0871
E215B-E245B
TEST PROCEDURES
Performance of swing brake PURPOSE Confirm the braking torque performances by the swing relief valve. BOOM FOOT PIN
ARM TOP PIN
CONDITIONS Hydraulic oil temperature: Firm, level ground Engine revolution:
45~55°C (113~131°F) 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.
MEASUREMENT AT TRAVEL LOCK 1.
2.
When operating in regular swing speed, by shifting lever to neutral position at pole position the swing operation stops. Calculate the swing drift angle by the following equation, after the upper swing body stops, using the amount of deflection (m) of the matching marks on the swing race and the length (m) of the circumference of the swing race:
Swing angle (°)
drift
Amount of deflection of matching marks [m (ft-in)]
=
Circumferenzial lenght of swing race [m (ft-in)]
Swing brake performance
x 360°
MEASURING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON OUTER RACE
MATCHING MARKS ON INNER RACE SM0873
Unit : degree
Measuring position
Standard value
Reference value for remedy
Service limit
Swing 180°
75°
85°
90°
T4-3-12
TEST PROCEDURES
E215B-E245B
Performance of swing parking brake 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
Put the angle meter on the shoe plate and make sure that the angle is more than 15 degree. Put a matching mark on the outer race side and on the inner race side.
MEASUREING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON OUTER RACE
MEASUREMENT AT TRAVEL LOCK When five minutes has passed after the engine stops, measure the length of the movement of the matching marks.
Performance of swing parking brake
Unit : mm(in)/5min
Measuring position
Standard value
Reference value for remedy
Service limit
C
0
1 (0.04)
2 (0.08)
T4-3-13
MATCHING MARKS ON INNER RACE SM0875
E215B-E245B
TEST PROCEDURES
Drain rate of swing motor 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.
4.
Put a plug to the tank side.
MEASUREMENT AT SWING LOCK 1.
Start the engine and put the side faces of bucket against the inside of the right or left shoe plates.
2.
Relieve the swing motor at full stroke of the swing motion.
3.
Collect the amount of drained oil in a container for 30 seconds.
Drain rate of swing motor
Unit : L(gal)/30sec
Measuring position
Standard value
Reference value for remedy
Service limit
Drain rate
2.1 (0.55)
5.2 (1.4)
6.2 (1.6)
T4-3-14
SM0876
TEST PROCEDURES
E215B-E245B
MEASURING ATTACHMENT OPERATING PERFORMANCES Operating time of cylinders 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
Measurement 2 ; Arm in and out, positioning, bucket digging and dump In a position in which the tooth of the bucket rises to a level of about 30cm (1ft) above ground, measure the full stroke operating time required with the arm and bucket operating levers at full stroke. Cylinder Operating time
6
Unit : sec
Measuring position
Standard value
Reference value for remedy
Service limit
1
2.2~2.8
2.8~3.6
3.8~
2
1.7~2.3
2.2~2.9
3.0~
3
2.5~3.1
3.2~4.0
4.2~
4
2.2~2.8
2.8~3.6
3.8~
5
3.5~4.1
4.4~5.9
5.5~
6
2.6~3.2
3.3~4.1
4.3~
7
3.0~3.6
3.8~4.6
5.0~
8
2.3~2.9
2.9~3.7
3.9~
9
2.9~3.5
3.7~4.4
4.6~
10
4.1~4.7
5.2~6.0
6.3~
30cm (1ft)
9
10 SM0877
T4-3-15
E215B-E245B
TEST PROCEDURES
Oil tightness of cylinders PURPOSE Confirm that the cylinder oil tight by checking the moving length of the cylinder rods.
B BOOM FOOT PIN
C
CONDITIONS Hydraulic oil temperature:
A
45~55°C (113~131°F)
Firm, level ground After cylinders are replaced, bleed off air from the 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. Oil tightness of cylinder
Unit: mm(in)/5min
Measuring position
Standard value
Reference value for remedy
Service limit
A
7 (0.28)
11 (0.43)
14 (0.55)
B
6 (0.24)
9 (0.35)
11 (0.43)
C
-
-
-
D
80 (3.1)
120 (4.7)
160 (6.3)
T4-3-16
D ARM TOP PIN
SM0878
TEST PROCEDURES
E215B-E245B
MEASURING PERFORMANCES OF SWING BEARING 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 fix it to the lower frame.
2.
Direct the upper swing body and the lower frame toward the travel direction, bring the probe of the dial indicator in contact with the bottom surface of the outer race on the swing body side and set the reading at zero.
LOCATION OF BEARING MOUNTING BOLTS
SWING BEARING A
DIAL INDICATOR LOWER FLAME
MEASUREMENT Measuring position 1 and 2 Measure the displacement of the outer race in the 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. Axial play of swing bearing
SM0879
Unit: mm (in)
Measuring position
Standard value
Reference value for remedy
Service limit
A
0.8~1.8 (0.03~0.07)
2.3~3.3 (0.09~0.13)
3.6 (0.14)
90 ~100
30cm
SM0879
Position 1
BOOM FOOT PIN
ARM TOP PIN
SM0872
Position 2
T4-3-17
E215B-E245B
TEST PROCEDURES
Measuring position 3 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. Then swing the bucket right and left by man power. But in this case, the gap of the attachment is included. Right and left movement of the tip of bucket
BOOM FOOT PIN
ARM TOP PIN
Unit: mm (in)
Measuring position
Standard value
Reference value for remedy
Service limit
Benna
30~50 (1.18~1.97)
80 (3.15)
120 (4.72)
T4-3-18
SM0872
Position 3
MECHATRO CONTROLLER
E215B-E245B
ENGINE CONTROL INPUT/OUTPUT
M-2: GOVERNOR MOTOR C-2: GAUGE CLUSTER
E-1: FUSE&RELAY BOX
ENGINE SPEED SENSOR
STARTER SWITCH
C-1: MECHATRO CONTROLLER
ACCEL POTENTIO METER
ENGINE
PUMP PROPORTIONAL VALVE
SM0881
T4-4-1
E215B-E245B
MECHATRO CONTROLLER
ENGINE CONTROL Engine control assy
3 1 11
3 3 5 Section A-A
10
4
HIGH
LOW LOW
HIGH 2 4 2 Section B-B
Detail aa 9
7
6
8
2
Section C-C
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
9
SM0882
MECHATRO CONTROLLER
E215B-E245B
ENGINE CONTROL EQUIPMENT Governor motor and C–1 controller 1.
By operating accel dial, the input voltage change issensed by CN102–8 pin of C–1 controller.
2.
The C–1 controller computes the input voltage, andoutputs command to governor motor (M–2), and incline governor lever of engine to the swing angle corresponding to accel dial set value.
3.
The limit switch in the governor motor is the starting point of the governor motor.
OIL SEAL OUTPUT SHAFT
REDUCTION GEAR SECTION MOTOR SECTION
CAM LIMIT SWITCH
SM0883
Speed sensor Installing place: engine flywheel housing. Sensor attaching procedure: push it into place and fix with partially self-sealing cylindrical screw M6x12, tightening torque 8±2 Nm.
CN-136F
SM0884
Work mode select switch If the work mode select switch is pressed, a signal istransmitted to the C–1 controller and changes the work modes in the order of H→B→A→S and back to H again.
WORK MODE SELECT SWITCH
SM0885
T4-4-3
E215B-E245B
MECHATRO CONTROLLER
ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) Purpose of the adjustment There are 3 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function to ensure performance of machine. 1.
Adjustment of engine ("A" adjustment) This adjustment is performed to set the relation between the stepping command output from mechatro controller to governor motor and the engine speed.
2.
Adjustment of pump ("B" adjustment) This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with engine rated output.
3.
Adjustment of unloading valve ("C" adjustment) This adjustment is performed to correct the open variation of unloading valve to improve the operability further.
In cases where the adjustment of mechatro controller is required When the following parts are replaced or repaired, carry out the adjustment without fail: 1.
Mechatro controller
2.
Engine
3.
Hydraulic pump or hydraulic pump proportional valve
4.
Unloading proportional unloading valve.
valve,
spool
of
Preparation 1.
Raise the oil temperature to about 50°C (122°F) to warm up the engine.
2.
Turn the air-con OFF.
3.
Turn the starter key switch OFF to stop the engine. When the mechatro controller was replaced, the following error code is displayed because the adjustment data is not entered. A215, A225, A015, A025, A035
As the error codes other than those shown above may suggest failures of machine, repair the machine into the ordinary operating condition according to Error Code List.
T4-4-4
MECHATRO CONTROLLER
E215B-E245B
Adjusting procedure
MULTI DISPLAY
WORK MODE SELECT SWITCH
BUZZER STOP SWITCH
WASHER SWITCH WIPER SWITCH
SELECT SWITCH
SM0886
ADJUSTMENT OF ENGINE ("A" ADJUSTMENT) PROCEDURE 1.
Turn starter key switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5~10 seconds, and then release 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 selecting adjustment 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.
Press selector switch on gauge cluster to display "START ENG"."Engine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (stepping command) are indicated.
T4-4-5
SM0887
E215B-E245B 4.
5.
MECHATRO CONTROLLER
After starting engine, press selector switch on gauge cluster, and "MEMORY ENG" is displayed, the engine speed is automatically increased, and the adjustment of engine is performed. (When trying to limit engine speed, press selector switch on gauge cluster at the speed as it is, and the adjustment of engine is terminated. The torque adjustment and unloading adjustment required later are not performed, and default value is written.). When normal HIGH idling speed is detected, the adjustment is completed. And "FINISH ENG" is displayed. (Press the buzzer stop switch on gauge cluster while this display is appeared, and the adjustment of engine is completed. The torque adjustment and unloading adjustment required later are not performed, and default value is written.)
FINISH ENG ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 STEP 400
2.0M
SM0888
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 adjustment of pump is automatically completed. And "FINISH PUMP" is displayed. (Press the buzzer stop switch on gauge cluster while this display is appeared and the adjustment is completed. The unloading adjustment required later is not performed, and default value is written.).
T4-4-6
FINISH PUMP ENGINE SPEED 2000rpm PUMP PRESSURE C-1 35.0M C-2 PROPO-VALVE E-1 300mA E-2
35.0M 300mA
SM0889
MECHATRO CONTROLLER
E215B-E245B
ADJUSTMENT OF UNLOADING VALVE (“C” ADJUSTMENT) PROCEDURE 1.
2.
The adjustment shifts from pump to unloading, and the unloading valve actuates, accordingly the pump pressure is detected. And "MEMORY UNLOAD" is displayed.The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PROPO-VALVE" voltage (command value) are indicated".
MEMORY UNLOAD ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 2.0M PROPO-VALVE D-1 300mA D-2 300mA
When the unloading valve operates to the specified value, the adjustment of unloading proportional valve is automatically terminated. And "FINISH UNLOAD" is displayed. The speed is shifted to the speed corresponding to acceleration potentiometer.The adjusting current value is indicated on the display of current of P1, P2 unloading proportional valves. The adjusting range is usually 520~635mA.
Stop the engine. (The adjusted data is automatically stored.). SM0890
CORRECTIVE ACTION TAKEN WHEN THE ADJUSTMENT CAN BE NOT PERFORMED 1.
In cases where the adjustment of engine can not be performed; And ERROR ENG" is displayed. Judging condition: The read engine speed is 50rpm lower than the last value. It is conceived that the error is caused by the speed read error, pump load applied to the engine and unusual stepping command applied to the governor motor in the course of adjustment. a. Checking speed sensor: check that it is free from wrong reading of speed due to engine vibratio. b. Checking load applied to pump: check that it is free from abnormal increase of pump pressure during adjustment of engine through adjustment screen.
T4-4-7
E215B-E245B 2.
MECHATRO CONTROLLER
In cases where the adjustment of pump can not be performed; And "ERROR PUMP" is displayed. Judging condition 1: P1 and P2 average pump pressure at the time when the adjustment is completed is 25MPa or less.
SM0891
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. 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
SM0892
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.
WHEN THE ADJUSTMENT OF UNLOADING VALVE ONLY IS PERFORMED (“C” ADJUSTMENT) In the event where only unloading valve and unloading proportional valve are replaced, perform the adjustment of unloading valve only. PROCEDURE 1.
Turn starter switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5~10 seconds, and then release 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". "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (stepping command) are indicated.
T4-4-9
MULTI DISPLAY (EXAMPLE)
SM0893
E215B-E245B 5.
6.
MECHATRO CONTROLLER
After starting engine, press selector switch on gauge cluster and "MEMORY UNLOAD" is indicated, the engine speed is automatically increased and the adjustment of unloading valve is performed. "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" are indicated. When the unloading proportional valve operates to the specified value, the adjustment of unloading proportional valve automatically completes. "FINISH UNLOAD" is indicated. The speed is shifted to the speed corresponding to acceleration potentiometer. The value of adjusting current is indicated on the display of current of P1 and P2 unloading proportional valves. The adjusting range is usually 520~635mA.
Stop the engine. (The adjusted data is automatically stored.) Operations in the event of a failure of equipment of mechatro controller PUMP EMERGENCY MODE In the event where a failure of P1 or P2 pump proportional valve represented in items of self diagnosis is indicated on multi display provided on the gauge cluster, the full power control of pump and positive control through mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched to emergency mode, making the operation with the power shift control of pump and the constant power control by means of selfpressure possible. But be careful that, at emergency mode, the accuracy of inching becomes poor, the frequency of engine down is increased, and the engine stalls in LOW speed condition. 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
MEMORY UNLOAD ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 2.0M PROPO-VALVE D-1 300mA D-2 300mA
SM0894
TROUBLESHOOTING
M0103
TROUBLESHOOTING
E215B-E245B
SECTION AND GROUP CONTENTS Section 5
TROUBLESHOOTING
Group 1 Group 2 Group 3
Troubleshooting (by Error Codes) Troubleshooting (by trouble) Troubleshooting (Trouble diagnosis mode)
SECTION 5
TROUBLESHOOTING
CONTENTS Group 1 - Troubleshooting (by Error Codes) 1. Judgment of actual thing at site ......... T5-1-1 2. Classification on failure and troubleshooting .................................. T5-1-2 3. The blown fuse of Mechatro Controller ........................................... T5-1-2 4. Troubleshooting by Error Codes ........ T5-1-2
Group 2 - Troubleshooting (by trouble) 1. Hydraulic system ............................... T5-2-1 2. Electric systems ................................. T5-2-30 2.1 Wiring checking procedure ......... T5-1-30 2.2 Trouble ....................................... T5-1-33
Group 3 - Troubleshooting (Trouble diagnosis mode) 1. Trouble diagnosis mode .................... T5-3-1
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
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.
1. JUDGMENT OF ACTUAL THING AT SITE
SM0100
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 additional works.
SM0101
Verifying background of trouble occurred
HOW TO DIAGNOSE TROUBLE 1. Verify defective part 2. Make the condition of trouble again 3. Where defective parts can not be verified, surmise causes systematically. 4. Verify reasons for surmise 5. Report methods, procedure, and period for repairing to user. SM0102
EXPLANATION OF THE CAUSE OF 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.
Confirm the symptoms of the trouble
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
Diagnosing fail by means troubleshooting
T5-1-1
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
2. CLASSIFICATION OF FAILURE AND TROUBLESHOOTING 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".
3. THE BLOWN FUSE OF MECHATRO CONTROLLER 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
4. TROUBLESHOOTING BY ERROR CODE 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.
Error Code
Trouble
Described page
A015
Engine adjustment (A adjustment) is not adjusted yet or is failed.
T5-1-5
A025
Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed.
T5-1-5
A035
Unload valve adjustment (C adjustment) is not adjusted yet or is failed.
T5-1-6
A215
Written data of ROM adjustment data is incorrect.
T5-1-6
A225
Writing of ROM adjustment data is incorrect.
T5-1-7
A235
Written data of ROM hour meter data is incorrect.
T5-1-7
A245
Writing of ROM hour meter data is incorrect.
T5-1-8
A255
Writing of proportional valve adjustment data is incorrect.
T5-1-8
B012
Incorrect output of boom up pressure sensor
T5-1-9
B013
Disconnection of boom up pressure sensor
T5-1-9
B014
Short-circuit of boom up pressure sensor
T5-1-10
B022
Incorrect output of boom down pressure sensor
T5-1-10
T5-1-2
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Error Code
Trouble
B023
Disconnection of boom down pressure sensor
T5-1-11
B024
Short-circuit of boom down pressure sensor
T5-1-11
B032
Incorrect output of arm out pressure sensor
T5-1-12
B033
Disconnection of arm out pressure sensor
T5-1-12
B034
Short-circuit of arm out pressure sensor
T5-1-13
B042
Incorrect output of arm in pressure sensor
T5-1-13
B043
Disconnection of arm in pressure sensor
T5-1-14
B044
Short-circuit of arm in pressure sensor
T5-1-15
B052
Incorrect output of bucket digging pressure sensor
T5-1-16
B053
Disconnection of bucket digging pressure sensor
T5-1-16
B054
Short-circuit of bucket digging pressure sensor
T5-1-17
B062
Incorrect output of bucket dump pressure sensor
T5-1-17
B063
Disconnection of bucket dump pressure sensor
T5-1-18
B064
Short-circuit of bucket dump pressure sensor
T5-1-18
B072
Incorrect output of swing pressure sensor
T5-1-19
B073
Disconnection of swing pressure sensor
T5-1-19
B074
Short-circuit of swing pressure sensor
T5-1-20
B092
Incorrect output of travel right pressure sensor
T5-1-20
B093
Disconnection of travel right pressure sensor
T5-1-21
B094
Short-circuit of travel right pressure sensor
T5-1-22
B102
Incorrect output of travel left pressure sensor
T5-1-23
B103
Disconnection of travel left pressure sensor
T5-1-23
B104
Short-circuit of travel left pressure sensor
T5-1-24
B113
Disconnection of pressure sensor of optional selector positioning
T5-1-25
B114
Short-circuit of pressure sensor of optional selector positioning
T5-1-26
B162
Incorrect output of P1 optional side pressure sensor
T5-1-26
B163
Disconnection of P1 side optional pressure sensor
T5-1-27
B164
Short-circuit of P1 side optional pressure sensor
T5-1-28
B172
Incorrect output of P2 optional side pressure sensor
T5-1-28
B173
Disconnection of P2 side optional pressure sensor
T5-1-29
B174
Short-circuit of P2 side optional pressure sensor
T5-1-29
C012
Incorrect output of P1 pump pressure sensor
T5-1-30
C013
Disconnection of P1 pump pressure sensor
T5-1-30
C014
Short-circuit of P1 pump pressure sensor
T5-1-31
C022
Incorrect output of P2 pump pressure sensor
T5-1-31
C023
Disconnection of P2 pump pressure sensor
T5-1-32
C024
Short-circuit of P2 pump pressure sensor
T5-1-32
C033
Disconnection of boom head pressure sensor
T5-1-33
C034
Short-circuit of boom head pressure sensor
T5-1-33
D012
Failure of output transistor ON at P1 unload proportional valve
T5-1-34
D013
Disconnection of P1 unload proportional valve
T5-1-34
D022
Failure of output transistor ON at P2 unload proportional valve
T5-1-35
D023
Disconnection of P2 unload proportional valve
T5-1-36
D032
Failure of output transistor ON at travel straight proportional valve
T5-1-36
D033
Disconnection of travel straight proportional valve
T5-1-37
D062
Failure of output transistor ON at arm in high speed proportional valve
T5-1-38
T5-1-3
Described page
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Error Code
Trouble
Described page
D063
Disconnection of arm in high speed proportional valve
T5-1-39
D152
Failure of output transistor ON at short-circuit valve
T5-1-39
D153
Disconnection of short-circuit valve
T5-1-40
E012
Failure of output transistor ON at P1 pump proportional valve
T5-1-40
E013
Disconnection of P1pump proportional valve
T5-1-41
E022
Failure of output transistor ON at P2 pump proportional valve
T5-1-42
E023
Disconnection of P2 pump proportional valve
T5-1-42
F011
Failure of output transistor OFF and GND short of attachment boost SOL valve
T5-1-43
F013
Failure of output transistor ON and disconnection of attachment boost SOL valve
T5-1-4
F021
Failure of output transistor OFF and GND short of swing parking SOL valve
T5-1-45
F023
Failure of output transistor ON and disconnection of swing parking SOL valve
T5-1-45
F031
Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve
T5-1-46
F033
Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve
T5-1-47
F041
Failure of output transistor OFF and GND short of optional selector SOL valve
T5-1-47
F043
Failure of output transistor ON and disconnection of optional selector SOL valve
T5-1-48
G011
Failure of output transistor ON at governor motor
T5-1-48
G013
Disconnection of governor motor
T5-1-49
G023
Starting point indexing is impossible
T5-1-49
G032
Overrun of speed sensor of direct input Mechatro-controller
T5-1-50
G033
Disconnection of speed sensor of direct input Mechatro-controller
T5-1-50
H013
Disconnection of acceleration potentio
T5-1-51
H014
Power short-circuit of acceleration potentio
T5-1-51
H023
Disconnection of boom angle potentio
T5-1-52
H024
Power short-circuit of boom angle potentio
T5-1-53
H033
Disconnection of arm angle potentio
T5-1-54
H034
Power short-circuit of arm angle potentio
T5-1-55
H091
Failure of GND short-circuit of fuel sensor
T5-1-56
H093
Disconnection of fuel sensor
T5-1-56
I313
Received error of cluster communication (time-out error)
T5-1-57
K014
Adhesion of battery relay terminal
T5-1-58
R014
Failure of arc prevention relay of wiper motor
T5-1-59
R024
Failure of normal rotation relay of wiper motor
T5-1-60
R034
Failure of reverse rotation relay of wiper motor
T5-1-61
R044
Failure of washer motor relay
T5-1-62
R134
Failure of swing flasher relay
T5-1-63
R144
Failure of swing flasher relay
T5-1-64
R154
Failure of travel alarm relay
T5-1-65
R164
Failure of auto idling stop relay 2
T5-1-66
R174
Failure of engine forcible stop relay
T5-1-67
R184
Failure of lever lock relay
T5-1-68
R214
Failure of safety relay
T5-1-69
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.
Service diagnosis Screen No. checking screen
2
G-3 SPEED SET
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)
Judging condition
Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within the 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.
Service diagnosis Screen No. checking screen
9
E-1 P1 PUMP
9
E-2 P2 PUMP
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)
Judging condition
The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting 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 No.
8
D-1 P1 UN-LOAD (BP-CUT)
Service diagnosis Screen checking screen No.
8
D-2 P2 UN-LOAD (BP-CUT)
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 1
Mechatro controller
Checking contents and remedy 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 1
Mechatro controller
Checking contents and remedy 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 1
Mechatro controller
Checking contents and remedy 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 1
Mechatro controller
Checking contents and remedy 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 1
Mechatro controller
Checking contents and remedy 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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the sensor after 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 No.
5
B-1 BOOM RAISE
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 pressure sensor and controller CN-126F CN-101F
When B012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
5
B-1 BOOM RAISE
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 No.
5
B-1 BOOM RAISE
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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the sensor after 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 No.
5
B-2 BOOM LOWER
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 exchanging the connector with other sensor. SE-4 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom down pressure sensor and controller CN-127F CN-101F
When B022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
5
B-2 BOOM LOWER
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 with other sensor. SE-4 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 No.
5
B-2 BOOM LOWER
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 exchanging the connector with other sensor. SE-4 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom down pressure sensor and controller CN-127F CN-101F
When B024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the sensor after 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 No.
5
B-3 ARM OUT
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 sensor and controller CN-131F CN-101F
When B032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
5
B-3 ARM OUT
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 No.
5
B-3 ARM OUT
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 pressure sensor and controller CN-131F CN-101F
When B034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the arm-in pressure 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 No.
5
B-4 ARM IN
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Arm-in pressure sensor SE-7
Checking contents and remedy When B042 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-in pressure sensor and controller CN-130F CN-101F
When B042 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Symptom
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but 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 No.
5
B-4 ARM IN
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Arm-in pressure sensor SE-7
When B043 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-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.
Symptom
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but 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, 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. Service diagnosis Screen No. checking screen Screen No.
5
B-4 ARM IN
Checking object
Checking contents and remedy
1
• Arm-in pressure sensor SE-7
When B044 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-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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the bucket digging 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 No.
5
B-5 BUCKET DIG
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 exchanging the connector with other sensor. SE-1 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F
When B052 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
5
B-5 BUCKET DIG
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 exchanging the connector with other sensor. SE-1 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F
When B053 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
5
B-5 BUCKET DIG
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 exchanging the connector with other sensor. SE-1 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F
When B054 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the bucket dump 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 No.
5
B-6 BUCKET DUMP
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 exchanging the connector with other sensor. SE-2 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F
When B062 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
5
B-6 BUCKET DUMP
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 exchanging the connector with other sensor. SE-2 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F
When B063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
5
B-6 BUCKET DUMP
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 exchanging the connector with other sensor. SE-2 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F
When B064 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the swing pressure 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 No.
6
B-7 SWING
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• Swing pressure sensor
When B072 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.
SE-5 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. Check wiring for possible failure according to the wiring checking procedure CN-169F and repair it if necessary. CN-103F
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 No.
6
B-7 SWING
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Swing pressure sensor SE-5
Checking contents and remedy When B073 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 swing pressure When B073 is displayed after turning the starter switch on after the connector sensor and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-169F and repair it if necessary. CN-103F
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 No.
6
B-7 SWING
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• Swing pressure sensor
When B074 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.
SE-5 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. Check wiring for possible failure according to the wiring checking procedure CN-169F and repair it if necessary. CN-103F
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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the travel right 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 No.
6
B-9 TRAVEL (R)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Travel right pressure sensor SE-9
Checking contents and remedy When B092 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 travel right pressure sensor and controller CN-301F CN-102F
When B092 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
6
B-9 TRAVEL (R)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Travel right pressure sensor SE-9
Checking contents and remedy When B093 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 travel right pressure sensor and controller CN-301F CN-102F
When B093 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
6
B-9 TRAVEL (R)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Travel right pressure sensor SE-9
Checking contents and remedy When B094 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 travel right pressure sensor and controller CN-301F CN-102F
When B094 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the travel left 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 No.
6
B-10 TRAVEL (L)
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• Travel left pressure sensor
When B102 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.
SE-10 2
• Wiring between travel left pressure sensor and controller CN-302F CN-102F
When B102 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
6
B-10 TRAVEL (L)
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• Travel left pressure sensor
When B103 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.
SE-10 2
• Wiring between travel left pressure sensor and controller CN-302F CN-102F
When B103 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
6
B-10 TRAVEL (L)
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• Travel left pressure sensor
When B104 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.
SE-10 2
• Wiring between travel left pressure sensor and controller CN-302F CN-102F
When B104 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
16
B-11
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. Check sensor unit for possible failure. If failure found, replace it. SE-29
2
• Wiring between option selector position detect pressure sensor and controller CN-162F CN-104F
When B113 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
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 No.
16
B-11
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. Check sensor unit for possible failure. If failure found, replace it. SE-29
2
• Wiring between option selector position detect pressure sensor and controller CN-162F CN-104F
When B114 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P1 side option 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 No.
6
B-16 P1 OPT.
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• P1 side option pressure sensor SE-20
Checking contents and remedy When B162 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 P1 side option pressure sensor and controller CN-304F CN-102F
When B162 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
6
B-16 P1 OPT.
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• P1 side option pressure sensor SE-20
Checking contents and remedy When B163 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 P1 side option pressure sensor and controller CN-304F CN-102F
When B163 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
6
B-16 P1 OPT.
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• P1 side option pressure sensor SE-20
When B164 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 P1 side option pressure sensor and controller CN-304F CN-102F
When B164 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P2 side option 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 No.
6
B-17 P2 OPT.
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• P2 side option pressure sensor SE-11
Checking contents and remedy When B172 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 P2 side option pressure sensor and controller CN-304F CN-102F
When B172 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
6
B-17 P2 OPT.
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• P2 side option pressure sensor SE-11
When B173 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 P2 side option pressure sensor and controller CN-303F CN-102F
When B173 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
6
B-17 P2 OPT.
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• P2 side option pressure sensor SE-11
Checking contents and remedy When B174 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 P2 side option pressure sensor and controller CN-303F CN-102F
When B174 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P1 pump 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 No.
7
C-1 PUMP P1
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P1 pump pressure sensor
When C012 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.
SE-22 2
• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F
When C012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
7
C-1 PUMP P1
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P1 pump pressure sensor
When C013 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.
SE-22 2
• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F
When C013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
7
C-1 PUMP P1
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P1 pump pressure sensor
When C014 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.
SE-22 2
• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F
When C014 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P2 pump 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 No.
7
C-2 PUMP P2
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P2 pump pressure sensor
When C022 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.
SE-23 2
• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F
When C022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
7
C-2 PUMP P2
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P2 pump pressure sensor
When C023 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.
SE-23 2
• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F
When C023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
7
C-2 PUMP P2
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P2 pump pressure sensor
When C024 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.
SE-23 2
• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F
When C024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
7
C-3 BOOM-HEAD
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• Boom head pressure sensor SE-24
When C033 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 head pressure sensor and controller CN-140F CN-103F
When C033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
7
C-3 BOOM-HEAD
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Boom head pressure sensor SE-24
Checking contents and remedy When C034 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 head pressure sensor and controller CN-706F CN-104F
When C034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
8
D-1 P1 UN-LOAD (BP-CUT)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• P1 unload proportional valve PSV-D
When D012 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 P1 unload proportional valve and controller CN-120F CN-105F
When D012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
The feed-back value from proportional valve is 100 mA or less. (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 No.
8
D-1 P1 UN-LOAD (BP-CUT)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• P1 unload proportional valve PSV-D
Checking contents and remedy When D013 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 P1 unload proportional valve and controller CN-120F CN-105F
When D013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
8
D-2 P2 UN-LOAD (BP-CUT)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• P2 unload proportional valve PSV-B
Checking contents and remedy When D022 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 P2 unload proportional valve and controller CN-118F CN-105F
When D022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
The feed-back value from proportional valve is 100 mA or less. (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 No.
8
D-2 P2 UN-LOAD (BP-CUT)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• P2 unload proportional valve PSV-B
When D023 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 P2 unload proportional valve and controller CN-118F CN-105F
When D023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
8
D-3 S-TRAVEL
Service diagnosis Screen checking screen No. Screen No. Checking object straight
Checking contents and remedy
1
• Travel valve
2
• Wiring between Travel straight proportional valve and controller CN-119F CN-105F
When D032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
PSV-C
proportional When D032 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.
T5-1-36
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 57 Error code
D033
Trouble
Travel straight proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100 mA or less. (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 No.
8
D-3 S-TRAVEL
Service diagnosis Screen checking screen No. Screen No. Checking object straight
Checking contents and remedy
1
• Travel valve
2
• Wiring between Travel straight proportional valve and controller CN-119F CN-105F
When D033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
PSV-C
proportional When D033 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.
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 No.
8
D-4 ARM IN-2-SPEED
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. Check sensor unit for possible failure. If failure found, replace it. PSV-A
2
• Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F
When D062 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
The feed-back value from proportional valve is 100 mA or less. (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 No.
8
D-4 ARM IN-2-SPEED
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. Check sensor unit for possible failure. If failure found, replace it. PSV-A
2
• Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F
When D063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
9
E-1 PUMP P1
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P1 pump proportional valve
When E012 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. When replacing of connector is executed, turn off power source once.
PSV-P1
2
• Wiring between P1 pump proportional valve and controller CN-141F CN-105F
When E012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
The feed-back value from proportional valve is 100 mA or less. (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 No.
9
E-1 PUMP P1
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P1 pump proportional valve
When E013 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. When replacing of connector is executed, turn off power source once.
PSV-P1
2
• Wiring between P1 pump proportional valve and controller CN-141F CN-105F
When E013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
9
E-2 PUMP P2
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P2 pump proportional valve
When E022 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. When replacing of connector is executed, turn off power source once.
PSV-P2
2
• Wiring between P2 pump proportional valve and controller CN-142F CN-105F
When E022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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.
Judging condition
The feed-back value from proportional valve is 100 mA or less. (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 No.
9
E-2 PUMP P2
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P2 pump proportional valve
When E023 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. When replacing of connector is executed, turn off power source once.
PSV-P2
2
• Wiring between P2 pump proportional valve and controller CN-142F CN-105F
When E023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure 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 No.
3
F-1 POWER BOOST
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• ATT boost solenoid valve
When F011 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
SV-2 2
• Wiring between ATT boost solenoid valve and controller CN-117F CN-105F
When F011 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure 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 No.
3
F-1 POWER BOOST
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• ATT boost solenoid valve
When F013 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
SV-2 2
• Wiring between ATT boost solenoid valve and controller CN-117F CN-105F
When F013 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure 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 No.
3
F-2 SWING-BRAKE
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• Swing parking solenoid valve SV-1
When F021 is cancelled and other error occurs by exchanging the connector 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 solenoid valve and controller CN-123F CN-105F
When F021 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure 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 No.
3
F-1 POWER BOOST
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Swing parking solenoid valve SV-1
Checking contents and remedy When F023 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between swing parking solenoid valve and controller CN-123F CN-105F
When F023 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure 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 No.
3
F-3 1/2-TRAVEL
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 for other solenoid valve. SV-3 Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between travel 1, 2 speed solenoid valve and controller CN-123F CN-105F
When F031 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
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 No.
3
F-3 1/2-TRAVEL
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 for other solenoid valve. SV-3 Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between travel 1, 2 speed solenoid valve and controller CN-122F CN-105F
When F033 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary..
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 No.
11
F-4 OPT SELECT
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Option selector solenoid valve SV-13
Checking contents and remedy When F041 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between option selector solenoid valve and controller CN-251F CN-105F
When F041 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure 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 No.
11
F-4 OPT SELECT
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Option selector solenoid valve SV-13
Checking contents and remedy When F043 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between option selector solenoid valve and controller CN-251F CN-105F
When F043 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure 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)
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
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 No.
2
G-3 MEAS 1 (for mechatro controller)
Service diagnosis Screen checking screen No.
2
G-3 MEAS 2 (receive from engine controller)
Screen No. Checking object
Checking contents and remedy
1
• Engine speed sensor
Measure the resistance between terminals of speed sensor.
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
SV-13
Normal value: 1.6~2.0k
.
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 No.
2
G-3 MEAS 1 (for mechatro controller)
Service diagnosis Screen checking screen No.
2
G-3 MEAS 2 (receive from engine controller)
Screen No. Checking object 1
• Engine speed sensor SE-13
Checking contents and remedy Measure the resistance between terminals of speed sensor. 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 and repair it if necessary. CN-136F 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 No.
2
H-1 ACCEL VOLT.
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• Accel potentiometer
Measure the resistance between terminals of speed sensor. 1.6~2.4k Turn the potentiometer and measure resistance between signal and GND.
SE-16 2
• Wiring between accel potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-402F 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 No.
2
H-1 ACCEL VOLT.
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Accel potentiometer SE-16
Checking contents and remedy Measure the resistance between terminals of accel potentiometer. 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 and repair it if necessary. CN-402F 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 No.
12
H-2 BOOM
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Boom angle potentiometer SE-17
Checking contents and remedy Measure the resistance between terminals of boom angle potentiometer. 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 and repair it if necessary. CN-702F 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 No.
12
H-2 BOOM
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Boom angle potentiometer SE-17
Checking contents and remedy Measure the resistance between terminals of boom angle potentiometer. 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 and repair it if necessary. CN-702F 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 No.
12
H-3 ARM
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Arm angle potentiometer SE-18
Checking contents and remedy Measure the resistance between terminals of arm angle potentiometer. 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 and repair it if necessary. CN-703F 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 No.
12
H-3 ARM
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Arm angle potentiometer SE-18
Checking contents and remedy Measure the resistance between terminals of arm angle potentiometer. 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 and repair it if necessary. CN-703F 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 No.
10
H-9 FUEL LEVEL
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• 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 and repair it if necessary. CN-152F 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 No.
10
H-9 FUEL LEVEL
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• 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 and repair it if necessary. CN-152F 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 and repair it if necessary. CN-600F 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.
Judging condition
The power 24 V is continuously supplied to controller for 40 seconds or more while the key switch ON 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 No.
4
K-1 AIS RELAY 2
Service diagnosis Screen checking screen No.
4
K-3 KEY SWITCH OFF
Screen No. Checking object
Checking contents and remedy
1
• Battery relay R-1 CN-256F
Turn key switch off and disconnect the connector (CN-256F) on the battery relay coil. If 24 V power lives on battery relay secondary side, check on battery relay for failure and replace it if failed.
2
• Auto idle stop relay 2 R-24 • Alternator relay
Turn off the key switch, and remove the connector (CN-256F) on the battery relay coil side. If power of battery relay on secondary side falls, remove either auto idling stop relay 2 or alternator relay. The failure may be occurred in case where the power falls after the relay was removed, and therefore check on the relay unit and replace it with new one if failed.
R-28 3
• Wiring between auto idle stop relay/alternator relay and When K014 is left displayed with the relay removed. Check that no power 24 V is produced on relay (-) line according to the wiring controller 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.
Judging condition
The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the 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 No.
25
PREVENT ARC
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 unit for failure, replace it with new one if failed. relay R-31 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between wiper motor arc prevention relay and controller CN-109F, CN2-1 • Fuse& relay box E-1
3
• Mechatro controller
When R014 is left displayed with the relay removed. Check that no power 24 V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R014 is left displayed. Replace fuse/relay box. 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.
Judging condition
The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the 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 No.
25
CW MOTOR RLY
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, check relay unit for failure, replace it with new one if failed. relay R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between wiper motor forward rotation relay and When R024 is left displayed with the relay removed. Check that no power 24 V is produced on relay (-) line according to the wiring controller checking procedure and replace it if necessary. CN-109F, CN2-1 When no failure found after checking on wiring and R024 is left displayed. • Fuse& relay box Replace fuse/relay box. E-1
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-60
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 91 Error code
R034
Trouble
Wiper motor reverse rotation relay error.
Judging condition
The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the 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 No.
25
CCW MOTOR RLY
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, check relay unit for failure, replace it with new one if failed. relay R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between wiper motor forward rotation relay and When R034 is left displayed with the relay removed Check that no power 24 V is produced on relay (-) line according to the wiring controller checking procedure and replace it if necessary. CN-109F, CN2-1 When no failure found after checking on wiring and R034 is left displayed • Fuse& relay box Replace fuse/relay box. E-1
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
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 No.
25
MOTOR RELAY
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Washer motor relay R-32
Checking contents and remedy When error is cancelled after removing washer motor relay, check relay 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 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 Replace fuse/relay box. E-1
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 No.
22
D13
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Swing flasher relay R-19
Checking contents and remedy When error is cancelled after removing connector (CN-74F) of swing flasher relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (HB) and (HC) is 0 condition.
, it is in abnormal
2
• Wiring between swing flasher When R134 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line (as shown right upper CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if necessary.
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 No.
22
D14
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Swing flasher relay R-19
Checking contents and remedy When error is cancelled after removing connector (CN-74F) of swing flasher relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (HB) and (HC) is 0 condition.
, it is in abnormal
2
• Wiring between swing flasher When R144 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line (as shown right upper CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if necessary.
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 No.
23
D15
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Travel alarm relay R-8
Checking contents and remedy When error is cancelled after removing of travel alarm relay, check relay 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 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. Replace fuse/relay box. E-1
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.
Symptom
Power source for mechatro controller often turns off. 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 No.
4
K-1 AIS RELAY 2
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• Auto idle stop relay 2 relay R-24
When error is cancelled after removing of auto idle stop relay 2, check relay 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 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. Replace fuse/relay box. E-1
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.
Symptom
When key switch is turned off but engine does not stop. 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 No.
4
K-3 ENG STOP
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• Engine forcibly stop relay R-25
When error is cancelled after removing of engine forcibly stop relay, check relay 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. Replace fuse/relay box. E-1
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 No.
4
K-4 LOCK LEVER
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Safety lock lever relay R-26
Checking contents and remedy When error R184 is cancelled after removing of safety lock lever relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is
2
• Wiring between safety lock lever relay and controller CN-109F, CN2-2 • Fuse & relay box E-1
3
• Mechatro controller
, it is in abnormal condition.
When R184 is left displayed with the relay removed Check that no power 24 V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R184 is left displayed. Replace fuse/relay box. 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 No.
4
K-2 SAFETY RLY
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Safety lock lever relay R-26
Checking contents and remedy When error R214 is cancelled after removing of safety relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0
2
• Wiring between safety lock lever relay and controller CN-109F, CN2-2 • Fuse & relay box
3
• Mechatro controller
E-1
, it is in abnormal condition.
When R214 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R214 is left displayed. Replace fuse/relay box. 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. 1.
All controls do not function/slow
2.
Engine down/stalled
3.
Move at lever neutral position
4.
Poor fine operability
5.
Slow boom up, insufficient power
6.
Slow boom down, insufficient power for lifting up body
7.
Slow arm in, insufficient power
8.
Slow independent arm out (in the air)
9.
Slow bucket digging
10. Slow bucket dumping 11. Swing operation not functioned/slow 12. Noise during swing operation 13. Swing on a slope drifts when control lever is in neutral position 14. Swing drifts when swing operation is stopped 15. Slow travel speed/weak 16. Travel deviation 17. Travel 1st/2nd speed not changed 18. Travel parking on a slope is not held 19. Travel does not run straightly when both crawlers and attachment operated simultaneously. 20. Slow breaker (crusher) operation, weak power 21. Option selector valve malfunction: not switched to breaker circuit 22. Option selector valve malfunction: not switched to nibbler circuit
T5-2-1
E215B-E245B 1.
TROUBLESHOOTING (BY TROUBLE)
All controls do not function/slow
No.
Sections
Contents/normal value
Corrective action, others
1
Fuse
Check fuse No.4 (10 A)
If the fuse is blown out, check on the short-circuited section.
2
Safety lever lock switch
Carry out service diagnosis
No.4 K-4 switch: Check action of switch by 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 switching
Check that the Measure both terminals of solenoid solenoid is switched connector. 24 V by pushing the lever correctly down, 0 V by pushing it up
4
Safety lever lock relay
Carry out service diagnosis
5
Pilot pressure sensor
6
Solenoid valve for safety lock lever
7
Check solenoid unit for possible failure. Check harness for possible failure.
No.4 K-4 lock lever: Check action of relay by tester Push down the lever and it turns off, push up and it turns on. • Stop engine stop and key is on position. All pilot low pressure sensors are 0 MPa to 0.1 MPa.
Check 5 V power for controller
Measure pressure of solenoid A1 port
About 0 MPa by pushing the lever up, and 4 MPa or more by push it down.
Replace solenoid valve
Pilot line filter
Disassemble and check it visually
Check filter for clogging
Clean filter
8
Pilot gear pump
Measure pilot Check that it is 4 MPa or more in high primary pressure at idling gear pump
9
Multi control valve (in Change position case that travel is operable)
Since all are blocked due to poor switching performance, check that the lever select pattern is set to the proper position.
10
Actual measuring current value of P1/ P2 unload proportional valve
• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.3 Boom up full lever & relief
11
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
12
Actual measuring current value of P1/ P2 pump proportional valve
Carry out service diagnosis
Carry out service diagnosis.
Check gear pump and the relief valve for possible failure
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2 MPa in boom up full lever and high idling operation
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
T5-2-2
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
TROUBLESHOOTING (BY TROUBLE)
No.
Sections
Contents/normal value
E215B-E245B
Corrective action, others
13
Secondary pressure Measure the pump of pump proportional proportional valve valve secondary pressure directly in idling operation. (Ports a3, a4)
Check that pump proportional valve Replace proportional valve secondary pressure is 2.7 MPa or more in right (left) travel full lever and high idling operation Right travel: P1 pump proportional valve Left travel: P2 pump proportional valve
14
Main relief pressure Carry out service diagnosis
• See Service Diagnosis Data List Measure the relief pressure Operation No.3 Boom up full lever & relief actually
15
Check set pressure Check that P1 and P2 pump pressures are 32 MPa in boom up full lever, high idling and H mode operation.
Reset or replace
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.
17
Pump
Visual check
When removing, inside parts (cylinder Replace block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.
2.
Engine down/stalled
No.
Sections
1
Actual measuring current value of P1/ P2 pump proportional valve
2
Contents/normal value Carry out service diagnosis
Corrective action, others
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No. 1 Operation is nil
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 pump proportional valve pressures are within the range of 0.5 to 1.0 MPa in control lever neutral and high idling operation.
Replace proportional valve
3
Pressure sensor of P1, P2 pump
Check pressure
• See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.3 Boom up full lever & relief
Check pressure sensor and replace it if necessary
4
Pump regulator
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.
Replace
5
Pump
Visual check
Replace When removing, inside parts (cylinder block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.
T5-2-3
E215B-E245B 3.
TROUBLESHOOTING (BY TROUBLE)
Move at lever neutral position
No. Sections
Contents/normal value
Corrective action, others
1
Pilot pressure sensor
Carry out service diagnosis
Check that targeted pilot pressure of sensor is 0MPa in high idling
Check remote control valve
2
Remote control valve
Check targeted remote control valve
Check that spool is free from abnormal damage and spring is free from breakage
Replace
3
Main spool
Check targeted spool visually
Check that spool is free from abnormal damage and spring is free from breakage
Replace
4
Over load relief valve
Check targeted spool visually
Free from dust entered in port relief valve. Seat is free from abnormality
Replace
5
Lock valve poppet Check targeted (in case of boom and poppet visually arm)
Seat is free from abnormality
Replace
6
Lock valve selector Exchange lock (in case of boom and valve selector of arm) boom/arm and boom/arm
Check that the trouble is reversed
Replace
7
Holding valve spool for boom (in case of boom)
Check that smooth sliding of spool in sleeve
Free from abnormal resistance against sliding
Replace Do not pull spool out of sleeve forcibly.
8
Holding valve relief valve for boom (in case of boom)
Check targeted spool visually
Filter free from abnormal contamination Replace
9
Cylinder
Check targeted cylinder visually
Make sure of no problem of seals by disassembling and investigation
4.
Replace cylinder or seals
Poor fine operability
No. Sections
Contents/normal value
Corrective action, others
1
Pressure sensor
Carry out service diagnosis
• See Service Diagnosis Data List Replace pressure sensor Operation No. 1 Operation is nil • All low pressure sensors are 0MPa to 0.1 MPa
2
Actual measuring current value of P1/ P2 unload proportional valve
Carry out service diagnosis
• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No. 1 Operation is nil
3
Secondary pressure Measure the of unload proportional valve proportional valve secondary pressure directly at the ports A7 and A8 of 8 sections solenoid block
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that P1/P2 unloads secondary Replace proportional valve pressures is within the range of 2.7 MPa or more in control lever neutral and high idling operation
T5-2-4
TROUBLESHOOTING (BY TROUBLE)
No. Sections
E215B-E245B
Contents/normal value
Corrective action, others
Carry out service diagnosis
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No. 1 Operation is nil
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
4
Actual measuring current value of P1/ P2 pump proportional valve
5
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly. (Ports a3, a4)
Check that P1/P2 pump proportional valve pressures are within the range of 0.5 to 1.0 MPa in control lever neutral and high idling operation
Replace proportional valve Check regulator
6
Command current Carry out service value of short-circuit diagnosis.
• No.15 D-15 • See Service Diagnosis Data List Operation No. 1 Operation is nil.
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
7
Secondary pressure Measure the Control lever is neutral, high idling and 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)
Replace proportional valve.
8
Slow return check Visual check valve of pilot line (in case of boom up or arm out)
Check that slow return check valve installed on pilot line is free from dust entered
Clean and replace
9
Short-circuit valve spool.
When removing, free from abnormal resistance against free from abnormal damage, etc on outside surface Spring is free from breakage, damage, etc.
Replace (Check on the casing site for damage).
5.
Visual check
Slow boom up, insufficient power
No. Sections
Contents/normal value
Corrective action, others
1
Boom up pressure sensor
Carry out service diagnosis
• See Service Diagnosis Data List Check and replace pressure Operation No.3 boom up full lever and sensor relief Check remote control valve
2
Remote control valve
Measure directly remote control pressure of boom up
Check that pressure is 3.0 MPa or more Check remote control valve in boom up full lever and high idling When equipped with multi operation control valve, check it while changing lever pattern
3
Pump pressure sensor
Carry out service • See Service Diagnosis Data List diagnosis for P1, P2 Operation No.4 boom up full lever and pump pressures in in operation operation.
When there is difference between P1 and P2 pump pressures, check high pressure sensor.
4
Actual measuring current value of P1/ P2 unload proportional valve
Carry out service diagnosis
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.3 Boom up full lever & relief
T5-2-5
E215B-E245B
No. Sections
TROUBLESHOOTING (BY TROUBLE)
Contents/normal value
Corrective action, others
5
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary pressures are within the range of 0.5~1.2 MPa in boom up full lever and high idling operation
Replace proportional valve
6
Actual measuring current value of P1/ P2 pump proportional valve
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.4 boom up full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
7
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are within the range of 1.8 to 3.0 MPa in boom up full lever and high idling operation
8
P2 by-pass cut valve Visual check Only P2 pressure is low.
No problem for sliding ability of main poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)
Clean and replace
9
Remote control valve
Check targeted remote control valve
Check that spool is free from abnormal damage and spring is free from breakage
Replace
10
Lock valve poppet Both P1 and P2 pressures are low.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
11
Conflux check valve Visual check Only P2 pressure is high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
12
Holding valve for boom (poppet) Both P1 and P2 pressures are high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
13
Boom spool Only P1 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Spring is free from breakage.
Replace (Check on the casing side for damage)
14
Check boom spool and recirculation Only P1 pressure is low.
Disassembly and investigation
Free from abnormal resistance against sliding Spring is free from breakage.
Replace spool assembly
15
Conflux spool Only P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Spring is free from breakage. Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
Carry out service diagnosis
T5-2-6
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
No. Sections
Contents/normal value
16
Main relief valve Relief pressure is low.
Check set pressure • See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
17
Over load relief valve Relief pressure is low.
Visual check (Head Pressure is 32 MPa or more in boom up When only relief pressure of side) full lever and high idling. Free from dust boom up is low, replace valve entered in over load relief valve. Seat is free from abnormality
6.
Corrective action, others
Slow boom down, insufficient power for lifting up body
No. Sections
Contents/normal value
Corrective action, others
1
Boom down pressure sensor
Carry out service diagnosis
Check and replace pressure sensor. Check remote control valve.
2
Remote control valve
Measure remote Check that pressure is 3.0 MPa or more Check remote control 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 current value of P1 unload proportional valve
Carry out service diagnosis
4
Secondary pressure Measure the of P1 unload proportional valve proportional valve secondary pressure directly at the ports A7 of 8 sections solenoid block.
Check that P1 unload secondary Replace proportional valve pressures are within the range of 0.8 to 1.2 MPa in boom down full lever and high idling operation
5
Actual measuring current value of P1 pump proportional valve
• No.9 E-1 P1 pump • See Service Diagnosis Data List Operation No.5 boom down full lever & in operation
6
Secondary pressure Measure the pump of P1 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1 pump proportional valve Replace proportional valve pressures are within the range of 2.0 to 2.5 MPa in boom down full lever and high idling operation
7
Actual measuring current value of travel straight proportional valve
Check that the value is not change • Check pressure sensor of regardless of operation 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 check proportional valve Operation No.19 Travel left full lever & and controller for possible idling failure.
Carry out service diagnosis
Carry out service diagnosis
• See Service Diagnosis Data List Operation No.5 boom down full lever & in operation
P1 unload valve (cut valve) • See Service Diagnosis Data List Operation No.5 boom down full lever & in operation
T5-2-7
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
E215B-E245B
No. Sections
TROUBLESHOOTING (BY TROUBLE)
Contents/normal value
Corrective action, others
8
Travel straight Measure directly proportional valve the travel straight secondary pressure proportional valve secondary pressure.
High idling pressure is 0.8 MPa or less regardless neutral/operation
9
Actual measuring current value of short-circuit valve.
Check that the value is not change • Check pressure sensor of 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 of proportional valve the travel straight in short-circuit valve proportional valve secondary pressure. (G Port)
High idling pressure is 0.8 MPa or less regardless neutral/operation
Replace proportional valve
11
Remote control valve
Check targeted remote control valve
Check that spool is free from abnormal damage and spring is free from breakage
Replace
12
Lock valve poppet Boom down is low.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
13
Holding valve Visual check (poppet) Boom down is slow.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
14
Boom spool Visual check Boom down is slow.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
15
Check boom spool and recirculation Machine can not be lifted by supporting with boom.
Disassembly and investigation
Free from abnormal resistance against sliding Spring is free from breakage.
Replace spool assembly
16
short-circuit valve spool.
Visual check.
When removing, free from abnormal resistance against free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing site for damage).
Carry out service diagnosis
T5-2-8
Replace proportional valve
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
No. Sections
Contents/normal value
17
Main relief valve Relief pressure is low.
Check set pressure • See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
18
Over load relief valve Machine can not be lifted by supporting with boom.
Visual check
7. No.
Corrective action, others
Free from dust entered in port relief valve. Seat is free from abnormality
Replace
Slow arm in, insufficient power Sections
Contents/normal value
Corrective action, others
1
Arm in pressure sensor
Carry out service diagnosis
• See Service Diagnosis Data List Operation No.6 arm in full lever and relief
2
Remote control valve pressure
Measure directly remote control pressure of arm in
Check that pressure is 3.0 MPa or more Check remote control valve in arm in full lever and high idling When equipped with multi operation control valve, check it while changing lever pattern
3
Pump pressure sensor
Carry out service • See Service Diagnosis Data List diagnosis for P1, P2 Operation No.7 arm in full lever and in pump pressures in operation operation.
When there is difference between P1 and P2 pump pressures, check high pressure sensor
4
Actual measuring current value of P1/ P2 unload proportional valve
Carry out service diagnosis
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
5
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2 MPa in arm in full lever and high idling operation.
6
Actual measuring current value of P1/ P2 pump proportional valve
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.7 Arm in full lever & in operation
Carry out service diagnosis
• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.6 Arm in full lever & relief
T5-2-9
Check and replace pressure sensor Check remote control valve
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
E215B-E245B
No.
TROUBLESHOOTING (BY TROUBLE)
Sections
Contents/normal value
Corrective action, others
7
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly. (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are 2.0 MPa or more in arm in full lever and high idling operation. (Secondary pressure is affected by oil temperature and attachment weight)
8
Actual measuring Carry out service current value of arm diagnosis in spool 2 proportional valve
• See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.6 Arm in full lever & relief Operation No.7 Arm in full lever & in operation
9
Secondary pressure Measure directly of arm in spool 2 the proportional proportional valve valve secondary pressure at the ports A8 (arm 2 spool) of 8 sections solenoid block.
Check that secondary pressure of Replace proportional valve proportional valve secondary pressures are within the range of following Lever neutral: 0 MPa Motion in the air: 1.7 to 2.2 MPa Arm in relief: 2.5 MPa or more
10
Actual measuring current value of travel straight proportional valve
Check that the value is not change • Check pressure sensor of regardless of operation 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 check proportional valve Operation No.19 Travel left full lever & and controller for possible idling failure.
11
Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
0.8 MPa or less in high idling operation regardless of neutral/operation
Replace proportional valve
12
Remote control valve
Check targeted remote control valve
Check that spool is free from abnormal damage and spring is free from breakage
Replace
13
Main relief valve Relief pressure is low.
Check set pressure • See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
14
Over load relief valve P1, P2 pressure is low.
When only relief pressure of Visual check (Head Pressure is 32 MPa or more in arm in arm in is low, replace valve side) and relief. Free from dust entered in over load relief valve. Seat is free from abnormality
Carry out service diagnosis
T5-2-10
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
TROUBLESHOOTING (BY TROUBLE)
No.
Sections
Contents/normal value
E215B-E245B
Corrective action, others
15
Over load relief valve P1, P2 pressure is low.
Visual check (Rod side)
Pressure is 32 MPa or more in arm out When only relief pressure of and relief. arm out is low, replace valve Free from dust entered in over load relief valve. Seat is free from abnormality.
16
Arm 1 spool P1, P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
17
Arm 2 spool P1, P2 pressure is high or low.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
18
Check arm 2 spool and recirculation Arm in power is poor.
Disassembly and investigation
Free from abnormal resistance against sliding Spring is free from breakage.
Replace spool assembly
19
Check lock valve poppet Both P1, P2 pressures are high.
Visual check
Free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
8. No .
Slow independent arm out (in the air) Sections
Contents/normal value
Corrective action, others
1
Arm out pressure sensor
Carry out service diagnosis
• See Service Diagnosis Data List Check and replace pressure Operation No.8 arm out full lever and sensor relief Check remote control valve
2
Remote control valve
Measure directly Check that pressure is 3.0 MPa or more Check remote control 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 sensor
Carry out service • See Service Diagnosis Data List diagnosis for P1, P2 Operation No.9 arm out full lever and pump pressures in in operation operation.
When there is difference between P1 and P2 pump pressures, check high pressure sensor
4
Actual measuring current value of P1/ P2 unload proportional valve
Carry out service diagnosis
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.8 Arm out full lever & relief
T5-2-11
E215B-E245B
No .
TROUBLESHOOTING (BY TROUBLE)
Sections
Contents/normal value
Corrective action, others
5
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2 MPa in arm out full lever and high idling operation
6
Actual measuring current value of P1/ P2 pump proportional valve
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.9 Arm out full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
7
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 pump proportional valve pressures are within the range of 1.5 to 2.7 MPa in arm out full lever and high idling operation (Secondary pressure is affected by oil temperature and attachment weight)
Replace proportional valve
8
Actual measuring current value of travel straight proportional valve
Check that the value is not change • Check pressure sensor of regardless of operation 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 check proportional valve Operation No.19 Travel left full lever & and controller for possible idling failure.
9
Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
0.8 MPa or less in high idling operation regardless of neutral/operation
Replace proportional valve
10
Remote control valve
Check targeted remote control valve
Check that spool is free from abnormal damage and spring is free from breakage
Replace
11
Main relief valve Relief pressure is low.
Check set pressure • See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
12
Over load relief valve P1, P2 pressure is low.
Visual check (Rod side)
13
Visual check Arm 1 spool P2 pressure is high.
Carry out service diagnosis
Carry out service diagnosis
Pressure is 32 MPa or more in arm out When only relief pressure of and relief. arm out is low, replace valve Free from dust entered in over load relief valve. Seat is free from abnormality
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
T5-2-12
Replace (Check on the casing side for damage)
TROUBLESHOOTING (BY TROUBLE)
No .
Sections
Contents/normal value
E215B-E245B
Corrective action, others
14
Arm 2 spool Visual check P1 pressure is high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
15
Check arm 2 spool and recirculation Both P1, P2 pressures are low.
Disassembly and investigation (spring side)
Free from abnormal resistance against sliding Spring is free from breakage.
Replace spool assembly
16
Check lock valve poppet Both P1, P2 pressures are high.
Visual check
Free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
9.
Slow bucket digging
No. Sections
Contents/normal value
Corrective action, others
1
Bucket digging pressure sensor
Carry out service diagnosis
• See Service Diagnosis Data List Operation No.12 bucket digging full lever and relief
Check and replace pressure sensor Check remote control valve
2
Remote control valve
Measure directly remote control pressure of bucket digging
Check that pressure is 3.0M Pa or more Check remote control valve in bucket digging full lever and high When equipped with multi idling operation control valve, check it while changing lever pattern
3
Pump pressure sensor
Carry out service • See Service Diagnosis Data List diagnosis for P1, P2 Operation No.13 Bucket digging full pump pressures in lever and in operation operation.
When there is difference between P1 and P2 pump pressures, check high pressure sensor
4
Actual measuring current value of P1/ P2 unload proportional valve
Carry out service diagnosis
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
5
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2 MPa in bucket digging full lever and high idling operation
6
Actual measuring current value of P1/ P2 pump proportional valve
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.13 Bucket digging full lever & in operation
7
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Carry out service diagnosis
• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.12 Bucket digging full lever & relief
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that P1 pump proportional valve Replace proportional valve pressures is 2.7 MPa or more and P2 pump proportional valve pressure is 1.6 to 2.2 MPa in bucket digging full lever and high idling operation.
T5-2-13
E215B-E245B
TROUBLESHOOTING (BY TROUBLE)
No. Sections
Contents/normal value
Corrective action, others
8
Attachment boost solenoid command
Carry out service diagnosis
No.3 POWER BOOST Check harness Bucket digging COMP OFF, MEAS OFF Replace solenoid valve
9
Attachment boost solenoid secondary pressure
Measure switching valve secondary pressure
Check that pressure is 0 MPa in bucket Replace solenoid valve digging full lever and high idling operation
10
Actual measuring current value of travel straight proportional valve
Carry out service diagnosis
• See Service Diagnosis Data List Operation No.12 Bucket digging full lever & relief
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
11
Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Check that travel straight secondary pressure is 2.7 MPa or more in bucket digging full lever and high idling operation
Replace proportional valve
12
P2 by-pass cut valve Visual check Only P2 pressure is low.
No problem for sliding ability of main poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)
Clean or replace
13
Check stroke limiter Visual check Both P1, P2 pressures are high.
When piston is removed from cover, it is Replace free from abnormal resistance against (Check on the casing side for sliding damage.) Free from abnormal damage, etc on outside surface
14
Remote control valve
Check targeted remote control valve
Check that spool is free from abnormal damage and spring is free from 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 P2 pressure is high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
17
Bucket spool Both P1, P2 pressures are high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
18
Over load relief valve
Check targeted spool visually
Free from dust entered in over load relief Replace valve. Seat is free from abnormality.
T5-2-14
Replace
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
10. Slow bucket dump No.
Sections
Contents/normal value
Corrective action, others
1
Bucket dump pressure sensor
Carry out service diagnosis
• See Service Diagnosis Data List Operation No.14 Bucket dump full lever and relief
2
Remote control valve
Measure directly remote control pressure of bucket dump
Check that pressure is 3.0 MPa or more Check remote control valve in bucket dump full lever and high idling When equipped with multi operation control valve, check it while changing lever pattern
3
Pump pressure sensor
Carry out service • See Service Diagnosis Data List diagnosis for P1, P2 Operation No.15 Bucket dump full pump pressures in lever and in operation operation.
When there is difference between P1 and P2 pump pressures, check high pressure sensor
4
Actual measuring current value of P1/ P2 unload proportional valve
Carry out service diagnosis
• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.14 Bucket dump full lever & relief
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
5
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary pressures are within the range of 0.5~1.2 MPa in bucket dump full lever and high idling operation. Replace proportional valve
Replace proportional valve
6
Actual measuring current value of P1/ P2 pump proportional valve.
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.15 Bucket dump full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
7
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1 pump proportional valve Replace proportional valve pressures is 2.7 MPa or more and P2 pump proportional valve pressure is 0.9 to 1.4 MPa in bucket dump full lever and high idling operation.
8
Actual measuring current value of travel straight proportional valve
• See Service Diagnosis Data List Operation No.14 Bucket dump full lever & relief
9
Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Carry out service diagnosis
Carry out service diagnosis
Check and replace pressure sensor Check remote control valve
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that travel straight secondary Replace proportional valve pressure is 2.7 MPa or more in bucket dump full lever and high idling operation
T5-2-15
E215B-E245B
No.
TROUBLESHOOTING (BY TROUBLE)
Sections
Contents/normal value
Corrective action, others
10
P2 by-pass cut valve Visual check Only P2 pressure is low.
No problem for sliding ability of main poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBP2 port.)
Clean and replace
11
Check stroke limiter Visual check Pilot pressure is low.
Free from abnormal damage and wear on outside of piston inside cover
Replace (Check on the casing side for damage.)
12
Remote control valve
Check targeted remote control valve
Check that spool is free from abnormal damage and spring is free from breakage
Replace
13
Main relief valve Relief pressure is low.
Check set pressure • See Service Diagnosis Data List Reset or replace Operation No.3 Boom up full lever and relief
14
Travel straight spool Visual check P2 pressure is high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
15
Bucket spool Both P1, P2 pressures are high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
16
Over load relief valve
Check targeted spool visually
Free from dust entered in over load relief Replace valve. Seat is free from abnormality.
11. Swing operation not functioned/slow No. Sections
Contents/normal value
Corrective action, others
1
Swing pressure sensor
Carry out service diagnosis
• See Service Diagnosis Data List Operation No.11 Swing full lever and in operation
Check and replace pressure sensor Check remote control valve
2
Remote control valve
Measure directly remote control pressure of swing
Check that pressure is 3.0 MPa or more Check remote control valve in boom up full lever and high idling When equipped with multi operation control valve, check it while changing lever pattern
3
Swing parking brake Carry out service solenoid diagnosis
No.3 F-2 SWING-BRAKE Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF
Check swing pressure sensor Check harness
4
Swing parking brake Measurement of solenoid solenoid valve A2 port
Lever neutral: 0 MPa In operation: 4 MPa or more
Replace solenoid valve
T5-2-16
TROUBLESHOOTING (BY TROUBLE)
No. Sections
Contents/normal value
E215B-E245B
Corrective action, others
5
Shuttle valve Visual check Pilot pressure is low.
No contamination on spool cover (short Clean or replace side) and orifice No damage on spool cover (long side) and shuttle
6
Pump pressure sensor
Carry out service diagnosis for P2 pump pressures in operation
• See Service Diagnosis Data List Operation No.11 Swing full lever and in operation
Check high pressure sensor
7
Actual measuring current value of P2 unload proportional valve
Carry out service diagnosis
• No.8 D-2 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.11 Swing full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
8
Secondary pressure Measure the of P2 unload proportional valve proportional valve secondary pressure directly at the ports A5 of 8 sections solenoid block
Check that P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2 MPa in swing full lever and high idling operation
9
Actual measuring current value of P2 pump proportional valve
• No.9 E-2 P2 pump • See Service Diagnosis Data List Operation No.11 Swing full lever & in operation
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 current value of travel straight proportional valve (Check this trouble by only swing operation)
Carry out service diagnosis
Check that the value is not change • Check pressure sensor of regardless of operation 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 check proportional valve Operation No.19 Travel left full lever & and controller for possible idling failure.
12
Secondary pressure of travel straight proportional valve (Check this trouble by only swing operation)
Measure directly the proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
0.8 MPa or less in high idling operation regardless of neutral/operation
Carry out service diagnosis
T5-2-17
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Replace proportional valve
E215B-E245B
No. Sections
TROUBLESHOOTING (BY TROUBLE)
Contents/normal value
Corrective action, others
13
Command current Carry out service value of short-circuit. diagnosis
Check that the value is not change • Check pressure sensor of 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 of proportional valve the secondary in short-circuit valve. pressure of the proportional valve in short-circuit valve. (G Port)
0.8 MPa or less in high idling operation regardless of neutral/operation.
Replace proportional valve.
15
Remote control valve
Check that spool is free from abnormal damage and spring is free from breakage
Replace
16
Travel straight spool Visual check P2 pressure is low.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
17
Swing spool Visual check P2 pressure is high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
18
Short-circuit valve spool.
Visual check.
• When removing, free from abnormal Replace (Check on the casing resistance against free from abnormal site for damage). damage, etc on outside surface Spring is free from breakage.
19
Swing relief valve Relief pressure is low.
Check set pressure • See Service Diagnosis Data List Operation No.10 Swing full lever and relief
20
Swing motor
Visual check
21
Swing reduction gear oil
Take sample oil Sampling oil does not include a lot of from swing metal powder. reduction gear drain
Disassemble and inspect reduction gear
22
Swing reduction
Visual check
Replace
Check targeted remote control valve
Reset or replace
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)
Tooth surface is not worn abnormally and is not chipped.
T5-2-18
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
12. Noise during swing operation No. Sections
Contents/normal value
Corrective action, others
1
Carry out service No.3 F-2 SWING-BRAKE diagnosis Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF
Check swing pressure sensor Check harness
Measurement of Lever neutral: 0 MPa solenoid valve A2 In operation: 4 MPa or more port
Replace solenoid valve
Swing parking brake solenoid
2
3
Boost check valve Visual check (Sound of cavitation at stopping)
When removing, free from abnormal Replace resistance against sliding Spring is free from breakage.
4
By-pass check valve (Sound of cavitation at stopping)
Visual check
When removing, free from abnormal Replace resistance against sliding Spring is free from breakage.
5
Swing motor (Brake valve/ friction plate)
Visual check
Disassemble and inspect abnormal Replace wear and scuffing
6
Swing motor piston
Visual check
When removing, free from abnormal Replace resistance against sliding Spring is free from breakage.
7
Swing reduction gear oil
Take sample oil from swing reduction gear drain.
Sampling oil does not include a lot of Disassemble and inspect metal powder. reduction gear
8
Swing reduction
Visual check
Tooth surface has no abnormally worn and chipped.
Replace
13. Swing on a slope drifts when control lever is in neutral position No.
Sections
Contents/normal value
1
Swing sensor
2
Remote valve
3
Swing parking brake Carry out service No.3 F-2 SWING-BRAKE solenoid diagnosis Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF
4
Corrective action, others
pressure Carry out service • •Engine stop & starter key ON Check and replace pressure diagnosis All pilot low pressure sensors are sensor within range of 0 to 0.1 MPa. control Check remote valve
targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage
Measurement of Lever neutral: 0 MPa solenoid valve A2 In operation: 4 MPa or more port
T5-2-19
Check swing pressure sensor Check harness Check parking brake release switch Replace solenoid valve
E215B-E245B
No.
TROUBLESHOOTING (BY TROUBLE)
Sections
Contents/normal value
Corrective action, others
5
Swing motor Visual check (Brake valve/friction plate)
Disassemble and inspect abnormal Replace wear and scuffing
6
Parking brake
Piston and friction plate do not have Replace abnormal resistance against sliding Free from spring damage
Visual check
14. Swing drifts when swing operation is stopped No .
Sections
Contents/normal value
1
Visual check Shuttle valve Pilot pressure is low
2
Swing sensor
3
Swing relief valve Check pressure Relief pressure is low.
4
Anti-reaction valve Visual check
5
Remote valve
6
Swing motor
Corrective action, others
No contamination on spool cover Clean or replace (short side) and orifice. No damage on spool cover (long side) and shuttle.
pressure Carry out service • Engine stop & starter key ON Replace pressure sensor diagnosis All pilot low pressure sensors are within range of 0 to 0.1 MPa.
control Check remote valve
set • See Service Diagnosis Data List Reset or replace Operation No.10 Swing full lever and relief Clean or replace Free from dirt entering Sliding part should be free from foreign matter entering, abnormal damage and wear.
targeted Check that spool is free from Replace control abnormal damage and spring is free from breakage
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)
15. Slow travel speed/weak No.
Sections
Contents/normal value
Corrective action, others
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 valve
control Measure directly Check that pressure is 2.1 MPa or more Check remote control 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)
No.
Sections
Contents/normal value
E215B-E245B
Corrective action, others
3
Actual measuring Carry out service • No.9 D-1 P1 unload valve (cut valve) current value of P1/ diagnosis D-1 P2 unload valve (cut valve) P2 unload • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & 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 the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
5
Actual measuring Carry out service • No.9 E-1 P1 pump current value of P1/ diagnosis E-2 P2 pump P2 pump • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
6
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
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.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 unload): 0.5 to 1.0 MPa Travel left (P2 unload): 0.5 to 1.0 MPa In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.7 MPa or more Travel left (P2 pump): 2.7 MPa or more
directly 0.8 MPa or less in high idling operation Replace proportional valve. 10 Secondary pressure Measure secondary regardless of neutral/operation. of proportional valve the in short-circuit valve. pressure of the proportional valve in short-circuit valve. (G Port)
T5-2-21
E215B-E245B
No.
TROUBLESHOOTING (BY TROUBLE)
Sections
11 Remote valve
Contents/normal value
control Check remote valve
targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage Check sealing ability of shuttle valve and entry of dust in orifice
12 Travel straight spool Visual check P1 pressure is high.
13 Travel spool Visual check targeted spool Pump pressure is high.
14 short-circuit spool.
valve 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. of 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. When removing, free from abnormal Replace (Check on the casing 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 valve 32 MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling 16 Travel motor
17 Parking brake travel motor
18 Travel gear oil
Corrective action, others
If P1 is low, right travel motorÅfs relief valve is failed. If P2 is low, left travel motorÅfs relief valve is failed.
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)
in Visual check
When removing, free from abnormal Replace resistance against sliding No sticking on friction plate and separator plate
reduction Take sample oil Sampling oil does not include a lot of Disassemble and 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
inspect
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
16. Travel deviation No.
Sections
Contents/normal value
Corrective action, others
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 valve
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) current value of P1/ diagnosis D-1 P2 unload valve (cut valve) P2 unload • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
6
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
7
Actual measuring Carry out service • No.9 E-1 P1 pump current value of P1/ diagnosis E-2 P2 pump P2 pump • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
8
Secondary pressure Measure the pump of P1, P2 pump proportional valve secondary pressure proportional valve directly (Ports a3, a4)
control Measure directly Check that pressure is 2.1 MPa or more Check remote control valve remote control in travel right (left), forward (reverse) full pressure of travel lever and high idling operation right and left
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 unload): 0.5 to 1.0 MPa Travel left (P2 unload): 0.5 to 1.0 MPa In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.7 MPa or more Travel left (P2 pump): 2.7 MPa or more
T5-2-23
E215B-E245B
No. 9
TROUBLESHOOTING (BY TROUBLE)
Sections
Contents/normal value
Exchange P1 for P2 Exchange delivery Check the direction of deviation pipe of P1 for P2
10 Remote valve
control Check remote valve
12 Travel spool Visual check targeted spool Pump pressure is high.
When removing, free from abnormal Replace (Check on the casing side for resistance against sliding Free from abnormal damage, etc on damage) outside surface Spring is free from breakage of 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
13 Travel motor relief Check set pressure Check P1 and P2 pump pressures are valve 32 MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling
15 Travel gear oil
If the direction is changed, inspect a pump. If the direction is not changed, inspect a valve and travel unit.
targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage Check sealing ability of shuttle valve and entry of dust in orifice
11 Travel straight spool Visual check P1 pressure is high.
14 Travel motor
Corrective action, others
Visual check
If P1 is low, right travel motorÅfs relief valve is failed. If P2 is low, left travel motorÅfs relief valve is failed. Replace as necessary
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)
reduction Take sample oil Sampling oil does not include a lot of Disassemble and 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.
18 Pump
Visual check
When removing, inside parts (cylinder Replace block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.
T5-2-24
inspect
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
17. Travel 1st/2nd speed notchanged (In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the speed may sometimes does not change from 1st to 2nd because this machine equips the function of automatic speed change.) No.
Sections
Contents/normal value
Corrective action, others
1
Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed switching solenoid diagnosis No.3 F-3 1/2-TRAVEL Lever neutral COMP OFF, MEAS OFF Travel operation COMP ON, MEAS ON
Check pressure sensor Check harness Check travel 1/2 speed switch on gauge cluster
2
Travel 1/2 speed Measure A3 port Lever neutral: 0 MPa switching solenoid pressure on In operation: 4 MPa or more solenoid valve
Replace solenoid valve
3
1/2 speed switching Visual check spool in travel motor
Check that spool is free from abnormal Replace damage and spring is free from (Check on the casing side for breakage damage)
4
1/2 speed switching Visual check orifice in travel motor
Free from entry of dust
5
Tilting piston travel motor
Free from abnormal wear on piston and Replace seal (Check on the casing side for damage)
in Visual check
Remove dust or replace
18. Travel parking on a slope is not held No.
Sections
Contents/normal value
1
Pilot sensor
2
Remote valve
3
Parking brake travel motor
4
Orifice of passage Visual check for parking brake in travel motor
Corrective action, others
pressure Carry out service • Engine stop & starter key switch is ON Check pressure sensor and diagnosis Targeted pilot low pressure sensor is replace as necessary in range of 0 to 0.1 MPa Check remote control valve control Check remote valve
targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage
in Visual check
When removing, free from abnormal Replace resistance against sliding Spring free from breakage, damage, etc. Free from entry of dust
Remove dust or replace
19. Travel does not run straightly when both crawlers and attachment operated simultaneously . No. 1
Sections
Contents/normal value
Corrective action, others
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
No.
TROUBLESHOOTING (BY TROUBLE)
Sections
Contents/normal value
Corrective action, others
2
Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure
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 spool.
When removing, free from abnormal Replace (Check on the casing resistance against free from abnormal site for damage). damage, etc on outside surface Spring is free from breakage.
valve Visual check.
Check secondary pressure is within Replace proportional valve range of 1.7 to 2.1 MPa in both travel full lever and in boom-up full lever at high idling. (Command value is changed according to operation. Above mentioned values indicate while boomup and full lever operation are performed).
20. Slow breaker (crusher) operation, weak power (In case of conflux, check p1 unload/pump and travel straight) No.
Sections
Contents/normal value
Corrective action, others
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 valve
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.
control Measure directly Check that pressure is 2.1 MPa or more Check remote control valve remote control in optional attachment full lever and high pressure of travel idling operation right and left
T5-2-26
TROUBLESHOOTING (BY TROUBLE)
No.
Sections
Contents/normal value
E215B-E245B
Corrective action, others
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 of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Check that travel straight secondary Replace proportional valve pressure is 2.7 MPa or more in optional attachment full lever and high idling operation
7
P1 by-pass cut valve Visual check Only P1 pressure is low.
No problem for sliding ability of main Clean or replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)
8
Relief pressure
9
Remote valve
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.)
control Check remote valve
targeted Check sealing ability of shuttle valve and Replace control entry of dust in orifice.
10 Travel straight spool Visual check P1 pressure is high.
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.
11 Spool for optional Visual check attachment P1, P2 pressures are high.
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.
12 Over valve
load
relief Check targeted Free from dust entered in over load relief Replace spool visually valve Seat is free from abnormality.
T5-2-27
E215B-E245B
TROUBLESHOOTING (BY TROUBLE)
21. Option selector valve malfunction: not switched to breaker circuit. (Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve") No.
Sections
Contents/normal value Visual check
Corrective action, others
1
N&B selector spool
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 solenoid
selector Screw emergency
3
N&B solenoid
selector Carry out service • No.11 F-4 Option selector is B mode diagnosis COMP ON, MEAS ON 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
for Check that the error indication is Replace solenoid valve disappeared by turning emergency screw Check solenoid valve Check harness
22. Option selector valve malfunction: not switched to nibbler circuit. (Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve") No.
Sections
1
N&B selector spool
2
N&B solenoid
Contents/normal value Visual check
Corrective action, others
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.
selector Carry out service • No.11 F-4 Option selector is A mode diagnosis COMP OFF, MEAS OFF Spool position NIB Selector switch NIB
T5-2-28
Check solenoid valve Check harness
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
Table 1 - Action of optional selector solenoid valve Safety Engine lock lever No. SW's condition input
1
Running
ON
Safety lock lever relay's output
OFF
Work mode
Optional selector valve COMP. MEAS.
A
OFF
Spool position
Selector valve detecting pressure sensor
Warning display
Failure diagnosis display
Nibbler
Normal
—
—
2
Running
ON
OFF
A
ON
Breaker
"SELECTOR Normal FAILURE"
3
Running
ON
OFF
A
OFF
Breaker
Normal
4
Running
ON
OFF
A
ON
Nibbler
Normal
—
[F042] displayed
5
Running
ON
OFF
B
ON
Breaker
Normal
—
—
6
Running
ON
OFF
B
OFF
Nibbler
Normal
"SELECTOR FAILURE"
VALVE [F043] displayed simultaneously
7
Running
ON
OFF
B
ON
N&B
Normal
"SELECTOR FAILURE"
VALVE
8
Running
ON
OFF
B
OFF
Breaker
Normal
—
[F043] displayed
9
Running
ON
OFF
—
—
—
Failure
"SELECTOR FAILURE"
VALVE [B113] displayed
10 Stopping
"SELECTOR FAILURE"
VALVE [F042] displayed simultaneously VALVE
—
—
—
—
—
—
—
—
—
—
11
—
OFF
—
—
—
—
—
—
—
12
—
—
ON
—
—
—
—
—
—
T5-2-29
E215B-E245B
TROUBLESHOOTING (BY TROUBLE)
2. ELECTRIC SYSTEMS 2.1 WIRING CHECKING PROCEDURE Check for continuity between connector terminals, presence or absences of short-circuit with other wires, and presence or absences of short-circuit with machine body grounding. 1.
CONNECTOR
Checking for disconnection between connectors. (When both ends measurement is easy because of short distance between connectors) Measure the resistance using tester. Pull out opposite connector first. When the resistance is zero (0), it is in normal condition.
WIRE TESTER
(When both ends measurement is difficult because of long distance between connectors) Measure the resistance using tester. Pull out opposite connector first. Where the resistance is zero (0), if the terminal on one side is connected to frame body grounding with jumper wire, it is in normal condition. The resistance is 1 M or more when the terminal on one side is not connected to frame body grounding with jumper wire, it is in normal condition.
2.
SM0104
JUMPER WIRE
TESTER FRAME BODY GROUNDING SM0105
Checking for presence or absence of shortcircuit with machine body Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1 M or more, it is in normal condition.
TESTER
FRAME BODY GROUNDING SM0106
3.
Checking for presence or absence of shortcircuit between wirings. Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1 M or more, it is in normal condition.
TESTER SM0107
T5-2-30
TROUBLESHOOTING (BY TROUBLE) 4.
Checking connector terminal for contact Insert male terminal into female terminal unit, and then check that the inserting force is equivalent to other female terminals. If looseness is there, replace the female terminal with new one. Clean the dirt terminal.
E215B-E245B
INSERT
MALE TERMINAL
FEMALE TERMINAL SM0108
ATTENTION Do not insert the male terminal the thickness differs. It may cause loose connection. 5.
Caution which should be paid in measuring voltage When measuring the power supply to electric equipment at connector position with the grounding terminal contained inside of connector, measure the voltage between grounding inside of connector and power terminal. When measuring the voltage between frame body grounding and power source, the disconnection of wiring to grounding inside of connector cannot be identified. Since the voltage may vary between with connector connected and with connector not connected. Measure the voltage with each connector connected whenever possible.
6.
Checking the general view of connector CRIMPED PART
a. Check the terminal crimped condition. Pull one electric cable with the about 3kg force, and make sure that the cable does not come out of the terminal. When came out, replace the terminal and crimp it again. b. Check connector for imperfect insertion Check that all top ends form a line on the same position as seen from the connector engaged side. When moved along, push it in further through wire inserting hole. c. Check connector for intruding of water. Pull out the connector and check that the inside is free from intruding of water. When water intruding is found, check rubber plug for damage and also that the sealing is fitted properly.
T5-2-31
RUBBER PLUG RECEPTACLE. CONTACT PLUG SEALING (is housed in plug) DOUBLE LOCK PLATE FOR PLUG DOUBLE LOCK PLATE FOR CAP CAP TAB.CONTACT RUBBER PLUG
SM0109
E215B-E245B 7.
TROUBLESHOOTING (BY TROUBLE)
When abnormality occurs at intervals When the abnormality situation can not be reoccurred during checking operation, try the following operations. a. Check that variable of display exists or not on the service diagnosis screen while shaking the harness or giving shock by operating the machine. b. Check that variables of resistance and voltage exist or not using tester while shaking the harness. c. Turn starter switch on and apply electricity continuously, and check it again after the temperature of wiring and equipment was raised.
8.
Checking on body grounding Check attaching bolts of grounding terminal for loosening. And also check that there is no loose connection due to corrosion. There are multiple groundings like centralized grounding box shown in the figure and battery grounding, engine grounding, horn grounding fixed together with horn, body grounding placed on attaching section of boom working light. Block of grounding is located under floor plate of cab.
T5-2-32
SM0110
TROUBLESHOOTING (BY TROUBLE) 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
E215B-E245B 1.
TROUBLESHOOTING (BY TROUBLE)
Engine does not stop.
No .
Sections
Contents/normal value
Corrective action, others
1
Starter key switch Check signal of starter key switch ON by carrying out service diagnosis.
Check continuity between No.4 K-3 Key switch OFF at starter key switch OFF terminals of starter switch using tester position ON at starter key switch ON position
2
Engine forcible When ON is stop relay displayed with the starter switch OFF, then pull out R-25 engine forcible stop relay and carry out the service diagnosis.
No.4 K-3 Key switch Check on engine forcible OFF at starter key switch OFF stop relay position ON at starter key switch ON position
3
Wiring
2.
Voltage between 0 V when starter switch is OFF line No.62 among starter switch, engine forcible stop relay, enginestop solenoid and the body grounding
Check harness Check diode D-9 between starter switch and auto idling stop relay 1
"CPU DATA COMMUNICATION ERROR" is displayed on multi display.
No .
Sections
Contents/normal value
Corrective action, others
1
Fuse
No.1 fuse (5 A)
Not blown fuse
Check harness Replace fuse
2
Mechatro controller
Accel control
Engine speed varies according to Check mechatro controller and replace as necessary accel potentiometer operation. (Use remote control because the auto accel function is working.)
3
Wiring
See “WIRING Transmission circuit line No.770 PROCEDURE" from mechatro controller to gauge cluster
4
Gauge cluster
Gauge cluster
CHECKING Repair wiring
Replace gauge cluster
T5-2-34
TROUBLESHOOTING (BY TROUBLE) 3. No .
Auto accel does not actuate. (The engine speed does not automatically slow down.) Sections
Contents/normal value
1
Engine coolant Check engine temperature coolant temperature by carrying out service diagnosis.
2
Gauge cluster
3
Low sensor
4. No .
1
E215B-E245B
Corrective action, others
Replace engine coolant No.2 G-5 WATER TEMP Auto accel does not work in the sensor temperature -15 °C or less. Warm up and raise the coolant temperature to – 15 °C or more
Indication of auto Mark "Display/not display" for auto Replace gauge cluster accel accel switches by auto accel switch operation on gauge cluster.
pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor No.6 is in the range of 0~0.1 MPa at control lever neutral position.
Auto accel does not actuate. (The engine speed does not automatically speed up.) Sections
Low sensor
Contents/normal value
Corrective action, others
pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor No.6 is raised with control lever operated.
T5-2-35
E215B-E245B 5.
TROUBLESHOOTING (BY TROUBLE)
Wiper does not function.
Wiping range of forward and reverse movements
Wiper motor Rise up limit switch's ON range Reverse limit switch's ON range
Rise up (storing) position Upper reversing position Lower reversing position
SM0111
No.
Sections
Contents/normal value
Corrective action, others
1
Fuse
Check fuse No.20
Replace fuse
2
SW-19: Wiper interlock switch
Service diagnosis No.19 D125 Check wiper interlock switch Wiper switch display (D125) is OFF with front window closed. and repair it if necessary Check according to "WIRING CHECKING PROCEDURE" and repair it if necessary
3
Rise up limit switch Service diagnosis No.25 Wiper system built-in wiper motor Reverse limit switch Switch action in operation
Check according to "WIRING CHECKING PROCEDURE"
Normal condition
4
Rise up limit switch
ON
OFF
OFF
Reverse limit switch
ON
ON
OFF
R-31: Service diagnosis No.25 Wiper system Arc prevention relay When started by forward rotation: STOP START R-29: Arc prevention relay OFF ON ON ON ON Forward rotation Forward rotation relay OFF ON ON ON ON Reverse rotation relay OFF OFF OFF OFF OFF relay Check that the relay is worked as shown in the table. R-30: * When the limit switch does not change in OFF after 4 seconds Reverse rotation from the wiper startup, turn OFF all relay's outputs. relay
T5-2-36
(STOP)
(STOP)
(REVERSE)
(FORWARD)
OFF
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
ON
ON
OFF
OFF
Check that the relay is excited. Check relay & fuse box and replace it if necessary.
ON
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
E215B-E245B
1. TROUBLE DIAGNOSIS MODE 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.
2.
How to use and flow chart The operation is performed through gauge cluster. No.1 Select service adjustment select screen. (Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing buzzer stop switch on the service diagnosis screen No.1.) No.2 Select Trouble diagnosis mode (Move the cursor to the desired position with screen change switch "
", and press the select switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2" (Move the cursor to the desired position with screen change switch "
", and press the select switch.)
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.
T5-3-1
E215B-E245B
No.1
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
No.2
LANGUAGE/LOGO
No.3
8 FAULT DIAG MODE
ADJUSTING MODE 1 PRESET BY FACTORY
SELECT SWITCH
DIAG MODE 1 DIAG MODE 2
BUZZER STOP SWITCH
FEED
SCREEN CHANGE SWITCH
CASE OF DIAG MODE 1 SENSOR CHECK
CHECK
START ENG
ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
C-2 00.0M
LOWER BOOM
DIAG MODE 1
RELEASE LOCK LEVER
TO GROUND
About 15 minutes
E-2 005mA D-2 300mA
Turn engine on manually.
BACK TO No.3
RESULT OF DIAGNOSIS
When not failed,
DIAG MODE 1
END
In diagnosis operation
START
ENGINE STOP
RESULT OF DETAIL
DIAG MODE 1
1 P1 UNLOAD
OK
O K DATA END
Engine stops automatically.
FEED
DIAG MODE 1 RESULT 1 P1 UN-LOAD PSV NG P1 UN-LOAD SPOOL NG
DATA END
BACK TO No.3
FEED
The data at the time of judgment can be confirmed with the select switch.
ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
C-2 00.0M E-2 005mA D-2 300mA
The other judgments can be confirmed with the feed button.
RESULT OF DIAGNOSIS
When failed,
For tthediagnosing Forthe diagnosingitems, items,see seeTable Table 48-1. 1. When Whenrequired requiredto tostop stopin indiagnosis diagnosis operation, operation,press pressthe thebuzzer buzzerstop stopswitch switch and andthe theoperation operationisisforcedly forcedlystopped. stopped.
1 P1 UNLOAD
NG DATA END
FEED
ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
C-2 00.0M E-2 005mA D-2 300mA
The suspected trouble sections are displayed in order of possibility. The suspected three sections in maximum are displayed. When desired to see other suspected trouble sections, press feed " " button. For diagnosis results and corrective actions to be taken, see Table 2.
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
No.4 CASE OF DIAG MODE 2 SENSOR CHECK
CHECK
START ENG
ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
C-2 00.0M
DIAG MODE 2
LOWER BOOM
START
TO GROUND
E-2 005mA D-2 300mA
Turn engine on manually.
AT CONTROL LEVER IS NEUTRAL
Example: Case of boom up WHEN FINISHING OF DIAGNOSIS IS REQUIRED.
BOOM UP
BOOM UP
OK PRESSURE 0.0
MPa
PRESSURE 1.5
MPa
PRESSURE 3.0
BACK TO No.3 MPa
In the normal condition, OK is displayed when the control lever is moved to stroke end.
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 "UNLOAD 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)
Table 1 - Failure diagnosis Mode-1/Diagnosis item No.
Display
Contents of diagnosis
1
1 P1 UNLOAD
Is normal pressure generated in the condition that the flow rate at P1 side is minimum and the unloading valve is in the emergency position?
2
2 P1 UNLOAD
Is normal pressure generated in the condition that the minimum flow rate is relieved at P1 side?
3
3 P1 UNLOAD
Is normal pressure generated in the condition that the unload valve is fully opened, and P1 side flow rate is minimum?
4
1 P2 UNLOAD
Is normal pressure generated in the condition that the unload valve is in emergency position, and P2 side flow rate is minimum?
5
2 P2 UNLOAD
Is normal pressure generated in the condition that the minimum flow rate is relieved at P2 side?
6
3 P2 UNLOAD
Is normal pressure generated in the condition that the unload valve is fully opened, and P2 side flow rate is minimum?
7
1 P1 PUMP
Is normal pressure generated in the condition that the flow rate at P1 side is emergency and the unloading valve is in the emergency position?
8
2 P1 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P1 side flow rate is minimum?
9
3 P1 PUMP
Is normal pressure generated in the condition that the unload valve is in emergency position, and P1 side flow rate is maximum?
10 1 P2 PUMP
Is normal pressure generated in the condition that the flow rate at P2 side is emergency and the unloading valve is in the emergency position?
11 2 P2 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P2 side flow rate is minimum?
12 3 P2 PUMP
Is normal pressure generated in the condition that the unload valve is in emergency position, and P2 side flow rate is maximum?
13 1 TRAVEL-S
Is normal pressure generated in the condition that P1 side flow rate is minimum, unload valve is emergency position and travel straight is stroked fully?
14 2 TRAVEL-S
Is normal pressure generated in the condition that P2 side flow rate is minimum, unload valve is emergency position and travel straight is stroked fully?
15 1 P1 ENGINE
Is rated engine speed obtained in the condition that P1 side flow rate increases little by little when P1 side flow rate is relieved?
16 2 P2 ENGINE
Is rated engine speed obtained in the condition that P2 side flow rate increases little by little when P2 side flow rate is relieved?
Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy Diagnosis (Display) SENSOR CHECK NG
Possible cause
Remedy
Check each pressure sensor by Disconnection of pressure sensor, Short service diagnosis and replace it if circuit, Abnormal output necessary
Secondary pressure is excessive high against the command Check P1 unload proportional valve P1 UN-LOAD PSV NG Secondary pressure is excessive low and replace it if necessary against the command P1 UN-LOAD SPOOL NG
Stuck at full-stroke side
Check P1 unload spool and replace it if necessary
Stuck at neutral side T5-3-4
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
E215B-E245B
Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy Diagnosis (Display)
Possible cause
Remedy
Secondary pressure is excessive high against the command Check P2 unload proportional valve P2 UN-LOAD PSV NG Secondary pressure is excessive low and replace it if necessary against the command P2 UN-LOAD SPOOL NG P1 B-P CUT NG P2 B-P CUT NG
Stuck at full-stroke side
Check P2 unload spool and replace it if necessary
Stuck at neutral side Stuck at closing side
Check P1 by-pass cut valve and replace it if necessary
Stuck at neutral side Stuck at closing side
Check P2 by-pass cut valve and replace it if necessary
Stuck at neutral side
P1 PUMP PSV NG
Secondary pressure is excessive high against the command Check P1 pump proportional valve Secondary pressure is excessive low and replace it if necessary against the command
P1 PUMP NG
Delivery rate is excessive large against the Check P1 pump regulator and command replace it if necessary. Delivery rate is excessive small against the Check P1 pump and replace it if necessary. command
P2 PUMP PSV NG
Secondary pressure is excessive high against the command Check P2 pump proportional valve Secondary pressure is excessive low and replace it if necessary against the command
P2 PUMP NG
Delivery rate is excessive large against the Check P2 pump regulator and command replace it if necessary. Delivery rate is excessive small against the Check P2 pump and replace it if necessary. command
S-TRAVEL PSV NG
Secondary pressure is excessive high against the command Check travel straight proportional Secondary pressure is excessive low valve and replace it if necessary against the command
S-TRAVEL SPOOL NG
Stuck at full-stroke side
Check travel straight spool and replace it if necessary
Stuck at neutral side
PUMP 1 PRESS. SENPressure is recognized lower than it is SOR NG
Check P1 high pressure sensor and replace it if necessary
PUMP 2 PRESS. SENPressure is recognized lower than it is SOR NG
Check P2 high pressure sensor and replace it if necessary
MAIN RELIEF NG ENGINE NG E/G R SENSOR NG
Set pressure decreases
Check main relief valve and replace it if necessary
Set pressure increases Output is lowered
Check engine and replace it if necessary
Characteristics is misaligned
Check engine speed sensor and replace it if necessary
T5-3-5
E215B-E245B
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
[MEMO:]
T5-3-6
REPAIR INSTRUCTIONS
M0103
REPAIR INSTRUCTIONS
E215B-E245B
SECTION AND GROUP CONTENTS Section 1
GENERAL INFORMATION
Group 1 Group 2
Precautions for Disassembly and Assembly Tightening Torque
Section 2
UPPERSTRUCTURE
Group 1 Group 2 Group 3 Group 4 Group 5
Upperstructure Pump device Control valve Swing device Pilot valve
Section 3
UNDERCARRIAGE
Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7
Swing bearing Travel device Swivel joint Track adjuster Front idler Upper and lower roller Tracks
Section 4
FRONT ATTACHMENT
Group 1
Front attachment
SECTION 1
E215B-E245B
GENERAL INFORMATION
CONTENTS Group 1 - Precautions for Disassembly and Assembly Precautions for Disassembly and Assembly .......................................... W1-1-1
Group 2 - Tightening Torque Torque Chart .......................................... W1-2-1 Piping Joint............................................. W1-2-4
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
E215B-E245B
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY PREPARATIONS FOR DISASSEMBLY - Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work. - Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. - Check and record the items listed below to prevent problems from occurring in the future. 1. The machine model, machine serial number, and hour meter reading. 2. Reason for disassembly (symptoms, failed parts, and causes). 3. Clogging of filters and oil, water or air leaks, if any. 4. Capacities and condition of lubricants. 5. Loose or damaged parts. - Prepare the necessary tools to be used and the area for disassembling work. - Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves. - Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency measure and ambulance to prepare for accidents and fire. - Attach "Don’t operate" tag to control lever, and begin a meeting before starting the work. DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT - Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return side to tank, and take out the filter. - Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground. - Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.
- If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified through service training. - Make match mark on parts for reassembling. - Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and assembly are permitted or not. - For parts which are required to use jig and tools, don’t fail to use the specified jig and tools. - For parts which can not be removed in the specified procedure, never force removal. First check for the cause. - Inspecting parts. Measure the wear of parts and clearance, and record the measured values. - If an abnormality is detected, repair or replace the parts. - The removed parts should be put in order and tagged so as to install on proper places without confusion. - For common parts, pay attention to the quantity and places. REASSEMBLING HYDRAULIC EQUIPMENT - During the parts cleaning, ventilate the room. - Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them. - Replace the removed O-ring, back-up rings and oil seal with new ones, and apply gear oil on them before assembling. - Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid sealant on them. - Before assembling, remove rust preventives on new parts. - Use special tools to fit bearings, bushing and oil seal. - Assemble parts matching to the marks. - After completion, check that there is no omission of parts.
- Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before putting them on working. DISASSEMBLING HYDRAULIC EQUIPMENT - Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from responsibility on the manufacture’s side, disassembly, assembly and modification without permission are strictly prohibited. W1-1-1
E215B-E245B
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
INSTALLING HYDRAULIC EQUIPMENT - Confirm hydraulic oil and lubrication oil. - Bleeding Air from Hydraulic System Air release is required in the following cases: 1. Change of hydraulic oil 2. Replacement of parts on suction pipe side 3. Removing and attaching hydraulic pump 4. Removing and attaching swing motor 5. Removing and attaching travel motor 6. Removing and attaching hydraulic cylinder IMPORTANT: if hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged. - For air bleed of hydraulic pump and swing motor, loosen drain plug on the upper part, start engine, and run in low idling, then bleed air until hydraulic oil is comes out. After completion of comes, tighten plug securely. - For air bleed of travel motor and hydraulic cylinder, starts engine and operate it for 10 minutes or more at no-load and low speed. IMPORTANT: for cylinder, don’t move it to the stroke end at beginning. - Air in pilot circuit can be bleed out by only operating digging, swing and travelling motions thoroughly. - Check hydraulic oil level. Move attachments to hydraulic oil check position, as indicated in the figure. - Open the hydraulic pump compartment door, then check the oil level on visual indicator (1) located on the hydraulic oil reservoir. If the indicator is within level marks, the oil quantity is acceptable.
W1-1-2
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
E215B-E245B
Floating Seal Precautions 1.
In general, replace the floating seal with a new one. If the floating is to be reused, follow these procedures:
A
1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. 2) Check the seal ring face (A) for scuffing, scoring, corrosion, deformation or uneven wear. 3) Check O-Ring (B) for tears, breaks, deformation or hardening. 2.
B
If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble.
SM0172
1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air. 2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it. 3) Check that the O-Ring is not twisted, and that it is installed correctly on the seal ring. 4) After installing the floating seal, check that seal ring surface (C) is parallel with mating face (A) by measuring the distances (a) and (b), as illustrated. If these distances differ, correct the O-Ring (B) seating.
RIGHT
WRONG
SM0173
RIGHT
WRONG a
A
a
C B
b
b a=b
W1-1-3
a≠b
SM0174
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 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. Hexagon T Bolt
Socket Bolt
SM0175
Specified Tightening Torque Chart
Bolt Dia.
Wrench Size
Hexagon Wrench Size
T Bolt, Socket bolt (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
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.
Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.
Equally tighten upper and lower alternately
Tighten diagonally 1
1.4
12
9
4
1
6
7
14
13
8
5
2
3
10
11
3
6 2.3
Tighten from center and diagonally
5
4 2
SM0176
W1-2-2
TIGHTENING TORQUE
E215B-E245B
Service Recommendations for Split Flange IMPORTANT 1.
Be sure to clean and inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component.
2.
Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file Oring 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 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 Orings or uneven tightening of bolts.
SM0177
WRONG
SM0178
Nut and Bolt Lockings •
SM0179
Lock Plate
IMPORTANT: do not reuse lock plates. Do not try to bend the same point twice. •
Cotter Pin
IMPORTANT: do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening. •
WRONG
RIGHT
Do not bend it round
Bend along edge sharply
RIGHT
RIGHT
WRONG
Lock Wire
IMPORTANT: apply wire to bolts in the bolttightening direction, not in the bolt-loosening direction. Bend along edge sharply
RIGHT
RIGHT Tighten
SM0180
WRONG
RIGHT
WRONG Loosen
SM0181
W1-2-3
E215B-E245B
TIGHTENING TORQUE
PIPING JOINT Pipe Thread Connection / Union Tightening Torque Specifications
Joint
4
1
5
3
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.
2.
Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to specifications.
37° 37°
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
Type 37° Union Joint
Wrench Size
Tightening Torque
Union Nut
Joint Body
(Nm)
19
17
29
22
19
39
27
22
78.5
36
30, 32
157
41
36
205
50
46
323.6
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
O-Ring Seal Joint O-Ring (6) seats against the end face of adaptor (7) to seal pressure oil.
7
9
6
IMPORTANT 1.
Be sure to replace O-Ring (6) with a new one when reconnecting.
2.
Before tightening union nut (9), confirm that ORing (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.
Wrench Size
Tightening Torque
Union Nut
Joint Body
(Nm)
19
17
29.4
22
19
68.6
27
22
93
30
27
137.3
36
30
175
41
36
205
50
46
320
W1-2-5
8
10
Joint body SM0184
E215B-E245B
TIGHTENING TORQUE
Screwed-In Connection IMPORTANT: many types of screwed-in connections are used for hose connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. Male Tapered Thread
PT
PF 30°
Male Tapered Thread
Wrench Joint Body
Tightening Torque (Nm)
17, 19
34
22
49
27
93
36, 32
157
41
205
50
320
60
410
Male Straight Thread SM0185
Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap. •
Internal Thread
Clearance External Thread
SM0186
Application Procedure 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.
Leave one to two pitch threads uncovered
Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. See below for correct tightening torque of each type of low-pressure-hose clamp.
SM0187
T-Bolt Type
Worm Gear Type
T-Bolt Type Band Clamp: 4.4 Nm (0.45 kgf m) Worm Gear Type Band Clamp: 5.9 a 6.9 Nm (0.6 a 0.7 kgf m)
SM0188
W1-2-6
SM0189
TIGHTENING TORQUE
E215B-E245B
Connecting Hose WARNING 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 separation of fitting. Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked.
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 with moving parts or sharp objects.
RIGHT
WRONG
SM0190
WRONG
RIGHT
Rubbing Against Each Other
SM0191
RIGHT
WRONG 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 Group 1 - Upperstructure
Group 2 - Control valve
Removal and installation of upperstructure....................................... W2-1-1 Preparation ....................................... W2-1-1 Removal of upperstructure ............... W2-1-1
Removal and installation of control valveW2-3-1 Preparation ....................................... W2-3-1 Removal of control valve................... W2-3-1 Installation of control valve................ W2-3-2
Removal and installation of the cab ....... W2-1-2 Removal of the cab ........................... W2-1-2 Installation of the cab ........................ W2-1-3
Control valve ports ................................. W2-3-3
Removal and installation of counterweight........................................ W2-1-4 Removal of counterweight ............... W2-1-4 Installation of counterweight ............ W2-1-5
Preparation for disassembly................... W2-3-12
Disconnecting hoses of swivel joint lower side.............................................. W2-1-6
Assembly................................................ W2-3-25
Swivel joint lower side hoses ................. W2-1-7 Removal and installation of main frame. W2-1-8 Removal of main frame..................... W2-1-8 Installation of main frame.................. W2-1-9
Group 2 - Pump device
Assembly and disassembly of control valve...................................................... W2-3-12 Disassembly........................................... W2-3-13 Inspection after disassembly.................. W2-3-25 Maintenance standards.......................... W2-3-32
Group 4 - Swing device Removal and installation of swing deviceW2-4-1 Preparation ....................................... W2-4-1 Removal............................................ W2-4-2 Installation......................................... W2-4-3
Removal and installation of hydraulic pump device.......................................... W2-2-1 Preparation ...................................... W2-2-1 Removal............................................ W2-2-1 Installation ........................................ W2-2-1
Disassembly and assembly of swing motor ..................................................... W2-4-4 Preliminary operations ...................... W2-4-5 Disassembly...................................... W2-4-5 Assembly .......................................... W2-4-7
Disassembly and assembly of pump device.................................................... W2-2-2
Disassembly and assembly of swing reducer .................................................. W2-4-9 Preliminary operations ...................... W2-4-10 Disassembly...................................... W2-4-10 Assembly .......................................... W2-4-13
Disassembly hydraulic pump device ..... W2-2-3 Assembly .......................................... W2-2-7 Maintenance standard ........................... W2-2-11 Disassembly and assembly of regulator W2-2-12 Disassembly of regulator .................. W2-2-14 Assembly of regulator ....................... W2-2-18 Disassembly and assembly of pto gear casing.................................................... W2-2-21 Disassembly ..................................... W2-2-22 Assembly .......................................... W2-2-23 Maintenance standard ...................... W2-2-23
Maintenance standards.......................... W2-4-18 Swing motor ...................................... W2-4-18 Swing reduction gear ........................ W2-4-19
Group 5 - Pilot valve Removal and installation of right and left pilot valve ........................................ W2-5-1 Preparation ....................................... W2-5-1 Removal............................................ W2-5-1
Installation......................................... W2-5-2 Removal and installation of travel pilot valve...................................................... W2-5-3 Preparation ....................................... W2-5-3 Removal............................................ W2-5-3 Installation......................................... W2-5-4 Disassembly right and left pilot valve ..... W2-5-5 Disassembly right and left pilot valve W2-5-6 Assembly right and left pilot valve.......... W2-5-9 Assembly right and left pilot valve..... W2-5-10 Pilot valve (for travel) ............................. W2-5-13 Construction ........................................... W2-5-13 Disassembly and assembly.................... W2-5-14 Drain of hydraulic pilot control unit ......... W2-5-21
UPPERSTRUCTURE
E215B-E245B
REMOVAL AND INSTALLATION OF UPPERSTRUCTURE 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
Removal of upperstructure
1.
Park the machine on a firm, level surface.
1.
2.
To drain the hydraulic pressure from the Hydraulic System, refer to procedure “Releasing the hydraulic pressure” at page T21-47.
Remove the front equipment and the boom cylinders, performing the operations described in the procedure at pages W4-1-1 (Refer to: Section 4 - “Front Attachment”).
2.
Remove the cab, performing the operations described in the procedure at page W2-1-2
3.
Remove the counterweight, performing the operations described at page W2-1-6.
4.
Disconnect the hoses of swivel joint lower side, performing the operations described in the procedure at page W2-1-6.
5.
Remove the main frame performing the operations described in the procedure at page W2-1-8.
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.
NOTE: be sure to run the vacuum pump continuously while working.
W2-1-1
E215B-E245B
UPPERSTRUCTURE
REMOVAL AND INSTALLATION OF THE CAB Removal of the cab 1.
Remove floor mat.
2.
Remove cover (1). Lift cover (1) upwards and remove it. (Fixed with 2 clips).
3.
Remove cover assy (2). 1) Loosen 4 sems bolts (3) M6x16 and lift cover assy (2) up. 2) Disconnect each connector for both speakers. Then remove cover assy (2).
4.
Remove the harness connector (See section T2, group 3) 1) Disconnect connectors of cluster gauge harness: (CN-5F), (CN-6F), (CN-61F), (CN62F) and earth wire (P-1) at rear right of cab. 2) Disconnect antenna cable coming from backside of tuner at rear left of cab.
5.
Remove the plastic tube for the window washer from the rear left of cab.
6.
Remove the right panel of cab. 1) Remove 2 caps (4), loosen 2 sems bolts (5) M6x25 and 1 sems bolt (6) M6x16, and right panels (7) and (8) are freed. : TORX driver T30 2) Lift cover (9) upwards and remove it. (Fixed with 3 clows and 2 clips). 3) Unfix 3 harness clips (10) of inside on right panel (8). And free the harnesses connected to key switch. 4) With harnesses are connected condition, install key switch cover (9) to bracket (11) of rear cab temporally. (See Fig. SM0261). 5) Disconnect harness connectors of work light switch on right panel (7), air conditioner panel and cigarette lighter, and remove right panel (7) and (8). 6) Loosen sems bolts (12) M6x16 and (13) M6x40, one each, and remove front panel (14) with air conditioner duct. : Plus driver
1
3 2
SM0259
Disassembly and assembly of cover (1) and cover assy (2)
9
3 5
10 7
4
10
6
5 10 4
8
12
14
13
SM0261
Disassembly and assembly of right panels (8), (9) and (14)
W2-1-2
UPPERSTRUCTURE 7.
E215B-E245B
Remove cab attaching bolt.
9
1) 5 capscrews (15) M12x65 and 1 capscrew (16) M12x30 2) 2 nuts (17) M16 8.
Slinging cab. 1) Remove two plastic plugs at the front of the ceiling of the cab. Then place a wire sling with eye bolts (18) and a hook around the cab, as shown in Fig. SM0263. 2) Then lift up slowly avoiding interference with surroundings. Eye bolts M10 (q.ty 2). Wire with hook: Length 1.5 m (4ft 11in), Dia. 8 mm (0.315in) – (3 pcs). Weight of cab: Approx. 250 kg. (550 lbs)
11
SM0261
17
15
installation of the cab Install it in reverse order of removing according to the Tightening Torque Table. Allen wrench HEX
Tightening torque Nm (lbf·ft)
Nut M16 - (17)
24
191 (140)
Capscrew - (2), (9)
19
79.4 (60)
Sems bolt M6 (5), (6)
Torxdriver T30
8.5 (6.3)
Sems bolt M6 (12), (13)
Plus driver
5.0 (3.7)
Tightening position
15
16 15 Smontaggio e rimontaggio dei bulloni di fissaggio 15 cabina
15
SM0262
18 18
SM0263
W2-1-3
E215B-E245B
UPPERSTRUCTURE
REMOVAL AND INSTALLATION OF COUNTERWEIGHT Removal of counterweight 1.
Remove plugs (1) from the counterweight and attach two M36 eye bolts to the counterweight.
1
NOTE: approximate mass of counterweight: 4600 kg 2.
3.
Attach wire rope (2) to eye-bolts (3) using shackles. Take out slack of wire rope by applying tension slowly with a crane or hoist. Wire with hook: Length 1.5 m, dia. more than 16 mm – (2 pcs.).
Remove 4 bolts (4) M30. Lift counterweight using a crane or hoist.
2
: 46 mm
4.
SM0264
Remove shim (5), (6), (7) from the frame.
3 5 6 7
4
5.
SM0265
Lower the counterweight on proper stand.
SM0266
W2-1-4
UPPERSTRUCTURE
E215B-E245B
Installation of counterweight NOTE: approx. weight of counterweight: 4600 kg
1.
2.
Attach lifting tools (2) to eye-bolts (3) of counterweight.
2
Install shim (5), (6), (7) onto the frame as it was.
3 3.
Lift counterweight and install it onto the frame.
5 6
4.
Install bolts (4) and washers to counterweight and tighten temporarily.
7
: 46 mm
4 5.
Remove wire rope. Tighten the bolts (4) with a power wrench and torque wrench.
SM0265
1
: 46 mm : 1570+200 Nm -100
6.
Remove eye-bolts (3) and install plugs (1) onto the counterweight.
4
W2-1-5
SM0267
E215B-E245B
UPPERSTRUCTURE
DISCONNECTING HOSES OF SWIVEL JOINT LOWER SIDE Disconnect the hose on the lower side of swivel joint. NOTE: close all openings with plugs to keep clean. 1.
Disconnect the two hose (1). (E Port: PF1/2) : 27 mm Tightening torque: 78.5 Nm
2.
Disconnect the hose (2) and (3). (A and B Port: PF1) : 36 mm Tightening torque: 177 Nm
3.
Disconnect the hose (4) and (5). (C and D Port: PF1) : 36 mm Tightening torque: 177 Nm
4.
Disconnect the two hose (6). (F Port: PF1/4) : 19 mm Tightening torque: 29.4 Nm
A
B
C
D
B
F
F
F
E
D
F
D
F
C B A
E
E SM0268
W2-1-6
UPPERSTRUCTURE
E215B-E245B
SWIVEL JOINT LOWER SIDE HOSES
2
4
5
3
6
A
A
6
4
6
5
3
2 1
section A - A SM0269
W2-1-7
E215B-E245B
UPPERSTRUCTURE
REMOVAL AND INSTALLATION OF MAIN FRAME Removal of main frame NOTE: approximate mass of main frame 5000 kg.
1.
2.
Insert two upper swing body lifting jigs (2) and two counterweight fastening cap screws (M30) (1) into the counterweight mounting holes from above.
3 4
2
Attach two chain blocks (4) to the boom foot side.
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.
IMPORTANT: make sure rear slings do not touch engine. 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 Special tool for lifting P/n 38xxxxxxx, 2 pcs
4.
ST. No. 38xxxxxxx
Put matching marks (M) on swing bearing and main frame.
SM0270
M
5 SM0271
W2-1-8
UPPERSTRUCTURE 5.
E215B-E245B
Remove the 32 bolts (5) M20x100, the reamer bolt (6) M20, from the swing bearing.
A
: 30 mm
6.
Lift main frame slightly from undercarriage. Level main frame by adjusting the chain blocks (4).
7.
Remove main frame. 6 SM0272
Installation of main frame NOTE: approximate mass of main frame 5000 kg. Installing is done in the riverse order of removing. 1.
Clean mating surfaces of upper frame and swing bearing.
2.
Apply Loctite # 515 to the inside of the capscrews on the contact surface (A) (fig. SM0272).
3.
Slinging upper frame. Match marks and install it with a reamer bolt (6) and a washer temporarily.
SM0273
CAUTION Confirm the reamer bolt position (X) referring to Fig SM0274.
4.
OUTER (S) ZONE POSITION
Apply Loctite # 262 onto thread of bolts (5) then, install bolts. : 30 mm Tightening torque: 392 Nm
5.
19,5°
X
Apply Loctite # 262 onto thread of reamer bolts (6) then, install reamer bolt. : 30 mm Tightening torque: 392 Nm
(*)
SM0274
(*) Apply Loctite # 515 to the shared area
W2-1-9
E215B-E245B
UPPERSTRUCTURE
NOTE:
W2-1-10
PUMP DEVICE
E215B-E245B
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP DEVICE 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.
3.
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 T21-47.
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.
NOTE: be sure to run the vacuum pump continuously while working.
Removal
Installation
1.
Remove all protection panels and doors to give access to the Hydraulic Pump Device.
1.
2.
Disconnect all electrical connectors.
NOTE: hydraulic pump device weight: 143 kg.
3.
Remove all hoses and collector from hydraulic pump device.
2.
4.
Lift the hydraulic pump device by means of hoist and ropes.
Install the hydraulic pump device to the engine by means of related bolts.
: 19, 22, 30, 36 mm
: 17 mm
: 8, 10 mm
: 431 ± 43.1 Nm
Fasten the hydraulic pump device by means of hoist and lifting ropes.
3.
Install all hoses and collector to the hydraulic pump device.
NOTE: hydraulic pump device weight: 143 kg.
: 19 mm : 29,4 Nm
5.
: 22 mm : 39,2 Nm
Remove the fixing bolts of hydraulic pump device and draw it from engine.
: 30 mm : 137,2 Nm
: 17 mm
: 36 mm : 156,9 Nm : 8 mm : 64 Nm : 10 mm : 108 Nm 4.
Connect all electrical connectors.
5.
Install all protection panels and doors.
W2-2-1
E215B-E245B
PUMP DEVICE
DISASSEMBLY AND ASSEMBLY OF PUMP DEVICE 9
532
728
824 262
113
251 401 127
214 212
717 724
124 546 901
808
954
407 325
725
156
406 261 774
313
710
151 153 152
468
710
9
271
717 127 123
412 413
792
789 732 535 953 886
806
534
702
531 548
141
124 314
490
490 727
116
717
157
725
111 8
727
6
467
885 886
7
5
466
211
885
312 886 710
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 5 6 7 8 9 10 11 111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 261 262 271 312 313 314 325 401 406
-
Pilot pump PTO gear casing O-Ring (Q.ty 2) Cover Socket bolt (Q.ty 2) Regulator Short-circuit valve Socket bolt Shaft (F) Shaft (R) 1st gear Roller bearing (Q.ty 2) Needle bearing (Q.ty 2) Bearing spacer (Q.ty 4) Cylinder block (Q.ty 2) Piston (Q.ty 18) Shoe (Q.ty 18) Plate (Q.y 2) Spherical bushing (Q.ty 2) Cylinder spring (Q.ty 18) Shoe plate (Q.ty 2) Swash plate (Q.ty 2) Tilting bushing (Q.ty 2) Swash plate support (Q.ty 2) Cover (front) Cover (rear) Pump casing (Q.ty 2) Valve block Valve plate (front) Valve plate (rear) Sensor Block Socket bolt M20×210 (Q.ty 8) Socket bolt M8×20 (Q.ty 4)
407 412 413 435 466 467 468 490 531 532 534 535 546 548 702 710 717 724 725 727 728 732 774 789 792 806 808 824 885 886 901 953 954
W2-2-2
-
Socket bolt M6×55 (Q.ty 3) Socket bolt (Q.ty 2) Socket bolt (Q.ty 2) Socket bolt (Q.ty 2) Plug VP PF 1/4 (Q.ty 2) Plug VP PF 3/8 (Q.ty 2) Plug VP PF 3/4 (Q.ty 4) Plug nptf 1/16 (Q.ty 27) Tilt Pin m24×2 (Q.ty 2) Servo piston M24×2 (Q.ty 2) Stopper (Q.ty 2) Stopper (Q.ty 2) Spacer (Q.ty 2) Feed back Pin (Q.ty 2) O-Ring (Q.ty 2) O-Ring (Q.ty 2) O-Ring (Q.ty 2) O-Ring (Q.ty 18) O-Ring (Q.ty 6) O-Ring (Q.ty 3) O-Ring (Q.ty 4) O-Ring (Q.ty 2) Oil seal Backup ring (Q.ty 2) Backup ring (Q.ty 2) Hex. nut M16 (Q.ty 2) Hex. nut M20 (Q.ty 2) Snap ring (Q.ty 2) Valve plate pin (Q.ty 2) Spring pin (Q.ty 4) Eye bolt M10 (Q.ty 2) Set screw M16×30 (Q.ty 2) Set screw M20 (Q.ty 2)
PUMP DEVICE
E215B-E245B
DISASSEMBLY HYDRAULIC PUMP DEVICE •
Proceed with disassembly operations in a clean place. Spread rubber sheet or cloth on work bench to protect parts from damaging.
•
Clean the parts removing dust and rust, etc. on pump surface with wash oil.
•
Drain out the oil in the pump casing by removing drain port plugs (466 and 468).
435 435
:19, 36 mm 311 312 466
1.
SM0276
Removing piloto pump. Remove the socket bolts (435), then remove pilot pump (4). : 8 mm
2.
Removing PTO gear casing. Remove the socket bolts (435), then remove PTO gear casing (5).
5
435
: 8 mm SM0278
3.
Removing regulator. Remove the socket bolts (412) e (413), then remove regulator (9). : 6 mm
9
SM0277
W2-2-3
E215B-E245B 4.
PUMP DEVICE
Loosen socket bolts (401) that fasten swash plate support (251), pump casing (271) and valve block (312).
312
271
401
: 17 mm
SM0279
5.
Place the pump level on a work bench with its mounting surface of the regulator facing down. Then separate pump casing (271) and valve block (312).
312
271
NOTE: When facing the mounting surface of the regulator down, place a rubber board on a work bench so as not to score the mounting surface. When the pump casing has been separated from the valve block, draw out the 1st gear (116) at the same time. SM0280
6.
Draw out cylinder (141) out of pump casing (271) in parallel to shaft (111). At the same time draw out piston (151), plate (153), spherical bushing (156) and cylinder spring (157).
271 141(151)(157) 153 156
NOTE: use care so as not to score the sliding surface of the cylinder, spherical bushing, shoe and the swash plate.
SM0281
W2-2-4
PUMP DEVICE 7.
E215B-E245B
Remove socket bolt (406) and seal cover (261).
406
: 6 mm
261
NOTE: the seal cover may be drawn out with ease if it is taken out by tightening bolts in the tapped holes of the seal cover. An oil seal is fitted to seal cover. Therefore, use care so as not to score the oil seal.
SM0282
8.
Knock lightly on the mounting flange of swash plate support (251) from the pump casing (271) side and separate the swash plate support from the pump casing.
271
251
SM0283
9.
Draw out shoe plate (211) and swash plate (212) from pump casing (271). 271
212 (211)
SM0284
10. Tap lightly the shaft end (111 and 113) by means of a plastic hammer and draw out the shaft from the swash plate support.
251
111 (113)
SM0285
W2-2-5
E215B-E245B
PUMP DEVICE
11. Remove valve plate (313 and 314) from valve block (312).
312
NOTE: the valve plate may come off during the separation of pump casing from valve block.
314 (313)
SM0286
12. If necessary, remove stoppers (534 and 535), servo piston (532) and tilting pin (531) from pump casing (271), and remove needle bearing (124) from valve block (312).
531
806
NOTE: When removing the tilting pin, use care so as not to score the head of the tilting pin, using a jig. It is hard to separate the tilting pin from the servo piston in some cases as Loctite is coated on the mating part between them. Use care so as not to score the servo piston by applying unreasonable force. Do not draw out needle bearings except when their service life has ended. Do not loosen hex nuts (806 and 808) of valve block (312) and swash plate support (251). A set flow rate changes.
534
535
532
808 271
312
124
251
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 ORings 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.
2.
Attach swash plate support (251) to pump casing (271) by tapping the swash plate support lightly with a plastic hammer.
271
NOTE: When the servo piston, the tilting pin, the stoppers have been removed, install them to the pump casing beforehand. When tightening servo piston and tilting pin, use a jig so as not to damage the head of the tilting pin and feedback pin. Coat the screwed part with Loctite 262.
251 SM0288
3.
Install swash plate placing the pump casing with its mounting surface of the regulator facing down. Insert the tilting bushing of the swash plate into tilting pin (531), and fit swash plate (212) to swash plate support (251) properly.
NOTE: Confirm by your both hands that swash plate moves smoothly. The shaft be installed easily if grease is applied to the sliding parts of swash plate and swash plate support. Do not damage the sliding surfaces of shoe plate.
271 (531)
251
212
SM0289
W2-2-7
E215B-E245B 4.
PUMP DEVICE
Install shaft (111) fitted with bearing (123), bearing spacer (127) and snap ring (824), to swash plate support (251). 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 the end by using a steel rod and others.
123 127,824
111 SM0290
5.
nstall seal cover (261) to pump casing (271) and fix it with socket bolts (406). 271
: 6 mm : 29.4 Nm
261
NOTE: Coat the oil seal in seal cover with a thin film of grease. Handle the oil seal with sufficient care so it is not scored.
406
SM0291
6.
Assemble the piston cylinder sub compound to the cylinder block (141), piston (151), shoe (152), plate (153), spherical bushing (156) and cylinder spring (157). Align the spherical bushing with the cylinder spline and insert them into the pump casing.
141(151,152,157) 156 153
SM0292
W2-2-8
PUMP DEVICE 7.
E215B-E245B
Install valve plate (313 and 314) to valve block (312) by aligning pin.
312
NOTE: do not mistake the suction and delivery sides of the valve plate.
314 (313)
SM0293
8.
Install valve block (312) to pump casing (271) and fasten them together with socket bolts (401).
312
271 401
: 17 mm : 430 Nm NOTE: Work will be promoted if assembly is started from the rear pump. Exercise care so as not to mistake the direction of the valve block (312). Install it so the regulator comes up as seen from the front side and the suction flange comes on the right. Insert the 1st gear into the valve block beforehand and connect it with the spline of the shaft.
9.
Install regulator (9) pinching feedback pin of tilting pin in feedback lever of the regulator, then install the regulator and fasten socket bolt (412) e (413).
SM0294
9
: 6 mm : 29,4 Nm IMPORTANT: do not mistake the front regulator for the rear regulator.
SM0295
W2-2-9
E215B-E245B
PUMP DEVICE
10. Install gear casing (5) and fasten it with socket bolt (435). : 8 mm : 17 Nm
5
435
SM0278
11. Install pilot pump (4) and fasten it with socket bolt (435). : 8 mm : 17 Nm
435 435
311 312 466
W2-2-10
SM0276
PUMP DEVICE
E215B-E245B
MAINTENANCE STANDARD:
Unit: mm (poll.) Part name and inspection item
Standard dimension (mm)
Recommended value for replacement (mm)
Clearance between piston and cylinder bore (D-d)
0.039
0.067
Replace piston or cylinder.
0 ~ 0.1
0.3
Replace piston shoe assy.
4.9
4.7
Replace piston shoe assy.
41.1
40.3
Replace cylinder spring.
23.0
22.0
Replace a set of spherical bushing or retainer plate.
Remedy
SM0520
Gap between piston and caulked part of shoe (d)
SM0521
Thickness of shoe (t)
t SM0522
Free height of cylinder spring (L)
L SM0523
Combined height of retainer plate and spherical bushing (H-h)
SM0524
Repair standards for cylinder, valve plate and swash plate (shoe plate face) Valve plate (sliding section). Swash plate (shoe plate face). Cylinder (sliding section). Roughness of each surface.
Surface correction.
roughness
Standard surface (correction value)
W2-2-11
requiring roughness
3-Z Less than 0.4 Z (lapping)
E215B-E245B
PUMP DEVICE
DISASSEMBLY AND ASSEMBLY OF REGULATOR
626 625 624
753 627
623 621
898
733 732 631
B
622
D
F
874 613
875 612
652
875
814
654
643
G
836 653
646 644
A
651
E
C
897
655
728
645
611
438
630
629 802 756
763
628
924 412 413
656 757
438
Y 418
D
X
E 601
722
496
755
W
Z
079 041 755
466
734 887
876 615
439
A
B
642 755
C
724 730 725
F 876
8-724 041 755
466
641
755
755 858
G
708 662
801
614
755
858
466
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 041 079 412 413 418 438 439 466 496 541 543 545 601 611 612 613 614 615 621 622 623 624 625 626 627 628 629 630 631 641 642 643 644 645
-
Check valve Solenoid proportional reducing valve Socket bolt M8×50 (Q.ty 2) Socket bolt M8×70 (Q.ty 2) Socket bolt M5×12 (Q.ty 2) Socket bolt M6×20 (Q.ty 8) Socket bolt M6×25 (Q.ty 5) Plug PF 1/4 (Q.ty 3) Plug (Q.ty 18) Seat (Q.ty 2) Stopper (Q.ty 2) Steel ball (Q.ty 2) Casing Feed back lever Lever 1 Lever 2 Fulcrum plug Adjust plug Compensating rod Piston case Compensating rod Spring seat Outer spring Inner spring Adjust stem Adjust screw Cover Lock nut M30×1.5 Sleeve Pilot cover Spool Pilot piston Spring seat Stelo di regolazione
646 651 652 653 654 655 656 662 708 722 724 725 728 730 732 733 734 753 755 756 757 763 801 802 814 836 858 874 875 876 887 897 898 924
Tightening torque of bolt, plug and nut Tightening torque Nm (lbf·ft)
No.
Thread size
412, 413
M8
29 (21)
438, 438
M6
12 (8.9)
418
M5
6.9 (5)
466
PF 1/4
36 (26)
496
NPTF1/16
8.8 (6.5)
630
M30x1.5
160 (118)
801
M8
16 (12)
802
M10
19 (14)
W2-2-13
-
E215B-E245B Pilot spring Sleeve Spool Spring seat Return spring Set spring Block cover Spring O-Ring O-Ring (Q.ty 3) O-Ring (Q.ty 8) O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring (Q.ty 7) O-Ring O-Ring O-Ring Nut M8 (Q.ty 2) Nut M10 Snap ring Snap ring Snap ring (Q.ty 2) Pin Ø 4×11.7 L Pin Ø 4×8 L (Q.ty 2) Pin Ø 5x8 L (Q.ty 2) Pin Pin Ø 4×19 L Pin Ø 7.5x11 L Socket bolt M8×20
E215B-E245B
PUMP DEVICE
Disassembly of regulator 1.
Proceed with disassembly operations in a clean place. Spread rubber sheet or cloth on work bench to protect parts from damaging.
2.
Clean the parts removing dust and rust, etc. on regulator surface with wash oil.
3.
Remove regulator remove socket bolts (412) and (413) and separate the regulator from the pump body.
438
656
629
413
412
: 6 mm 4.
Remove socket bolt (438) and separate the port plate (656). : 5 mm
5.
438
Remove socket bolts (438) and remove cover (629).
601
: 5 mm
SM0297
NOTE: the cover is equipped with adjust screws (628 and 925), adjust stem (627), lock nut (630), hex nut (801) and set screw (924). Do not loosen those parts. If they are loosened, preadjusted set pressure and flow values change. 624,625,626 627 801 629( 628 )
630 924
W2-2-14
SM0298
PUMP DEVICE 6.
E215B-E245B
After removing the cover (629) sub assy, take out outer spring (625), inner spring (626) and spring seat (624) from the compensating part. Then take out adjust stem (645), pilot spring (646) and spring seat (644) from the pilot part.
(A)
645
644,646
629
NOTE: Adjust stem (645) comes out easily if an M4 bolt is used (A).
SM0299
7.
Remove socket bolt (439) and pilot cover (641). Once the pilot cover comes off, separate set spring (655) from the pilot section. : 5 mm
439 641 SM0501
8.
Remove snap ring (814), spring seat (653), return spring (654) and sleeve (651). 814(653)
NOTE: Sleeve (651) is equipped with snap ring (836). When removing snap ring (814), return spring (654) comes out, use care so as not to lose it.
654, 651(836)
SM0502
9.
Remove snap ring (858) and take out fulcrum plug (614) and adjust plug (615). 858
615 614
SM0503
W2-2-15
E215B-E245B
PUMP DEVICE
NOTE: fulcrum plug (614) and adjust plug (615) come off easily if a M6 bolt is used.
614
SM0504
10. Remove lever 2 (613) with tweezer.
NOTE: do not draw out pin (875).
613(875)
SM0505
11. Draw out pin (874) and remove feedback lever (611).
874 NOTE: push out pin (874) from above with a slender steel rod (Ø 4 x 100) so as not to interfere with lever (612).
611
SM0506
611 SM0507
W2-2-16
PUMP DEVICE
E215B-E245B
12. Remove lever 1 (612). 612
NOTE: do not draw out pin (875).
875
611
874 897 613 875
13. Draw out pilot piston (643) and spool (652).
14. Draw out piston casing (622), compensating piston (621) and compensating rod (623).
643 SM0504
NOTE: Piston casing (622) comes out from the opposite side of the piston casing if compensating rod (623) is pushed out.
466
662
15. Remove VP plug (466) from pilot cover (641) and draw out spool (642) and spring (662).
642 466
641
W2-2-17
SM0509
E215B-E245B
PUMP DEVICE
Assembly 1.
Assembly is the reverse order of disassembly. Do the work paying attention to the following: - Repair those parts that were damages during disassembly and prepare replacement parts beforehand. - Clean parts thoroughly in cleaning oil, blow them with jet air and assemble parts in a clean place. - Always tighten screws and plugs to the specified torque. Tolerance of torque should be within 10% - Do not fail to coat the moving parts with clean hydraulic oil, before assembly. - Replace seals such as O-Ring.
2.
3.
4.
612
875
611 874 897 613
Put the pin mounted in lever 1 (612) into the groove of the compensating rod. Then assemble the lever to the pin that is pressed in the casing (601).
875
SM0510
Assemble compensating rod (623) into the compensating hole of casing (601).
652 651 836 655 654 653
Assemble spool (652) and sleeve (651) into the spool hole of the casing.
NOTE: Make sure that the spool and the sleeve move smoothly in the casing. Beware of the direction of the spool. 5.
623
814
SM0511
Assemble feedback lever (611). Then put pin (874) into the pin hole of the feedback lever.
874
NOTE: The work is eased if the pin is put in the feedback lever a little, beforehand. Take care so as not to mistake the direction of the feedback lever.
611 652 SM0512
W2-2-18
PUMP DEVICE 6.
Assemble pilot piston (643) into the negative control hole of the casing.
NOTE: make sure that the pilot piston moves smoothly.
7.
E215B-E245B
613(875)
Place pin (875) pressed in lever 2 (613) into the groove of the pilot piston and assemble lever 2 (613). SM0513
8.
Assemble fulcrum plug (614) so pin (875) pressed in the fulcrum comes in the pin hole of lever 2 (613). Then fit snap ring (858). 614(875,858)
9.
Insert adjust plug (615) and fit a snap ring (858).
NOTE: Use care so as not to mistake the holes into which the fulcrum and adjust plug are inserted. Operate the feedback lever and make sure that the gap is not large and that the lever moves smoothly.
SM0514
858 615 614
SM0515
W2-2-19
E215B-E245B
PUMP DEVICE
10. Assemble return spring (654) and spring seat (653) into the spool hole and fit snap ring (814).
11. Assemble set spring (655) into the spool hole. Place compensating piston (621) and piston casing (622) into the compensating hole and attach pilot cover (641) with socket bolts (438 and 439). : 5 mm 622(621)
: 11.7 Nm
SM0516
12. Assemble spool (642) and spring (662) into pilot cover (641) and tighten VP plugs (466).
466
: 19 mm : 36 Nm 662
13. Put spring seat (644), pilot spring (646) and adjust stem (645) into the pilot hole. Then assemble spring seat (624), inner spring (626) and outer spring (625) into the compensating hole.
642 466
641
SM0509
NOTE: do not mistake the direction of the spring seat.
14. Attach cover (629) fitted with adjust screws (628 and 925), adjust stem (627), lock nut (630), nut (801) and socket bolt (924). Then fasten them with socket bolts (438).
644,645,646 626 625(624)
: 5 mm : 12 Nm
15. Attach block cover (656) and tighten screws (438).
SM0517
: 5 mm : 12 Nm
16. Install the regulator on the pump and fasten socket bolt (412 and 413).
624, 625, 626
:6 mm
627
: 29 Nm
801 629 ( 628 ) 630 924 W2-2-20
SM0518
PUMP DEVICE
E215B-E245B
DISASSEMBLY AND ASSEMBLY OF PTO GEAR CASING
128
117 126
435
711
262
414
886
826 128 885 728
886 115
468 326
435
125 118 825
115 117 118 125 126 128 262 326 414
-
125
Idle shaft 2nd gear 3rd gear Ball bearing (Q.ty 2) Roller bearing Bearing spacer (Q.ty 2) Cover Gear casing Socket bolt M10×20 (Q.ty 2)
SM0519
435 468 711 728 825 826 885 886
W2-2-21
-
Flange socket M10×20 (Q.ty 4) VP plug PF3/4 O-Ring O-Ring Snap ring Snap ring Spring pin Pin (Q.ty 2)
E215B-E245B
PUMP DEVICE
Disassembly 1.
Proceed with disassembly operations in a clean place. Spread rubber sheet or cloth on work bench to protect parts from damaging. 414
2.
Remove dust, rust, etc, on pump surface with wash oil (468).
262
: 27 mm : 74 Nm
3.
468
Remove the socket bolts (414). Then remove the cover (262).
SM0525
: 8 mm : 33.3 Nm
4.
115
Remove snap ring (885) and idle shaft (115). Then draw out 2nd gear (117), roller bearing (126) and bearing spacer (128).
117 (126, 128)
NOTE: roller bearing can not be separated from 2nd gear (117). SM0526
5.
Remove snap ring (825) and draw out 3rd gear (118) and ball bearing (125).
NOTE: ball bearing (125) can not be separated from 3rd gear (118).
125
118
SM0527
W2-2-22
PUMP DEVICE
E215B-E245B
Assembly Assembly is a reverse order of disassembly, but notice the following: - Repair scored parts at disassembly. replacements ready beforehand.
Get
- 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. Maintenance standard In case a pitching (1 pit is more than 1mm, while the area ratio is more than 5%) is seen on the gear tooth surface of 2nd gear (117) and 3rd gear (118), replace the gears. Replace the gears also in case they show excessive damage. Air pulling out point 1.
After the relief valve installation, start the engine.
2.
Loosen the air pulling out plug (1), until O-ring (2) comes off, to allow the air flows out.
3.
Air pulling out operation is completed when, for two seconds, only hydraulic oil flows out from plug (1).
4.
Tighten the plug (1) to specified torque.
1
2
: 17 : 23 Nm (17 lbf.ft)
SM1251
W2-2-23
E215B-E245B
PUMP DEVICE
NOTE:
W2-2-24
CONTROL VALVE
E215B-E245B
REMOVAL AND INSTALLATION OF CONTROL VALVE 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.
3.
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. T21-47.
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.
NOTE: be sure to run the vacuum pump continuously while working.
Removal of control valve 1.
Remove the panel protecting the control valve, removing the securing screws. : 19 mm
2.
Disconnect all hoses, pipes and connectors from the control valve (1).
1
NOTE: attach caps to hoses and pipes. Attach labels or tags to hoses and pipes, to aid in assembly.
3.
Remove the control valve securing screws (2). : 19 mm
2
NOTE: control valve assembly mass: 232 kg.
4.
2
2
Remove the control valve.
W2-3-1
SM0528
E215B-E245B
CONTROL VALVE
Installation of control valve 1.
Install control valve (1) to frame and tighten the bolts (2). : 19 mm : 235 Nm
2.
1
Connect all hoses, pipes and connectors to the control valve.
2 2 2
SM0528
Connector / Bolt Tread size
Ports
PF 1/4
Pss, PLc2, PBp1, PBp2, PL, PB1, PTb, PCa, PCb, PCc, XAb
PF 3/8
PAa1, PBa1, Pab, PBb, Pac, PBc, PAL, PBL, Par,PBr, Pas, PBs, PAa2, PBa2, Pao, Pbo, DR
PF 3/4
MU
M10 M12
3.
Name
Hose nut
Tightening Tightening Remarks Opposing Opposing torque torque flats flats Nm (lbf·ft) Nm (lbf·ft) 19
36 (27)
19
29 (21)
22
74 (55)
22
49 (36)
36
162 (119)
36
118 (87)
Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc
14
42,4 (31)
-
-
Ab, Bb, Ao, Bo
14
57 (42)
-
-
17
62,2 (45)
-
-
17
96 (70)
-
-
ORS Joint
Sems bolt
P1, P2 T1, T2
Install the panel protecting the control valve using the relevant securing screws. : 19 mm : 108 Nm
W2-3-2
CONTROL VALVE
E215B-E245B
CONTROL VALVE PORTS (1/2)
Functions
Ports
Ports on upper sides
LEFT
Ports
RIGHT PBp1 P1 bypass cut
P2 bypass cut PBp2 Option Arm (R) relief valve
PBa2 Arm 2 in
PAo
Mu
-
-
Bucket (R)relief valve
XAb
Boom lowering valve
PBb
Boom down
Arm 1 out PBa1 Swing (LH)
PBs
Boom conflux
PB1
Travel left forward
PAL
Tank return
Functions
PAr -
T2
Make-up line
Boom (H) relief valve Travel right forward Main relief valve
PCb
P1 unload
P1
P1 pump
P2
P2 pump
Ports on rear sides (on machine)
LEFT
RIGHT
Ports on right sides (on machine)
UPPER SIDE
LOWER SIDE
Bucket dump
BC
Bucket dump
PBc
Bucket (H) stroke limit
PCc
AC
Bucket digging
Boom up
Ab
Bb
Boom down
Drain
Dr
BR
Travel right reverse
Travel right forward
AR
ATT power boost
PL SM0529
W2-3-3
E215B-E245B
CONTROL VALVE
CONTROL VALVE PORTS (2/2)
Function
Ports
Option
Bo
Ports on left side (on machine)
LOWER SIDE
Ports
UPPER SIDE
Function
Ao
Option
Ba
Arm 1 out
PLc2 Arm in lock release
Arm 1 in
Aa
Swing left
Bs
Pss
Swing low pressure sensor
Travel left reverse
BL
As
Swing right
AL
Travel left forward
T1
Tank return
Ports on lower side (on machine)
LEFT SIDE
RIGHT SIDE
Travel left reverse
PBL
PTb Travel straight
P2 unload
PCa
PBr
Travel right reverse
Swing right
PAs
PAb
Boom up
-
-
Boom (R) relief valve
-
Bucket (H) relief valve
Arm (H) relief valve
Arm in PAa1 Option
PBo
PAc
Bucket digging
PAa2 Arm 2 in SM0530
W2-3-4
CONTROL VALVE
E215B-E245B
Control valve (1/6)
A
B
H
273x10
T2
P1 unload (Travel priotity)
Travel right
273x10
H
Travel left
C
USE FOR YN30V00101F1
C
PAL
PCb
PAr
PB1
Boom conflux (P2 unload)
D
D PBs
Boom
Swing
E
PBb
PCc
E
Pss
PBa1
Bucket
Arm 1
F
F PAo PA
PBa2
Arm 2
Option
MU
G
G K (P3)
PBp1
PBp2
K A
B
PAo
PBa2
PBp1
PBp2
274x4
275x4 (P4)
(P3)
213
212
PAa2
273x10
W2-3-5
PBo
273x10
SM0531
E215B-E245B
CONTROL VALVE
Control valve (2/6)
J 164
154
101 P2
T2
T1
JJ
PBL
YT1
PAL
PAs
YS1
PBs
PCa
P2-20
YBG1
PB1
Pss PAa1
YA1
PBa1
PBo
YP1
PAo
SECTION A-A
(P4)
163
162 163 169
155 162
154
164
P1
102
973
973 PCb
P1-20
PTb
973
973 YT1
PAr
YB1
PBr
PBb
973 PAb
973
973
PBc PCc YK1
PAc
974
973 PBa2
YAG 1
PAa2
974 (P3) SM0532
162
162
169
155
W2-3-6
163
162
SECTION B-B
CONTROL VALVE
E215B-E245B
Control valve (3/6) 202 333 331 336 329 327
P1 unload
Travel left
PCb
201 333 331
PAL
336
601 331 261 309
324
MR
323 PL
159
AL
512
511 521
522 CP2
552 562 562
551 164 162
CMR2
CMR1
331 261 306 163 162
BL
552 522 512 307 261 331 327 329 336 331 333 202 201 333 331 336 324 323
163
264 205
PBL
SECTION C-C
PTb
Travel priority
Travel right
Boom conflux
PAr
202 333 331
PB1
339
306
326 325 331 261
161
511 521
331 261
163 511 521 551 164 163 161
CCb Ar
CP1
551 164 305 551 164
Br
310 164 (T3)
264
PBr
205 SECTION D-D
SM0533
PCa
P2 unload
W2-3-7
154 261 331 327 329 336 331 333 202
E215B-E245B
CONTROL VALVE
Control valve (4/6) Swing 203 333 331 603 211 279 x 3 331 215
Boom
AbR
XAb
204
PBs
336
333 Pss
331
322 321
336 322
266
321
261
331 261 303
160 514 524 556 164 511 521 551 164
161 As
CRb
162 163 511 523
Ab
LCs
LCb
Bb
556 164 162
Bs
161 301 264 602
266 264 206
PAb
205
160
BbR
PAs
SECTION E-E
551 164 209 216 333 331 336 322 321 602
Bucket PCc
Arm 1 PBa1
PBc BaR BcR
331 261 304
CRar
Bc
511 521 551 164
Ba LCc
LCa
201 333 331 336 322 321 603 171 331 261 211 160 514 524 556 164 511 521 551 164
Ac
162
Aa
302 161 264
264 603 205
PAc AcR
PAa1
SECTION F-F
W2-3-8
AaR
205 605
SM0534
CONTROL VALVE
E215B-E245B
Control valve (5/6)
Arm 2
201 333 331 340 328 321
PBa2
Option
201
PAo
333 331 336 324
331 261
AoR
308
323 604 331
MU
162 162 162 511 521 551 164 515 521
261 311 Ao
511 521
LCAT2 LCo
551 164
LCAP2
551 164
Bo
162 161
604
BoR
264 PAa2
205
264
PBo
205
SECTION G-G
T2
161 P1
511
T1
521 CT1
163 163
551
162 511
164
P2
521 CT2
551 164 SECTION H-H
W2-3-9
SM0535
E215B-E245B
CONTROL VALVE
Control valve (6/6)
207
266
160 278 x 5
264
264 528 527
T2 517
T1
518
SECTION J-J
PBp1
PBp2
606 606
163
SM0536
SECTION K-K
W2-3-10
CONTROL VALVE
Tightening torque N•m (lbf•ft)
No.
Parts Name
Q.ty
Tightening torque N•m (lbf•ft)
E215B-E245B
No.
Parts Name
Q.ty
101 Casing A
1
321 Spring
102 Casing B
1
322 Spring
4
3
323 Spring
3
220~250 (162~184) 154 Plug PF3/4
5
110~130 (81~96)
155 Plug PF1/2
2
324 Spring
3
20~24 (15~18)
159 Plug PT1/4
1
325 Spring
1
7.8~9.8
160 Plug PT1/16
5
326 Spring
1
161 O-ring
7
327 Spring
3
162 O-ring
15
328 Spring
1
163 O-ring
11
329 Spring
3
164 O-ring
19
331 Spring seat
24
333 Spacer bolt
12
169 O-ring 9,8~14 (7.2~13)
2
171 Socket bolt
336 Stopper
10
201 Cover
5
339 Stopper
1
202 Cover
4
340 Stopper
1
203 Cover
1
511 Poppet
11
204 Cover
1
205 Cover
7
512 Poppet
2
1
514 Poppet
2
1
515 Poppet
1
209 Cover
1
517 Boost check valve
1
211 Lock valve selector sub
2
518 Poppet
1
212 Plate
1
521 Spring
11
206 Cover Back pressure 207 valve cover 9.8~14 (7.2~13)
16~18 Loctite #262
check
213 Plate
1
522 Spring
2
215 Boom dowering valve
1
523 Spring
1
216 Piston
1
524 Spring
2
261 O-ring
12
527 Spring
1
264 O-ring
10
266 O-ring
4
528 Spring
1
25~34 (18~25)
273 Socket bolt
40
98~120 (72~89)
274 Socket bolt
4
98~120 (72~89
275 Socket bolt
4
25~34 (18~25)
278 Socket bolt
5
9.8~14 (7.2~13)
279 Socket bolt
3
301 Boom spool sub
1
302 Arm 1 spool 303 Swing spool
230~260 (170~192) 551 Plug 130~150 (96~111)
13
552 Plug
2
230~260 (170~192) 556 Plug
3
562 O-ring
2
69~78 (51~58)
601 Main relief valve
1
1
69~78 (51~58)
602 Over load relief valve
2
1
69~78 (51~58)
603 Over load relief valve
3
304 Bucket spool
1
69~78 (51~58)
604
305 Boom conflux spool
1
69~78 (51~58)
605 Over load relief valve
1
306 Travel spool
2
98~120 (72~89)
606 By-pass cut valve
2
307 Travel priority spool
1
140~180 (103~133) 973 Socket bolt
8
308 Arm 2 spool sub
1
140~180 (103~133) 974 Socket bolt
2
309 P1 unload spool
1
310 P2 unload spool
1
311 Option spool
1
W2-3-11
Plug assy for relief valve hole
2
E215B-E245B
CONTROL VALVE
ASSEMBLY AND DISASSEMBLY OF CONTROL VALVE PREPARATION FOR DISASSEMBLY 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 Prepare the following tools before disassembling the control valve.
No. a
Tools Vise
Q.ty
Remarks
1
b
Box and wrench
1 of each size
c
Allen wrench
1 of each size
d
Spanner
1
e
Loctite # 262
1
f
Spatula
1
g
Pincers
1
h
Adjustable wrench
1
24 mm, 27 mm, 32 mm 5 mm, 6 mm, 10 mm, 12 mm, 14 mm, 22 mm 32 mm
W2-3-12
CONTROL VALVE
E215B-E245B
DISASSEMBLY Place the control valve on a work bench so as to locate back pressure check valve upwards. IMPORTANT: disassemble the valve in a clean place, and be careful not to damage flange surfaces or plate mounting surfaces. 1.
Disassembling P1 unload spool 1.1 Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for P1 unload spool. SM0537
1.2 Draw out, from casing B (102), as a assy of P1 unload spool (309), spring seat (331), springs (327), (329), stopper (336) and bolt (333). IMPORTANT: when drawing out the spool assy, use care so as not to score casing B (102).
SM0538 SM0504
1.3 Fix the P1 unload spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (327), (329) and stopper (336) from P1 unload spool (309).
SM0539
SM0540
W2-3-13
E215B-E245B 2.
CONTROL VALVE
Disassembling the travel spool (left travel and right travel) 2.1 Loosen the socket bolts (273) and remove the spring cover (201) and the O-ring (261) for travel.
SM0541
2.2 Draw out the assy of travel spool (306), spring seat (331), springs (323), (324), stopper (336) and bolt (333) from casing A (101) or casing B (102). IMPORTANT: when drawing out the spool assy, take care so as not to score the casing A (101) or the casing B (102).
SM0542
2.3 Fix the travel spool assy with vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and separate spring seat (331), springs (323), (324) and stopper (336) from travel spool (306).
SM0543
SM0544
W2-3-14
CONTROL VALVE 3.
E215B-E245B
Disassembling the boom conflux spool 3.1 Loosen socket bolts (273) and remove spring cover (201) for boom conflux and Oring (261). 3.2 Draw out the assy of boom conflux spool (305), spring seat (331), springs (325), (326), stopper (339) and bolt (333) from casing A (101).
IMPORTANT: when drawing out the spool assy, use care so as not to score casing A (101).
SM0545
3.3 Fix the boom conflux spool with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (325), (326) and stopper (339) from boom conflux spool (305).
SM0546
4.
Disassembling the boom spool 4.1 Loosen socket bolts (273) and remove spring cover (203) for boom spool and Oring (261), (266). 4.2 Draw out the assy of boom spool (301), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing B (102).
IMPORTANT: when drawing out the spool assy, take care so as not to score casing B (102). SM0547
W2-3-15
E215B-E245B
CONTROL VALVE
4.3 Fix the boom spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from boom spool (301). Do not disassemble boom spool (301) further unless there is special reason.
SM0548
5.
Disassembling the swing spool 5.1 Loosen the socket bolts (273) and remove the spring cover sub (204) and the O-ring (261), (266) for swing. Do not disassemble spring cover sub (204) further unless there is special reason. 5.2 Draw out the assy of swing spool (303), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing A (101).
IMPORTANT: when drawing out the spool assy, use care so as not to score casing A (101).
SM0549
5.3 Fix the swing spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from swing spool (303).
SM0550
W2-3-16
CONTROL VALVE 6.
E215B-E245B
Disassembling bucket spool 6.1 Loosen socket bolts (273) and remove bucket spring cover (209) and O-ring (261).
SM0801
6.2 Draw out the assy of bucket spool (304), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing B (102). IMPORTANT: when drawing out the spool assy, use care so as not to score casing B (102).
SM0802
6.3 Fix the bucket spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from bucket spool (304). 6.4 When needed to disassemble the spring cover of bucket spool, loosen plug (551) with casing B (102) installed. After removed cover (209) from casing B (102), remove plug (551) and then take out piston (216).
SM0803
W2-3-17
E215B-E245B 7.
CONTROL VALVE
Disassembling arm 1 spool 7.1 Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 1 spool. 7.2 Draw out the assembly which is consist of arm 1 spool (302), spring seat (331), spring (321, 322), stopper (336) and bolt (333) from casing A (101).
IMPORTANT: when drawing out the spool assy, use care so as not to score casing A (101).
SM0804
7.3 Fix the arm 1 spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (321, 322) and stopper (336) from arm 1 spool (302).
SM0805
8.
Disassembling arm 2 spool 8.1 Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 2 spool. 8.2 Draw out the assembly which is consist of arm 2 spool (308), spring seat (331), spring (321, 328), stopper (340) and bolt (333) from casing B (102).
IMPORTANT:when drawing out the spool assy, use care so as not to score casing B (102). SM0806
8.3 Fix the arm 2 spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (321, 328) and stopper (340) from arm 2 spool (308). Do not disassemble arm 2 spool (308) further unless there is special reason.
SM0807
W2-3-18
CONTROL VALVE 9.
E215B-E245B
Disassembling option spool 9.1 Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of option spool. 9.2 Draw out the assembly which is consist of option spool (311), spring seat (331), spring (323, 324), stopper (336) and bolt (333) from casing A (101).
IMPORTANT: when drawing out the spool assy, use care so as not to score casing A (101).
SM0808
9.3 Fix the option spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (323, 324) and stopper (336) from option spool (311).
SM0809
10. Disassembling travel straight spool 10.1 Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for travel straight. 10.2 Draw out the assy of travel straight spool (307), spring seat (331), springs (327), (329), stopper (336) and bolt (333) from casing B (102). IMPORTANT: when drawing out the spool assy, take care so as not to score the casing B (102). 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
SM0810
E215B-E245B
CONTROL VALVE
11. Disassembling P2 unload spool 11.1 Loosen socket bolts (273), and remove spring cover (202) of P2 unload spool and O-ring (261). 11.2 Draw out the assembly which is consist of P2 unload spool (310), spring seat (331), spring (327, 329), stopper (336) and bolt (333) from casing A (101). IMPORTANT: when drawing out the spool assy, use care so as not to score casing A (101).
SM0811
11.3 Fix the P2 unload spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (327, 329) and stopper (336) from P2 unload spool (310).
SM0812
12. Removing spool covers 12.1 Travel, boom, bucket, arm 1, arm 2 and option Loosen socket bolts (273) and remove spool cover (205) and O-ring (264). 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
13. Removing relief valve and plug assy for relief valve hole
13.1 Remove the main relief valve (601) and overload relief valve (602), (603) and (605) from the casing.
NOTE: distinguish overload relief valve between (602), (603) and (605) with a tag to prevent them from being confused during reassembly, as they are the same in appearance and shape but differ in pressure setting. Regarding the disassembly of the relief valves themselves, do not disassemble it. SM0814
SM0815
13.2 Remove plugs assy (604) for relief valve from the casing.
SM0816
W2-3-21
E215B-E245B
CONTROL VALVE
14. Removing by-pass cut valve 14.1 Remove by-pass cut valve (606) from the casing. NOTE: remove the by-pass cut valve, giving particular attention to the poppet and spring which may be remained on the inside of casing.
SM0817
15. Removing lock valve selector valve sub and boom lowering valve 15.1 Loosen socket bolt (211-171) and remove lock valve selector valve sub (211) from the casing. Further disassembly of the lock valve selector sub is not allowed. 15.2 Loosen socket bolt (279) and remove boom lowering valve (215) from the casing.
SM0818
W2-3-22
CONTROL VALVE
E215B-E245B
16. Removing back pressure check valve 16.1 Loosen socket bolt (278) and remove back pressure check valve (207) from the casing.
SM0819
16.2 Remove springs (527), (528), boost check valve poppet sub (517) and by-pass check valve poppet (518) from the casing. The further disassembly of boost check valve poppet sub (517) is not allowed. Replace control valve so that the spool cover face directs downward. IMPORTANT: when replacing, take care so as not to score the spool cover.
SM0820
17. Removing plate 17.1 Loosen socket bolts (274), (275) and remove plates (212), (213). 17.2 After removing plates, remove all O-rings (162), (163) remained on the casing side.
SM0821
W2-3-23
E215B-E245B
CONTROL VALVE
18. Removing check valve 18.1 Remove plugs of load check valve, conflux check valve, etc. and then remove poppet (511) and spring (521). 18.2 Load check valve on the swing section Remove plug (556) and then remove poppet (511) and spring (523). IMPORTANT: the plug and spring in use differ from the above (18.1). Do not mix the parts when assembling parts again. 18.3 Load check valve on arm 2 section Remove plug (551) and then remove poppet (515) and spring (521).
SM0822
IMPORTANT: the poppet in use differs from the above (18.1). Do not mix the parts when assembling parts again. 18.4 Lock valve. Remove plug (556) and then remove poppet (514) and spring (524). IMPORTANT: the plug, poppet and spring in use differ from the above (18.3). Do not mix the parts when assembling parts again. 18.5 Main relief valve Remove plug (552) and then remove poppet (512) and spring (522). IMPORTANT: the plug, poppet and spring in use differ from the above (18.4). Do not mix the parts when assembling parts again The plugs in which the procedure for disassembly is not included in the above procedure are usually used to block auxiliary holes and holes caused by casting. Do not disassemble further if unnecessary.
19. Disassembling casing 19.1 Further disassembly of the casing is not allowed.
W2-3-24
SM0823
CONTROL VALVE
E215B-E245B
INSPECTION AFTER DISASSEMBLY Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a clean sheet of paper or cloth for inspection. 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. Precautions on reassembling O-ring 1.
Confirm that O-rings are free from defects caused by poor handling.
2.
Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3.
Do not stretch O-rings to the extent that they become permanently set.
4.
When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after installation, and can cause oil leaks.
5.
Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance Standards.".
W2-3-25
E215B-E245B
CONTROL VALVE
Installing check valve 1.
Load check valve, conflux check valve, and so on Attach poppet (511) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified torque. (9 places)
2.
Load check valve of swing section Attach poppet (511) and spring (523) in place, place O-ring (164) in plug (556) and tighten them to the specified torque. (1 place)
3.
Load check valve of arm 2 section Attach poppet (515) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified torque. (1 place)
4.
Lock valve section Attach poppet (514) and spring (524) in place, place O-ring (164) in plug (556) and tighten them to the specified torque. (2 places)
5.
Main relief valve section Attach poppet (512) and spring (522) in place, place O-ring (562) in plug (552) and tighten them to the specified torque. (2 places)
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.
Replace control valve so that this plate face directs downward. Assembling back pressure check valve 1.
Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527) and (528).
2.
Attach O-rings (264), (266) in back pressure check valve cover, attach it to casing A (101) and tighten socket bolt (278) to the specified torque.
Assembling boom lowering valve 1.
Attach boom lowering valve (215) to O-ring and tighten the socket bolts (279) to the specified torque.
Assembling lock valve selector sub 1.
Attach lock valve selector sub (211) to the casing and tighten socket bolt (171) to the specified torque.
Assembling by-pass cut valve 1.
Attach by-pass cut valve (606) to casing and tighten it 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
Assembling relief valve and relief valve hole plug assembly 1.
Tighten main relief valve (601), port relief valves (602), (603), (605) and relief valve hole plug assembly (604) in respective place to the specified torque.
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. Assembling P2 unload spool 1.
Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.
NOTE: • • 2.
apply Loctite #262 when tightening bolt (333). take care not to deform P2 unload spool (310) because of careless over clamping. Place P2 unload spool assembly in casing A (101).
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.
Assembling travel priority spool 1.
Hold the mid section of travel priority spool (307) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.
NOTE: • • 2.
apply Loctite #262 when tightening bolt (333). Take care not to deform travel priority spool (307) because of careless over clamping. Place travel priority spool assembly in casing B (102).
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
Assembling spool in option 1.
Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) to the specified torque.
NOTE: • • 2.
apply Loctite #262 when tightening bolt (333). take care not to deform option spool (311) because of careless over clamping Place spool assembly in option in casing A (101).
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.
Assembling arm 2 spool 1.
Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (328) and stopper (340) and tighten bolt (333) to the specified torque.
NOTE: • • 2.
apply Loctite #262 when tightening bolt (333). take care not to deform arm 2 spool (308) because of careless over clamping. Place arm 2 spool assembly in option in casing B (102).
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.
Assembling arm 1 spool 1.
Hold the mid section of arm 1 spool (302) with vise provided with protection plate (aluminum plate, etc.) and fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) 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.
•
Place arm 1 spool assembly in casing A (101).
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
Assembling bucket spool 1.
Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.
NOTE: • • 2.
apply Loctite #262 when tightening bolt (333). take care not to deform bucket spool (304) because of careless over clamping. Place bucket spool assembly in casing B (102).
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.
Assembling swing spool 1.
Hold the mid section of swing spool (303) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.
NOTE: • • 2.
apply Loctite #262 when tightening bolt (333). take care not to deform swing spool (303) because of careless over clamping. Place swing spool assembly in casing A (101).
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
Assembling boom spool 1.
Hold the mid section of boom spool (301) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.
NOTE: • apply Loctite #262 when tightening bolt (333). • take care not to deform boom spool (301) because of careless over clamping. 2.
Place boom spool assembly in casing B (102).
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.
Assembling boom conflux spool 1.
Hold the mid section of boom conflux spool (305) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (325), (326) and stopper (339) and tighten bolt (333) 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. 2.
Place boom conflux spool assembly in casing A (101).
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.
Assembling travel spool (travel right and left) 1.
Hold the mid section of travel spool (306) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) 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. 2.
Place travel spool assembly in casing A (101) or casing B (102).
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
Assembling P1 unload spool 1.
Hold the mid section of P1 unload spool (309) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.
NOTE: • apply Loctite #262 when tightening bolt (333). • take care not to deform P1 unload spool (309) because of careless over clamping. 2.
Place P1 unload spool assembly in casing B (102).
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.
Assembling spool cover, and so on 1.
Travel, boom, bucket, arm 1, arm 2, option - Place O-ring (264) in spool cover (205) 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 Part name
Casing
Spool
Inspection item
1. Look for corrosion.
scratches,
Criterion and remedy
rusting
1. If any of the following parts are damaged, replace the casing. • Sliding part of casing hole and spool, particularly the land, to which holding pressure is applied. • Area of sealing part that is in contact with and O-ring. • Sealing and seating part of main or overload relief valve. • Area of seating part or sliding part of poppet. • Sealing part of plug. • Defects of other parts that seem to prevent normal function.
1. Look for scratches, galling, rusting and corrosion.
1. If a detectable defect with your fingernail is found on the sliding part of the outer circumference, replace the spool.
2. Insert the spool in the casing bore, and 2. If the spool damages the O-ring or does not move it while turning it move smoothly, repair or replace the spool.
Poppet
1. Look for damage on the poppet and If spring is damaged, replace it. the spring. 1. If the seat of poppet or spring are damaged, correct or replace it. 2. Insert the poppet in the casing, and 2. If the poppet moves lightly without catching, it move it. is normal.
Spring and related parts
1. Look for rust, corrosion, deformation, and breakage of the spring, spring 1. If damaged heavily, replace. seat, stopper, spacer bolt and cover.
Main relief valve, Port relief valve, By-pass cut valve
1. Look for rust and damage on outer 1. Replace. surface. 2. Inspect the contact face of the valve 2. If damaged, replace. seat. 3. Inspect the O-ring, backup ring, and 3. As a general rule, replace all parts with new seal ones. (Between casing and seal)
W2-3-32
SWING DEVICE
E215B-E245B
REMOVAL AND INSTALLATION OF SWING DEVICE 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.
2.
To drain the hydraulic pressure from the Hydraulic System, refer to procedure “Releasing the hydraulic pressure” at page T21-47.
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.
NOTE: be sure to run the vacuum pump continuously while working.
W2-4-1
E215B-E245B
SWING DEVICE
Removal 1.
Remove hose (1) from the Tee in the makeup port M. : 36 mm 6
2.
Remove the hoses (2 and 3) from the Tee in the drain port Dr.
4
5
: 27 mm 3.
1
Remove the hoses (4 and 5) from the elbows of the A, B port.
2 3
: 36 mm
SM0701
4.
Remove the hose (6) from the elbow of the PG port. : 19 mm
5.
6.
Put in plugs into the opened ports on the swing motor unit.
8
8
7
Remove the swing motor unit by loosing the screws (7) (q.ty 13). : 30 mm
7.
Remove the plastic cap (8) M12 at the top of the swing motor and install the lifting eye bolt. : 36 mm
8.
Sling and remove the swing unit.
NOTE: swing unit weight: 192 kg
W2-4-2
SM0702
SWING DEVICE
E215B-E245B
Installation 1.
Clean mating surfaces of swing motor unit and upper frame.
2.
Apply Loctite FAG3 on entire mounting surface of swing motor unit.
3.
Place the swing unit on the upper frame.
8
8
7
NOTE: swing unit weight: 192 kg 4.
5.
Remove the lifting eye bolts and inserts on the holes, the plastic caps (8) M12, previsiously removed. Fix the swing unit to the frame by tightening the screws (7) (q.ty 13). : 30 mm
6 4
5
: 539 ± 54 Nm 6.
SM0702
Install the hoses (4 and 5) on the elbows of port A and B. : 30 mm
1 2 3
: 108 Nm
SM0701
7.
Install the hose (6) on the elbow of port PG. : 19 mm : 29.4 ± 2.9 Nm
8.
Install the hoses (2 and 3) on the tee in the drain port Dr. : 27 mm : 93.1 ± 9.3 Nm
9.
Install the hose (1) on the make up port M. : 36 mm : 176.5 ± 17.6 Nm
W2-4-3
E215B-E245B
SWING DEVICE
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR 33 27
44
20
1
21 31 2 15 3 17 13-14 19 43 38
16 A
43
29
42
A
12 30 32 37
35 36 4
41 25
26
24
6 40
8 9
7
A-A
45 18 11
28
5
34
10 SM0703
12345678910 11 12 13 14 15 -
Relief valve (q.ty 2) O-Ring (q.ty 2) Swing shockless valve Shockless valve casing Drive shaft Cylinder Spring Piston (q.ty 9) Shoe Set plate Shoe plate Valve plate Plug (q.ty 2) O-Ring (q.ty 2) O-Ring (q.ty 2)
16 17 18 19 20 21 24 25 26 27 28 29 30 31 32 -
O-Ring (q.ty 2) Socket bolt (q.tà: 4) Swing motor casing Valve casing Plunger (q.ty 2) Spring (q.ty 2) Swing shockless valve (q.tà: 2) O-Ring (q.ty 2) Backup ring (q.ty 2) Socket bolt (q.ty 4) Roller bearing Plug (PF 3/8) Pin (q.ty 2) Plug (q.ty 2) O-Ring
W2-4-4
33 34 35 36 37 38 39 40 41 42 43 44 45 -
O-Ring (q.ty 2) Oil seal Brake piston O-Ring O-Ring Brake spring (q.ty 16) Friction plate (q.tty 3) Separation plate (q.ty 4) Plug (PF 1/4) Roller bearing Plug (PF 3/4) (q.ty 3) Plug (PT 1/2) Plug (PT 3/4)
SWING DEVICE
E215B-E245B
Preliminary operations 1.
Hydraulic components are precision products and have small clearance. Therefore, assemble and disassemble in a less dusty clean place. Use clean tools and cleaning oil and handle components with full care.
3.
Study the structural drawing before the work begins and prepare necessary parts according to your purpose and the scope of work. Seals and O-Rings once removed can not be used again.
2.
If a component is removed from the main body, clean the area around the ports thoroughly and plug them up so no dust and water do not enter. When fitting them back to the body, do not remove the plugs till piping is completed.
4.
The piston and the cylinder block are shop fitted when new. If you intend to reuse them, put a matching mark on the piston and the cylinder block.
Disassembly 1. 2.
Remove the drain plug and drain hydraulic oil from casing (18).
3
Fix the motor on a work bench so the drive shaft (5) end comes down. On that occasion, put a matching mark on the mating parts of casing (18) and valve casing (19).
17
12 1
19 38
NOTE: choose a clean place, and lay with a rubber sheet or a cloth on a work bench. Handle the valve casing with care so parts do not have dents. 3.
18
Loosen relief valve (1) and separate it from valve casing (19). : 41 mm
4.
Loosen anti-reaction valve sub assy (3) and remove from valve casing (17). 5
: 6 mm 5.
Separate plugs (31) from valve casing (19) and draw out springs (21) and plungers (20). : 17 mm
6.
SM0704
27
Loosen socket bolts (27) and separate valve casing (19) from casing (18).
NOTE: if the socket bolt (27) are loosened, the valve casing (19) floats off casing (18) by the force of brake springs (38). 7.
Separate valve plate (12) from valve casing (19). : 17 mm
20 21
31 SM0705
W2-4-5
E215B-E245B 8.
9.
SWING DEVICE
Draw out brake spring (38) from brake piston (35). Draw out the brake piston (35) with the special tool (xxxxxxxxx).
38
35
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). 11. Draw out friction plate (39) and separator plate (40) from casing. 12. Draw out drive shaft (5) using a plastic mallet. 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 (28) from casing (18), by lightly tapping the steel rod from the oil seal (34) housing side.
11
7
8
c. Separate the outer race of roller bearing (42) from valve casing (19), using a slide hammer bearing puller. IMPORTANT: do not reuse the bearing. 5
10
39
40
6 SM0707
5 34 28 18 SM0708
W2-4-6
SWING DEVICE
E215B-E245B
Assembly 1.
Place casing (18) on a proper bench facing upward.
The following operations are necessary only when the roller bearings (28) and (42) are removed: a. Shrinkage fit the inner race of roller bearing (28) into drive shaft (5). b. Shrinkage fit the inner race of roller bearing (42) to drive shaft (5). c. Fit oil seal (34) to casing (18). d. Assemble the outer race of roller bearing (28) into casing (18), by lightly tapping the steel rod. 2.
Attach drive shaft (5) to casing (18).
3.
Insert shoe plate (11).
4.
Set the set plate (10) and spring (7), then set piston sub (8, 9) assy.
5
34 28 18 SM0709
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.
6.
Place casing (18) with oil seal facing downward and assemble separator plate (40) and friction plate (39) into casing (18).
8
6
9
7
11 10
5 SM0710
39
40
SM0711
W2-4-7
E215B-E245B
SWING DEVICE
7.
Fit O-rings (36), (37) to casing (18).
8.
Assemble brake piston (35) into casing (18).
9.
Assemble brake spring (38) into brake piston (35). Make sure that a spring is placed securely in the spot faced part of the brake piston.
36
37
NOTE: this operation is necessary only where roller bearing (42) is removed. 10. Insert the outer race of roller bearing (42) into valve casing (19), while lightly tapping the steel rod using a hammer.
18 SM0712
11. Assemble valve plate (12) into valve casing (19) and fit O-ring (32) in it. 3
12. Install valve casing (19) to casing (18) and fasten them with socket bolts (27).
17
42 12 1
19
: 17 mm
38
: 431 Nm
35 32
13. Fit plunger (20) and spring (21) to valve casing (19). Then tighten plug (31) fitted with O-ring (33) against valve casing (19).
18
: 14 mm : 334 Nm 14. Fit relief valve (1) to valve casing (19). : 41 mm 5
:177 Nm
SM0713
15. Fit anti-reaction sub assy (3) to valve casing (19). 27
: 6 mm : 29 Nm
20 21
31 SM0705
W2-4-8
SWING DEVICE
E215B-E245B
DISASSEMBLY AND ASSEMBLY OF SWING REDUCER
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
12345678910 -
Pinion shaft #1 sun gear #1 pinion (q.ty: 3) #2 sun gear #2 pinion (q.ty: 4) Ring gear #1 spider assy #2 spider assy Shaft (q.ty: 4) Spherical bearing
11 12 13 15 16 17 18 19 20 21 -
Spherical bearing Oil seal Housing Thrust washer (q.ty: 6) Needle bearing (q.ty: 3) Needle bearing (q.ty: 4) Thrust washer (q.ty: 8) Snap ring Snap ring Sleeve
W2-4-9
22 23 24 25 26 27 28 30 31 32 -
Spring pin (q.ty: 4) Socket bolt (q.ty: 11) Cap (q.ty: 2) Tube Elbow Plug Snap ring (q.ty: 3) Oil seal Grease fitting Relief fitting
E215B-E245B
SWING DEVICE
Preliminary operations: 1.
Before disassembly, clean thoroughly the swing reduction unit outer, checking for no damage or scratches.
2.
Drain out the gear oil from reduction unit.
3.
Remove the draining pipe.
4.
In order to case the re-assembly, before disassembly put a matching mark (X) on the parts to be connected on the reduction casing.
23
x x
27
SM0715
Disassembly
7
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.
2.
Loosen all socket bolt (18) (M14). Attach eye bolts (M10) in the lifting bolt holes in the top surface of the swing motor and lift the assy by crane. If it is hard to remove the swing motor assy from the reduction unit, float it by inserting a flatblade screwdriver in the groove of the flange.
2
SM0716
: 12 mm 3.
Remove #1 sun gear (2).
4.
The spider assy (7) [consisting of thrust washers (15), #1 pinions (3), needle bearings (16) and snap rings (28)] can be removed from the spline easily if it is lifted up in that condition.
5.
6.
6 13
Attach eye bolts (M10) to the top surface of ring gear (6) and lift the ring gear lightly by a wire sling. Put a flat-blade screwdriver into the matching surface of ring gear (6) and housing (13) and remove ring gear (6) by lightly tapping the outer circumference of the ring gear with a plastic mallet. Draw out #2 sun gear (4) and remove the #2 spider assy (8).
SM0717
4
8
SM0718
W2-4-10
SWING DEVICE
E215B-E245B
NOTE: particularly if no failure is found, the further disassembly is not allowed. Check on parts for possible failure according to the inspection procedure shown in maintenance standards. It is recommended that the pinion shaft and housing assy are replaced together as one set. But if it is unavoidably necessary to replace a part of them, follow the procedure shown below. 7.
Remove retaining ring (20) from pinion shaft (1).
8.
Pull pinion shaft (1), sleeve (21), oil seal (30) and spherical bearing (lower) (11) out by means of press while supporting housing (13) with special tool (xxxxxxxxx).
SM0719
NOTE: spherical bearing (upper) (10) and oil seal (12) are left in the housing. 9.
20
1
Pull oil seal (30), sleeve (21) and spherical bearing (lower) (11) out by means of special tools (xxxxxxxxx) and (xxxxxxxxx) while supporting pinion shaft assy as shown in the figure. Press force: 30 t
NOTE: do not reuse the removed oil seal and bearing.
xxxxxxxxx
SM0720
xxxxxxxxx 21 30 11
xxxxxxxxx
SM0721
W2-4-11
E215B-E245B
SWING DEVICE
10. Set housing (13) as shown in the figure, insert special tool (xxxxxxxxx) between bearing (10) and oil seal (12) and remove bearing (10) by striking from the upper side. 13
11. Remove oil seal (12) from housing (13). NOTE: do not reuse the removed oil seal and bearing. 12. Disassembe #1 spider assy performing the following operations.
12 10
a. Remove retaining rings (28) with a plier. b. Remove thrust washers (15), pinions (3) and needle bearings (16).
xxxxxxxxx SM0722
NOTE: the shaft attached to spider assy (17) is caulked. When replacing parts, replace the spider assy as a set. Pinions (3) can not be replaced singly. Replace them in a set of three.
3
15
16 28
13. Disassembling #2 spider assy performing the following operations. a. Draw out spring pin (22). b. Draw out shafts (9) from spider (8) and remove thrust washers (18), pinions (5) and needle bearings (24). NOTE: pinions (5) can not be replaced singly. Replace them in a set of four.
17
15
SM0723
8
9 18 5
24 18 22 SM0724
W2-4-12
SWING DEVICE
E215B-E245B
Assembly 1.
Sufficiently clean every part with wash oil and dry it with compressed air.
2.
Check on every part for failure. xxxxxxxxx
3.
Attach oil seal (30) to sleeve (21) by means of special tool (xxxxxxxxx).
4.
Insert sleeve (21) and oils seal (30) assy in pinion shaft (1).
5.
Apply gear oil to the perimeter of axis of pinion shaft (1) lightly to prevent seizure.
6.
Seal sufficient grease in spherical bearing (lower) (11) and force it in pinion shaft (1) by means of special tool (xxxxxxxxx). Press force: 4~5 t
30
21
SM0725
NOTE: since the bearing is formed with a partition at the center section, seal grease in it from both sides.
1 21
30
SM0726
xxxxxxxxx
1
11
SM0727
W2-4-13
E215B-E245B
SWING DEVICE
7.
Apply sufficient grease to the pinion shaft assy. Grease: lithium extreme-pressure grease (SHELL Albania EP2 or equivalent)
8.
Place housing (13) on level bench and attach eye bolt to screw (M10) at the axis end of pinion shaft assy, and perpendicularly hang up pinion shaft assy and place it in the housing.
NOTE: horizontally orient the outer race of spherical bearing and insert it in by striking lightly. If the outer race is tilted, it is hard to insert even if striking. Then do not force to insert it in, but take it away once and horizontally orient the outer race twice and insert it in again. 9.
Set housing assy so that the pinion directs downward and fit oil seal (12) in housing (13) by means of special tool (xxxxxxxxx).
SM0728
NOTE: apply Loctite #515 to the perimeter of oil seal. Fill one third (1/3) of the space of the grooveshaped section provided on the oil seal (12) lip with grease. Insert it horizontally giving attention to the lip of oil seal so as not be damaged.
13
SM0729
xxxxxxxxx
12
13
SM0730
W2-4-14
SWING DEVICE 10. Press fit spherical bearing (upper) (10) in pinion shaft (1) and housing (13) at the same time by means of special tool (xxxxxxxxx).
1
E215B-E245B
xxxxxxxxx
10
11. Attach retaining ring (20). 12. Assemble #1 Spider assy performing the following operations. a. Coat the bore surface of pinion (3) with grease. Put pinion (3) on thrust washer (15) and assemble needle bearings (16) into the bore surface. b. Fit thrust washers (15), pinions (3) and fit snap rings (28) by means of pliers.
13
SM0731
20
SM0732
3
16 28
15
15
SM0733
W2-4-15
E215B-E245B
SWING DEVICE
13. Assemble #2 Spider assy performing the following operations.
A
a. Coat the bore surface of pinion (5) with grease. Put pinion (5) on thrust washer (18) and fit needle bearing (17) to the bore surface. b. Fit thrust washer (18) and pinion (5), insert shaft (9) into spider (8) and drive spring pin (22). 6 - 7 mm
14. Insert #2 spider assy (8) in spline axis of pinion shaft.
6 - 7 mm
8
9
18 5
15. Install #2 sun gear (4) directing the spline upward.
17
A 22 SM0734
8
SM0735
4
SM0736
W2-4-16
SWING DEVICE
E215B-E245B
16. Apply a thin film of sealant Loctite #515 to the matching surface of housing (13) and ring gear (6) and assemble them, aligning the gear teeth and according to the matching marks given.
6 13
17. Mesh the #1 spider assy (7) with ring gear (6) and set them in place.
x
18. Mesh #1 sun gear (2) with #1 pinions (3) and set them in place. 19. Fit drain tube (25) and plug (27).
SM0737
: 12 mm : 70 Nm
7
2
3
20. Fill in 3 L of gear oil (API GL-5). 21. Attach eye bolts (M10) in the tapped holes of the swing motor and put a wire sling in them. Coat the matching surface of ring gear (6) with sealant Loctite #515. Insert the spline joint of the swing motor and match the matching marks. Coat socket bolts (23) with sealant Three-Bond 1360K and fasten them.
6
: 12 mm
SM0738
: 181 Nm 23
x x
25 27
SM0739
W2-4-17
E215B-E245B
SWING DEVICE
MAINTENANCE STANDARDS Swing motor
Unità: mm (poll.) Item
Standard dimension (mm)
Recommended value for replacement (mm)
0.027
0.052
0
0.3
Replace piston and shoe assy.
5.5
5.3
Replace piston and shoe assy.
2.0
1.8
Replace.
Remedy
Clearance between piston and cylinder bore (D-d)
D
Replace piston or cylinder.
d
Gap between piston and caulked part of shoe (d)
Thickness of shoe (t)
Thickness of friction plate (t)
Standard for correcting sliding surfaces If the surface roughness of the sliding surface of parts exceeds the following standard, correct it or replace the parts. Standard for correcting sliding surfaces Name of parts Shoe
Standard surface roughness
Surface roughness requiring correction
0.8—Z (Ra=0.2) (lapping)
3—Z (Ra=0.8)
Shoe plate
0.4—Z (Ra=0.1) (lapping)
3—Z (Ra=0.8)
Cylinder
1.6—Z (Ra=0.4) (lapping)
12.5—Z (Ra=3.2)
Valve plate
0.8—Z (Ra=0.2) (lapping)
6.3—Z (Ra=1.6)
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
Swing reduction gear
A D
C D E C B
F
SM0740
Code
Item
Repairable level (mm)
A
Wear in #1 planetary shaft
0 Ø 39 -0.011
Wear in #2 planetary shaft
0 29 -0.009
Service Limit (mm)
No flaking B
Ø
Remedy Replace spider assy
entire
Replace four shafts as a set
Condition of There should be no pitting exceeding 1.6 mm dia, Replace (Planetary tooth face abnormal wear or seizure pinion should be replaced in a set of Condition of There should be no cracks four.) tooth flank
C
Gears
D
Thickness of thrust washer
0 1,6-0.2
1.3
Replace
E
Thickness of thrust washer
0 2.0-0.2
1.6
Replace
F
Wear in shaft (diameter of part coming in contact with oil seal)
Ø 94.9
Replace
0 Ø 95-0.087
W2-4-19
E215B-E245B
SWING DEVICE
NOTE:
W2-4-20
PILOT VALVE
E215B-E245B
REMOVAL AND INSTALLATION OF RIGHT AND LEFT PILOT VALVE 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. T21-47.
2.
To drain the hydraulic pressure from the Hydraulic System, refer to procedure
3.
Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure present in the tank itself.
Removal 1.
Free and lift rubber cap (5) complete with plate (4) unlocking its hooks using a screwdriver.
2.
Remove side panels (2) and (3) removing securing screws.
3.
Remove the handgrip (1) removing lock-nut (6) disconnecting the relevant electric connection.
: 22 mm IMPORTANT: attach an identification tag on each hose to aid in reassembly.
4.
Disconnect hoses from port connector PF 3/8 (7) and PF 1/4 (8) of pilot valve body (9).
60
: 19, 22 mm
NOTE: attach a cap on each of disconnectd hose ends. 5.
Remove pilot valve (9) removing securing screws (10) M6x25 complete with washers.
: 5 mm
60
W2-5-1
E215B-E245B
PILOT VALVE
Installation 1.
Install pilot valve (9) on the frame tightening securing screws (20) M6x25 complete with washers.
7
: 5 mm
: 11.8 Nm (8.7 lbf·ft) 2.
7
Connect hoses to pilot valve body (9).
: 19 mm (Port: P)
3
3
60
: 29.4 Nm (22 lbf·ft) : 22 mm (Port: 1 to 8, T)
LEFT SIDE
: 49 Nm (36 lbf·ft) 3.
Tighten the handgrip on the pilot valve (9), tighten lock-nut (6) and reconnect the electric connector. : 22 mm
4.
Install side panels (2) and (3) tightening securing screws.
5.
Arrange rubber cap (5) complete with plate (4) locking the hooks on side panel (2).
RIGHT SIDE BUCKET 1 (H)
RED
BUCKET (R)
BLUE
5 SWING (L)
GRAY
6 SWING (R)
RED
2
7 ARM (H)
BLUE
3 BOOM (H)
GREEN
8 ARM (R)
GREEN
4 BOOM (R)
GRAY
60
W2-5-2
PILOT VALVE
E215B-E245B
REMOVAL AND INSTALLATION OF TRAVEL PILOT VALVE 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. T21-47.
2.
To drain the hydraulic pressure from the Hydraulic System, refer to procedure
3.
Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure present in the tank itself.
. Removal 1.
Remove the cover under the cab
2.
Remove the floor mats in the cab.
3.
Remove the pedal removing securing screws (1) (Q.ty 4) then remove the levers, removing securing screws (2) (Q.ty 4). : 13, 17 mm
4.
Disconnect pressure sensors (7) from body (8). : 24 mm
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.
6.
Remove body (8) removing securing screws (9) complete with washers. : 17 mm
W2-5-3
60
E215B-E245B
PILOT VALVE
Installation 1.
Install body (8) on the frame tightening securing screws (9) complete with washers. : 17 mm : 37 Nm (27.4 lbf·ft)
2.
Connect pipes (from 3 through 6) to body (8). : 19 mm : 16.7 Nm (12.3 lbf·ft) : 22 mm : 30 Nm (22.0 lbf·ft)
3.
Connect pressure sensors (7) to body (8).
: 24 mm
: 16.7 Nm (12.3 lbf·ft) 4.
Install the levers tightening securing screws (2) and the pedals tightening securing screws (1).
: 17 mm : 46.1 Nm (34.1 lbf·ft)
: 13 mm
: 23.5 Nm (17.4 lbf·ft)
5.
Install the cover under the cab : 19 mm : 108 Nm (80.0 lbf·ft)
W2-5-4
60
PILOT VALVE
E215B-E245B
DISASSEMBLY RIGHT AND LEFT PILOT VALVE
60
123456-
Adjusting nut M14 Boots Circular plate Joint M14 Plate Seal (Q.ty 4)
789121415-
Plug (Q.ty 4) O-Ring (Q.ty 4) Push rod (Q.ty 4) Spring seat 1 (Q.ty 2) Spring seat 1 (Q.ty 2) Spring (Q.ty 4)
W2-5-5
171819202122-
Spring (Q.ty 2) Spring (Q.ty 2) Washer 2 (shim) (Q.ty 4) Spool (Q.ty 2) Spool (Q.ty 2) Casing
E215B-E245B
PILOT VALVE
Disassembly right and left pilot valve Be sure to thoroughly read "Precautions for Disassembly and Assembly" on page W1-1-1 before starting the disassembly work. NOTE: replace O-Ring operations, as a rule.
every
disassembly
1.
Plug each port of pilot valve, and clean it. P Port : PF 1/4” 1÷4 Port and T: PF 3/8”
2.
Fix pilot valve with vise, via a protective plate (Alminum plate etc.), and remove boot (2).
3.
Remove adjusting nut (1) applying spanners to circular plate (3).
60
: 22, 32 mm 4.
Remove circular plate (3).
: 32 mm
5.
Turn joint (4) in counterclockwise with jig (E) (380001055) to remove it. : 24 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 6.
E215B-E245B
Remove plate (5).
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 ORing (8).
60
60
7.
Pull plug (7) out with a driver. WARNING
To prevent personal injury, plug (7) must be removed slowly and evenly until the return spring (15) force is completely released
8.
Remove push rod (9), plug (7), pressure reducing valve assy (spool) and the return springs (15) from casing (22).
NOTE: record combination of port holes on casing and the pulled out parts. The stroke differs according to direction.
60
60
W2-5-7
E215B-E245B 9.
PILOT VALVE
Press springs seats (12 and 14) so that the movement is 7 mm (max), then remove spools (20 and 21) through the larger hole of the seat.
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
10. Remove spool (20 and 21), spring seats (12 and 14), springs (17 and 18) and washer (19).
60
11. Pull out push rod (9) from plug (7).
12. Remove O-Ring (8) from plug (7).
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.
W2-5-8
60
PILOT VALVE
E215B-E245B
ASSEMBLY RIGHT AND LEFT PILOT VALVE
60
12345678-
Adjusting nut M14 Boots Circular plate Joint M14 Plate Seal (Q.ty 4) Plug (Q.ty 4) O-Ring (Q.ty 4)
910111213141517-
Push rod (Q.ty 4) Spring (Q.ty 4) Spring seat 2 (Q.ty 2) Spring seat 1 (Q.ty 2) Spring seat 2 (Q.ty 2) Spring seat 1 (Q.ty 2) Spring (Q.ty 2) Spring (Q.ty 2)
W2-5-9
18192021222324-
Spring (Q.ty 2) Washer 2 (shim) (Q.ty 4) Spool (Q.ty 2) Spool (Q.ty 2) Casing 2E4 Port 1E3 Port
E215B-E245B
PILOT VALVE
Assembly right and left pilot valve 1.
Fit washer 2 (19), springs (17) and (18), spring seats (12) and (14) to spools (20) and 21).
60
2.
Push spring seat 1 (12) so that the movement is 7 mm or less, and install spool (20) through the large hole of spring seat 1. For spring seat 1 (14), push spring seat (14) in 9.4 mm or less and install spool (21).
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
3.
Place springs (15) into ports 1 of casing (22), and then install pressure reducing valve assy in it. Place spring (16) into ports 2,4 and then install pressure reducing valve assy in it.
NOTE: install the removed respective assy into respective holes.
60
W2-5-10
PILOT VALVE 4.
E215B-E245B
Fit O-Ring (8) and seal (6) into plug (7). Apply hydraulic oil on surface of push rod (9).
60 60
5.
Insert push rod (9) in plug (7).
6.
60
Fit plug (7) assy to casing (22).
NOTA: When the force of spring (15) is low, it stops at the position where it is pushed in by the sliding resistance of O-Ring (8). When the force of spring (15) is high, attach plate (5) and press 4 push rods by hand at the same time, and tighten joint (4) temporarily. Install spools (20) ande (21) straight and evenly into the hole of casing (22). Take care so that plugs (7) and plate (5) do not jump out of casing (22)
60
60
W2-5-11
E215B-E245B 7.
PILOT VALVE
nstall joint (4) on casing (22) with special tool (E) (380001055) securely. : 22 mm : 47.1±2.9 Nm (34.8±2.1 lbf·ft)
(
60
8.
Install circular plate (3) to joint (4).
IMPORTANT: screw it in until it comes in contact with 4 push rods (9) equally. The exceeding of screw in may cause malfunction of machine.
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 *
10. Apply heat-resisting grease (G) to joint (4) rotating section and the top of push rod (9).
60
11. Cover it with boots (2). 12. Spray rust preventives through each port and attach plug respectively.
60
W2-5-12
PILOT VALVE
E215B-E245B
PILOT VALVE (FOR TRAVEL) CONSTRUCTION
R R
K
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I G /RFWLWH J 7 J
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T
7
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L 7 N 7 K
X W 7
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X
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No.
Parts
NOTE: T=tightening torque Nm (lbf·ft) Q.ty No. Parts
5
Rubber boots
6
Foot pedal (Switch plate)
2 (2)
Q.ty
12-x Seal ø14×20×3
6
12-y Wiper ring
6
6-d
Switch plate
2
13
Damper spring
4
6-f
Regulation screw M8×28
4
14
Check valve kit
(2)
6-g
Set screw M5x8
4
14-q Plug M8
2
6-l
Damping screw
4
14-r Ball M6, 35
2
7
Retaining plate kit
7-h
Plate
7-i 7-j 7-k
(1)
15
Orifice
1
15-u Plug M6
Capscrew M10×20
2
15-t Orifice M6, ø0.6
Shaft
2
17
(4) 4 4
Shuttle valve kit
(2)
17-w’ Shuttle valve & orifice
2
Set screw M4×10
2
8
Flange kit
4
17-r Ball M6, 35
10
Control spool
4
17-z Orifice M5, ø0.8
11
Return spring
4
21
Plug
4
12
Damper flange kit
(4)
22
Valve body
1
12-o Damper plunger ø14
4
W2-5-13
2 2
E215B-E245B
PILOT VALVE
DISASSEMBLY AND ASSEMBLY 1.
Boot replacement
NOTE: the pilot control unit does not need to be removed from the machine to perform this operation.
1) Remove both faulty boots. (using a flat screw driver if necessary) 2) Replace both boots with a new one. * Reassembly: • First fit the lower part of the rubber boot (5) on the retaining plate (7-h) between the 2 switch plate (6) • Then put the lower part in the external groove of the retaining plate. • Finish by fitting the upper part of the rubber boot on the switch plate.
K
60
2.
Switch plate removal 1) Remove: • The pilot control unit from the machine • Both rubber boots 2) Remove the screw (7-k) locking the axis using a 2 mm socket wrench. (See Fig. SM0757 A) * Reassembly: • Apply a droplet of Loctite #262 on the locking screw thread. • Torque: 1.2 Nm (0.89 lbf·ft) 3) Fit a M3 screw on the switch plate axis (7-j) in order to remove it (Using pliers if necessary). (See Fig. SM0757 B) * Reassembly: • Position the axis so that the hole (f) is aligned with the locking screw (7-k) as shown on the picture (See Fig. SM0757 C) 4) Mark out the position of the switch plate before removing it. 5) Repeat the operation for the second switch plate. 6) Reassemble parts in reverse order.
W2-5-14
%
$
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M
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60
PILOT VALVE 3.
E215B-E245B
Switch plate adjustment
I NOTE: if the switch plate (6) is replaced, it is necessary to adjust the regulation screws (6-f). 1) Unscrew the 2 locking screws (6-g) using a 2.5 mm socket wrench * Reassembly : • Apply a droplet of Loctite #262 on the locking screw thread. • Torque: 3 Nm 2.2 (lbf•ft) 2) Set the switch plate (6) horizontally 3) Screw on simultaneously both regulation screws (6-g) using a flat screw driver (5.5x150) until feeling some resistance. NOTE: do not misadjust the two damping screws (6-l).
J
60
4) Tighten the locking screws (6-g) to hold the regulation screws (6-f) in position. 5) Repeat the operation for the second switch plate making sure both switch plates are parallel.
O
I 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 : • Apply a droplet of Loctite #262 on the screw thread. • Torque: 30 Nm (22 lbf•ft)
60
L K
60
W2-5-15
E215B-E245B
PILOT VALVE
3) Lift the retaining plate (7-h) to remove it. * Reassembly: • Use the retaining plate (7-h) to insert the 4 guides into the body simultaneously and perpendicularly (22). 4) Reassemble parts in reverse order. 5) Drain the pilot control unit.
5.
K
Damping plunger seals replacement
60
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: • Replace with a new wiper ring (12-y).
R
\ %
$
60
CAUTION Always place the damping plunger (12-o) prior to the wiper ring (12-y), and make sure the wiper ring (12-y) is correctly positioned.
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3) Remove the damping plunger (12-o). 4) Using a needle, remove the seal (12-x) placed inside the body (22) * Reassembly: • Replace with a new seal and grease it.
[ R 60
[
$
W2-5-16
%
60
PILOT VALVE • A: Squeeze the seal (12-x) between your fingers to obtain a 8-shape. • B, C: Insert the seal (12-x) ithin the groove with your fingers (lip in bottom position). • D: Push the seal (12-x) against the side using the round head of a small socket wrench.
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$ IMPORTANT: during the reassembly, make sure the seal (12-x) is correctly positionned, and pay attention not to damage nor twist it. 5) Repeat the operation for the other 3 assemblies. 6) Extract the damping springs (13) from the body (22) (using flat nose pliers). 7) Inspect the damping springs (13). If defects are detected, replace the 4 springs. 8) Reassemble parts in reverse order. 6.
E215B-E245B
[
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60
Guide/plunger and regulation unit replacement. 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.
NOTE: hold the guides with the other hand during the extraction operation to limit the effect of the return spring. 3) Remove the guide / plunger assembly. 4) Repeat the operation for the other 3 subassemblies. 5) Visually check that the guides / plungers are in good condition. If defects are present, replace the 4 sub-assemblies.
60
W2-5-17
E215B-E245B
PILOT VALVE
6) Guide/plunger and relulation unit replacement. • Extract the regulation units from the body (22) (using flat nose pliers). • Inspect the regulation units. If defects are detected on the parts, replace the 4 units. 7) Return spring replacement (11): • Extract the return springs (11) from the body (22) (using flat nose pliers).
60
• Inspect the return springs (11). If defects are detected, replace the 4 springs.
8) Reassemble parts in reverse order.
60
7.
Throttle kit replacement 1) Remove • The pilot control unit from the machine • Both rubber boots • Both switch plates • The retaining plate • The damping plungers and springs 2) Unscrew the screw (15-u) using a 3 mm socket wrench * Reassembly: • Apply a droplet of Loctite #262 on the screw thread • Screw on until it sets just above the body (22).
W2-5-18
X
60
PILOT VALVE
E215B-E245B
3) Unscrew the throttle (15-t) using a 3 mm socket wrench. * Reassembly: • Torque: 4 Nm (3 lbf•ft) 4) Repeat the operation for the other 3 assemblies. 5) Replace with new screws (15-u) and new throttles (15-t). 6) Reassemble parts in reverse order.
X
W 60
8.
Shuttle valve kit removal (17) 1) Remove the pilot control unit from the machine
NOTE: the pilot control unit does not need to be disassembled to perform this operation. 2) Unscrew the shuttle valve (17-w) using a 4 mm socket wrench * Reassembly: • Thoroughly clean the body to remove any trace of loctite. • Apply a droplet of Loctite #242 on the shuttle valve thread (17-w). • Torque: 4 Nm (3 lbf•ft) 60
IMPORTANT: wait for 8 hours before using the machine to let the Loctite #242 dry completely.
Z
60
W2-5-19
E215B-E245B
PILOT VALVE
3) Put the body up-side-down to remove the shuttle valve (17-w) and the ball (17-r). 4) Unscrew the throttle (17-z) using a 2.5 mm socket wrench. * Reassembly: • Hand tighten 5) Repeat the operation for the other subassemblies. 6) Inspect the shuttle valves (17-w), balls (17-r) and throttles (17-z). If defects are detected, replace all the assemblies. 7) Reassemble parts in reverse order.
60
W ]
Z
60
9.
Check valve kit removal (14) 1) Remove the pilot control unit from the machine
T
NOTE: the pilot control unit does not need to be disassembled to perform this operation. 2) Unscrew the check valve plug (14-q) using a 4 mm socket wrench. * Reassembly: • Drain the pilot control unit • Torque: 5 Nm (3.7 lbf•ft) 3) Put the body (22) up-side-down to remove the ball (14-r). 4) Repeat the operation for the second check valve kit. 5) Inspect the check valve plugs (14-q), Orings and balls (14-r). If defects are detected, replace all the assemblies. 6) Reassemble parts in reverse order.
60
T
U
W2-5-20
60
PILOT VALVE
E215B-E245B
DRAIN OF HYDRAULIC PILOT CONTROL UNIT 1.
When removing the retaining plate, the throttle kit or the shuttle valve kit, it is necessary to drain the pilot unit.
2.
Reassemble the pilot unit control completely.
3.
Install the pilot unit control in the machine.
4.
Slightly unscrew the check valve plug (14-q) using a 4 mm socket wrench
5.
Switch on the machine.
6.
Operate gently the pedal until the bubbles disappear.
7.
Tighten the check valve plug (14-q). Torque: 5 Nm (3.7 lbf•ft)
8.
Repeat the operation for the other check valve plug.
T
W2-5-21
60
E215B-E245B
PILOT VALVE
NOTE:
W2-5-22
SECTION 3
E215B-E245B
UNDERCARRIAGE
CONTENTS Group 1 - Swing bearing Removal and installation of swing bearing .................................................. W3-1-1
Group 2 - Travel device
Tool table ............................................... W3-5-4
Group 6 - Upper and lower roller Removal and installation of upper roller ...................................................... W3-6-1
Removal and installation of travel device (E215B) ..................................... W3-2-1
Removal and installation of lower roller ...................................................... W3-6-4
Disassembly travel device .................... W3-2-2
Upper roller disassembly........................ W3-6-7
Disassembly and assembly of travel device (E215B) .................................... W3-2-3 Maintenance standard ...................... W3-2-61 Sprocket............................................ W3-2-61
Upper roller assembly ............................ W3-6-7
Removal and installation of travel device (E245B) ..................................... W3-2-63 Disassembly procedure of travel device (E245B)................................................. W3-2-67 Assembling procedure of travel device (E245B)................................................. W3-2-80 Motor...................................................... W3-2-88 Tool table ............................................... W3-2-98
Group 3 - Swivel joint Removal and installation of swivel joint . W3-3-1 Swivel joint disassembly and assembly . W3-3-4 Maintenance standard ........................... W3-3-9
Group 4 - Track adjuster Removal and installation of track adjuster (with front idler) ..................................... W3-4-1 Disassembly and assembly track adjuster ................................................. W3-4-2 Tool table ............................................... W3-4-6
Group 5 - Front idler Disassembly and assembly front idler assy....................................................... W3-5-1 Maintenance standard ........................... W3-5-4
Lower roller disassembly........................ W3-6-11 Lower roller assembly ............................ W3-6-13 Maintenance standard............................ W3-6-15 Tool table ............................................... W3-6-16
Group 7 - Tracks Removal and installation of tracks ......... W3-7-1 Maintenance standard............................ W3-7-5 Tool table ............................................... W3-7-7
SWING BEARING
E215B-E245B
REMOVAL AND INSTALLATION OF SWING BEARING WARNING Wear close-fitting clothing and safety equipment appropriate 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. Before removing the swing bearing, the upperstructure must be removed first. For removal and installation of the upperstructure, refer to “Remove and Install Main Frame” section. In this section, the procedure starts on the premise that the upperstructure has already been removed. Removal 1.
$
Put alignment marks on (A) swing bearing (1) and track frame (2).
60
2.
Remove screws M20 (3) (Q.ty 36) and the relevant washers (Q.ty 36). : 30 mm
60
IMPORTANT - Swing bearing weight: 251 kg (553 lbs). 3.
Attach lifting tools (380001026), hoist swing bearing (4) and remove it.
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 surfaces of swing bearing and track frame.
IMPORTANT - Swing bearing weight: 251 kg (553 lbs).
60
IMPORTANT - Inner race soft zone (S) and the ball filler port should be placed on the same position (right side of the frame). 2.
$ 6
Hoist the swing bearing. Align the swing bearing with the alignment mark on the track frame and install the swing bearing.
% NOTE - Apply Loctite #262 on the thread of the screws (3) before assembling. 60
A: Front Side B: Position of Plug
3.
Install screws M20 (3) (Q.ty 36) with the relevant washers (Q.ty 36) and tighten them to the prescribed torque. : 30 mm : 563 ± 56 Nm (415 ± 41 lbf·ft)
NOTE - Fill in greasebath with 8.6 ±0.86 kg of IP BIMOL 481 or equivalent grease.
60
TOOL TABLE TOOL NO.
DESCRIPTION
380001026
Lifting tools slewing ring
W3-1-2
TRAVEL DEVICE
E215B-E245B
REMOVAL AND INSTALLATION OF TRAVEL DEVICE (E215B) 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.
2.
To drain the hydraulic pressure from the Hydraulic System, refer to procedure "Releasing the hydraulic pressure" at page. T2-1-47.
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.
NOTE: be sure to run the vacuum pump continuously while working. Removal The procedure starts on the premise that the track link has already been removed. 1.
2.
Loosen bolts M12 (7) to remove cover (6). Disconnect hoses (2), (3), (4) and (5). : 19 mm : 29.4 ±5 Nm (21.7 ± 3.7 lbf·ft) : 27 mm : 78.5 ±5 Nm (57.9 ± 3.7 lbf·ft) : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf·ft)
Attach the travel device to a crane using a wire rope. Remove any slack from the wire rope so as to secure the travel device when the mounting bolts are removed.
NOTE: Travel device weight: Approx. 300 kg (661.5 lbs). 3.
NOTE: Install caps on all disconnected hose and line ends.
W3-2-1
Remove bolts M16 (1). Remove the travel device using the crane. : 24 mm : 279 ±29 Nm (206 ± 21 lbf·ft)
E215B-E245B
TRAVEL DEVICE
DISASSEMBLY TRAVEL DEVICE
Installation 1.
Install the travel device using bolts (1).
2.
Connect hoses (2), (3), (4) and (5).
3.
Install cover (6) and fix it with screws (7) and washers (8) and (9). : 19 mm : 83.4 ±8.4 Nm (61.5 ± 6.2 lbf·ft)
Preliminary operations
IMPORTANT - After completing travel motor installation, be sure to fill the travel motor with hydraulic oil. After completing installation of the travel motor or the travel device, be sure to perform test driving to prevent motor seizure. Test drive as follows: 1. Run the engine with the engine control dial in the slow idle position. 2. Turn the travel speed mode switch to the slow speed position. 3. Test drive the machine back-and-forth for 0.5 m to 1 m in each direction five times or more.
In the case that it was necessary to undergo a (partial or total) revision, it will be necessary to dismount the gearmotor from the machine. As this is known as an out of the ordinary maintenance procedure, it is important that only personnel with specific skills and experience undertake it. It is also important that this procedure is undertaken in a workshop that is adequately tooled. As well as normal workshop tools it will be necessary to use special tools. In the following pages all the procedures for disassembling and reassembling the gearmotor are given, it is important to strictly adhere to them. Proceed with these operations using all the necessary safety measures, like for example: 1.
Cutting off all the hydraulic system connections on the gearmotor to avoid the introduction of any foreign parts in the circuit and the gearmotor.
2.
Making sure that the coupling surfaces are not damaged.
3.
Following the handling so as to be sure that there are no risks for human safety and to guarantee the reliability of the gearmotor.
4.
Making available a work area that is in line with work and health safety in the workplace guidelines.
5
4
3 2
8
1 6
7 9
NOTE: Initial inspection of hydraulic motor and gears, can be made without disassembling the track drive from the machine.
SM0300
Initial inspection of the gears, can be made without disassembling the track and the track drive from the machine. Before track drive disassembling, make sure that the oil is discharged.
W3-2-2
TRAVEL DEVICE
E215B
DISASSEMBLY AND ASSEMBLY OF TRAVEL DEVICE (E215B) Gearbox disassembling method By using a tackle place the gearbox unit (1) on a spacer (2).
2.
dz
dz
1.
60
Unscrew the nos. 2 plugs M22 x 1.5 (3) and the washers from the end cover (4).
60
3.
Unscrew the nos. 13 screws M10x30 (5), grade 12.9, from the end cover (4). 8 mm
60
W3-2-3
E215B 4.
TRAVEL DEVICE
Remove the end cover (4).
60
5.
Remove the O-ring seal (6) from its seat in the end cover (4).
60
6.
Remove the 1st stage sun gear (7).
60
7.
Remove the 1st reduction assembly (8).
60
W3-2-4
TRAVEL DEVICE 8.
E215B
Remove the 2nd reduction assembly (9).
60
9.
By using pliers remove the circlips (10) from their seats placed in the hydraulic motor’s pins (11).
60
10. By using a puller remove the planet assemblies of the 3rd reduction (12).
60
11. Take out the spacer (13).
60
W3-2-5
E215B
TRAVEL DEVICE
NOTE - in order to proceed with the gearbox disassembly, it is now necessary to remove it from the machine and bring it to a properly equipped workshop.
12. By using a drill remove the calkings on the ring nut (14).
60
13. By using a tackle place the torque multiplier (A) (XXXXXXXXX) on the ring nut (14) and, by using the torque multiplier, loosen the ring nut (14).
$
60
14. Take out the ring nut (14).
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
15. By using a press, push on a metal stopper and remove the hydraulic motor (16) from the gearbox housing (17).
60
NOTE: In case of oil leakages, it might be necesary to check and eventuallu replace the lifetime seals (18), wich means both the metal rings parts and the O-ring seals.
16. By using a screwdriver remove the half seal (18) from the hydraulic motor (16).
60
W3-2-7
E215B
TRAVEL DEVICE
17. By using a puller and a metal stopper, remove the bearing inner raceway from the hydraulic motor (16).
60
18. Remove the bearing inner raceway (20) from the gearbox housing (17).
60
19. Remove the bearing balls (21) from the gearbox housing (17).
60
W3-2-8
TRAVEL DEVICE
E215B
Hydraulic motor disassembling method Disassembly of the flushing valve 1.
Unscrew the first plug (1) from the flushing valve (2).
NOTE: it is suggested to operate like that when motor is completely assembled.
60
2.
Remove th O-ring seal (3) from its seat in the first plug (1).
60
3.
Unscrew the second plug (4) from the flushing valve (2).
60
4.
Remove the O-ring seal (3) from its seat in the second plug (4).
60
W3-2-9
E215B 5.
TRAVEL DEVICE
Remove the spring (5) from the poppet (6).
60
6.
Take out the poppet (6) from the flushing valve (2).
60
7.
Unscrew the third plug (7) from the flushing valve (2).
60
8.
Remove the O-ring seal (3) from its seat in the third plug (7).
60
W3-2-10
TRAVEL DEVICE 9.
E215B
Remove the 1st spring (8) from the plunger assy (9).
60
10. Unscrew the fourth plug (10) from the flushing valve (2).
60
11. Remove the O-ring seal (3) from its seat in the fourth plug (10).
60
12. Remove the 2nd spring (11) from the plunger assy (9).
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 flushing valve (2).
60
16. Unscrew the nos. 4 socket head screws M10x30 (13), grade 8.8, of the flushing valve (2) by a male hex head wrench. : 8 mm
60
W3-2-12
TRAVEL DEVICE
E215B
17. Remove the flushing valve (2).
60
18. Remove the O-ring seals (14) from the flushing valve (2).
60
19. Unscrew the orifice M5 (15) from the flushing valve (2).
60
Disassembly of the two speed control 20. Unscrew the plug (16) from the base plate (17).
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
23. Remove the spring (20) from its seat in the base plate (17).
60
24. Unscrew the plug (21) from the base plate (17).
60
W3-2-14
TRAVEL DEVICE 25. Remove the O-ring seal (18) from its seat in the plug (21).
E215B
60
26. By using a screwdriver take out the two speed spool (22).
60
Disassembly of the relief valve assy 27. Unscrew the nos.2 relief valve kits (23).
60
28. Take out the free piston (24) from the relief valve (23).
60
W3-2-15
E215B
TRAVEL DEVICE
29. Remove the O-ring seal (25) and the backup rings (26) from their seats in the free piston (24).
60
30. Remove the O-ring seal (27) from relief valve (23). Repeate the same steps for the 2nd relief valve disassembly.
60
Disassembly of the counterbalance valve assy
31. Unscrew the nos. 4 socket head screws M12x40 (28), grade 12.9 of the first flanged plug assy (29) by a male hex head wrench. : 10 mm
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
34. Remove the first spring (31).
60
35. Take out the first spring seat (32) from the counterbalance valve spool (33).
60
36. Remove the springs (34) from the base plate (17).
60
W3-2-17
E215B
TRAVEL DEVICE
37. Remove the O-ring seals (35) from the base plate (17).
60
38. Remove the check valves (36) from the base plate (17).
60
39. Unscrew the nos. 4 socket head screws M12x40 (28), grade 12.9, of the second flanged plug assy (29) by a male hex head wrench. : 10 mm
60
40. Take out the second flanged plug assy (29) and the spring seat.
60
W3-2-18
TRAVEL DEVICE 41. Take out the spring seat (30) from the second flanged plug (29).
E215B
60
42. Remove the second spring (31).
60
43. Take out the second spring seat (32) from the counterbalance valve spool (33).
60
44. Take out the counterbalance valve spool (33).
60
W3-2-19
E215B
TRAVEL DEVICE
Disassembly of flanged plug assy 45. Remove the O-ring seal (34) from the flanged plug (29).
60
46. Unscrew the plug (35) from the flanged plug (29).
60
47. Remove the O-ring seal (36) from the plug (35).
60
Disassembly of the base plate
48. Unscrew the plug (37) from the base plate (17).
60
W3-2-20
TRAVEL DEVICE
E215B
49. Remove the O-ring seals (38) from the plugs (39).
60
50. Unscrew the plug (40) from the base plate (17).
60
51. Unscrew the nos. 4 orifices M5 (41) from the base plate (17).
60
52. Remove the caulking with a M5 tap before unscrewing the orifices.
60
W3-2-21
E215B
TRAVEL DEVICE
53. Unscrew the nos. 2 orifices M5 (42) from the base plate (17).
60
54. Unscrew the nos. 10 socket head screws M14x40 (43), grade 12.9, that fix the base plate (17) to the flanged hub (44).
60
IMPORTANT: Remove carefully the base plate (17) until pins are completely out.
60
55. Remove the pins (45) from their seats.
60
W3-2-22
TRAVEL DEVICE
E215B
56. Remove the valve plate (46).
60
57. By using a puller, remove the bearing (47) from the base plate (17).
60
Disassembly of the motor shaft and cylinder block
58. Remove the O-ring seal (48) from its seat in the flanged hub (44).
60
59. Remove the O-ring seal (49) from brake pilot hole.
60
W3-2-23
E215B
TRAVEL DEVICE
60. Remove the O-ring seals (50) from speed shifting holes.
60
61. Remove the springs (51) from the brake piston (52).
60
62. Mark the position of the brake piston (52) as a reference for the reassembling step.
60
63. By using two screws M8, take out the brake piston (52).
60
W3-2-24
TRAVEL DEVICE
E215B
64. Remove the O-ring seals (53) from the brake piston (52).
60
65. Take out the 1st brake disc (54).
60
66. Remove brake discs pack (55).
60
67. Remove the cylinder block (56) from the flanged hub (44).
60
W3-2-25
E215B
TRAVEL DEVICE
68. Take out the spherical retainer plate holder (57).
60
69. Take out the nos. 3 pins (68) from their seats in the cylinder block (56).
60
70. Remove the pistons and the retainer plate (58) and (59) from the flanged hub (44).
60
71. Take out the pistons (58) from the retainer plate (59).
60
W3-2-26
TRAVEL DEVICE 72. Remove the swash plate (60) from the flanged hub (44).
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
76. By using a rubber hammer take out the motor shaft (64) from the the flanged hub (44).
60
77. By using a puller take out the bearing (65) from the motor shaft (64).
60
78. By using a screwdriver remove the seal ring from its seat in the flanged hub (44).
NOTE - Disassemble the seal ring only in case of replacement, because this will damage it. NOTE - The disassembly ends with the above operation. All items are now available for the necessary inspections.
60
W3-2-28
TRAVEL DEVICE Evaluation of the Pieces to be Replaced The pieces that are subject to general wear and tear are the following: - Gears. - Bearings. - All the seals. Replace the used or irregular parts respecting the following steps: 1.
Accurately remove dirt, and in particular properly clean the seals, bearings and locking rings seating.
2.
Lubricate the parts before connecting them.
3.
In the case of damaged gears, for example a planetary, do not proceed to replace the individual gear but the entire reduction assembly.
4.
When reconnecting a part always replace all the seals involved. Add some grease on the seats and on the new seals to make easier the reassembly.
5.
Replace all the damaged parts with original spare parts and doing so follow all the steps given by the manufacturer in sections 4.9.-4.10.
W3-2-29
E215B
E215B
TRAVEL DEVICE
Hydraulic motor reassembling method
Reassembly of motor shaft and cylinder block 1.
Assemble the back-up ring (66) inside its seat in the flanged hub (44).
60
2.
By using a plastic hammer and the stopper (B) (XXXXXXXXX), push the back-up ring into the flanged hub shoulder (44) until assembly is complete.
% 60
3.
Place the bearing outer ring (65) on the motor shaft (64).
60
By using a plastic hammer and a metal stopper, completely assemble together the bearing (65) and the motor shaft (64).
4.
60
W3-2-30
TRAVEL DEVICE 5.
Place the bearing-motor shaft sub-assembly (65-64) in the seat inside the flanged hub (44).
E215B
IMPORTANT - Be careful when inserting the shaft inside the motor seal (52).
60
6.
By using a plastic hammer and a metal stopper, completely assemble together the bearing-motor shaft sub-assembly into the flanged hub shoulder (44) until assembly is complete.
60
7.
Assemble the nos. 2 steel balls (61) into their seats inside the flanged hub (44).
60
8.
Assemble the nos. 2 springs (63) into their seats inside the pistons (62).
60
W3-2-31
E215B 9.
TRAVEL DEVICE
Assemble the nos. 2 pistons (62) into their seats inside the flanged hub (44).
NOTE - Be sure that the pistons (62) can move freely into the seats.
60
10. Insert the swash plate (60) inside the flanged hub (44) being careful that spherical housings matches with the 2 steel balls.
60
11. Assemble the nos. 3 pins (68) in their seats in the cylinder block (56).
60
12. Assemble the spherical retainer holder (57) on the cylinder block (56). NOTE - The two splines must be aligned together.
60
W3-2-32
TRAVEL DEVICE 13. The orifice of the piston (58) must be open and free of dust or dirt.
E215B
60
14. Assemble correctly the nos. 9 pistons (58) in the retainer plate (59).
60
15. Assemble the pistons-retainer plate sub assembly (58-59) in the cylinder block (56).
60
16. Assemble the cylinder block sub assembly (56) into the flanged hub (44) on the motor shaft spline (64).
60
W3-2-33
E215B
TRAVEL DEVICE
17. Assemble the brake discs package according to the following order: firstly, insert one brake disc (54) with internal teeth.
60
18. Then insert an externally toothed steel disc (55) Repeat the operation untill all nos. 3 brake discs and nos. 2 steel discs have been assembled.
60
19. Assemble the O-ring seals (53) into their seatsin the brake piston (52).
60
NOTE - Assemble the brake piston (52) respecting the markings set out previously and being careful not to damage the seals already fitted.
60
W3-2-34
TRAVEL DEVICE
E215B
20. Assemble the O-ring seal (48) into its seat in the flanged hub (44).
60
21. Assemble the O-ring seal (49) in the brake pilot hole of the flanged hub (44).
60
22. Assemble the O-ring seals (50) in the speed shifting holes of the flanged hub (44).
60
23. Insert the springs (51) in their seats in the brake piston (52).
60
W3-2-35
E215B
TRAVEL DEVICE
Reassembly of the base plate
24. Place the bearing (47) into its seat in the base plate (17).
60
25. By using a plastic hammer and a metal stopper, push the bearing into the base plate (17) shoulder until assembly is complete.
60
26. Place the valve plate (46) on the base plate (17).
IMPORTANT - Bronze layer surface must be upwards.
60
27. Assemble the pins (45) in their seats in the base plate (17).
60
W3-2-36
TRAVEL DEVICE
E215B
28. Place the base plate (17) on the flanged hub (44).
IMPORTANT: The base plate is centered by two pins (45) and the second speed oil passages must match together.
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
30. By using the tool (C) (XXXXXXXXX), fit the Oring seals in their seats in the plugs (39).
&
60
31. Insert the plugs (39) and tighten by a torque wrench at 36.8 ±2.5 Nm torque. : 36.8 ±2.5 Nm (27.1 ± 1.8 lbf·ft)
60
W3-2-37
E215B
TRAVEL DEVICE
32. Seal the thread of the orifices and the plugs (40) by "Teflon" tape. NOTE - Be sure that the tape is correctly winded around the plugs (40).
60
33. Insert the nos. 4 orifices M5 (41) in the base plate (17) and tighten by a torque wrench at 2.5 ±0.5 Nm torque. : 2.5 ±0.5 Nm (1.85 ± 0.35 lbf·ft)
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
35. Tighten the nos. 2 orifices M5 (41) in the base plate (17) by a torque wrench at 2.5 ±0.5 Nm torque. : 2.5 ±0.5 Nm (1.85 ± 0.35 lbf·ft)
60
W3-2-38
TRAVEL DEVICE 36. By using a punch and a hammer deform the thread hole (69).
E215B
60
Reassembly of the flanged plug assy 37. By using the stopper (D) (XXXXXXXXX), assemble the O-ring in its seat in the plug (35).
'
38. Tighten the plugs (35) by a torque wrench at 20.6 ±1 Nm torque. : 20.6 ±1 Nm (15.2 ± 0.7 lbf·ft)
60
60
39. Assemble the O-ring (34) in its seat in the flanged plug (29).
60
W3-2-39
E215B
TRAVEL DEVICE
Reassembly of the counterbalance valve assy 40. Insert the counterbalance valve spool (33).
60
41. Insert the check valves (36) in the base plate (17).
60
42. Insert the O-ring seals (35) in the base plate (17).
60
43. Insert the springs (34) in the base plate (17).
60
W3-2-40
TRAVEL DEVICE 44. Insert the first spring seat (32) on the counterbalance valve spool (33).
E215B
60
45. Insert the first spring (31) on the counterbalance valve spool (33).
60
46. Assemble the spring seat (30) into its seat in the 1st flanged plug (29).
60
47. Assemble the first flanged plug assy (29).
60
W3-2-41
E215B
TRAVEL DEVICE
48. Tighten the nos. 4 socket head screws M12x40 (28), grade 12.9, of the first flanged plug assy (29) by a male hex head torque wrench at 108 ±10 Nm torque. : 10 mm : 108 ±10 Nm (79.7 ± 7.3 lbf·ft)
60
49. Insert the second spring seat (32) on the counterbalance valve spool (33).
60
50. Insert the second spring (31) on the counterbalance valve spool (33).
60
51. Assemble the spring seat (30) into its seat in the 2nd flanged plug (29).
60
W3-2-42
TRAVEL DEVICE
E215B
52. Assemble the second flanged plug assy (29).
60
53. Tighten the nos. 4 socket head screws M12x40 (28), grade 12.9, of the second flanged plug assy (29) by a male hex head torque wrench 108 ±10 Nm torque. : 14 mm : 108 ±10 Nm (79.7 ± 7.3 lbf·ft)
60
Reassembly of the relief valve assy
(
54. By using the stopper (E) (XXXXXXXXX), assemble the O-ring seal in its seat in the relief valve (23).
60
55. Assemble the first backup-ring (26) into its seat in the free piston (24).
60
W3-2-43
E215B
TRAVEL DEVICE
56. Assemble the O-ring seal (25) into its seat in thefree piston (24). After this step assembly the second backup ring as shown on the sketch.
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
59. Tighten the relief valve (23) by a torque wrench at 373 ±20 Nm torque. : 373 ±20 Nm (275 ± 14.7 lbf·ft)
60
W3-2-44
TRAVEL DEVICE
E215B
Reassembly of the two speed control 60. By using the tool (F) (XXXXXXXXX), fit the Oring seal into its seat in the plug (44).
)
60
61. Insert the plug (44) and tighten by a torque wrench at 118 ±5 Nm torque. 118 ±5 Nm (87 ± 3.7 lbf·ft)
60
62. Insert correctly the two speed spool kit (22) in the base plate (17). NOTE: Two speed spool (22) have to move smoothly inside its seat in the base plate (17).
60
63. Insert the spring (20) in the second speed spool (22).
W3-2-45
60
E215B
TRAVEL DEVICE
64. Insert the spring seat (19) in the spring (20).
60
65. By using the tool (F) (XXXXXXXXX) fit the Oring seal into its seat in the plug (16).
)
60
66. Insert the plug (16) and tighten by a torque wrench at 118 ±5 Nm torque. : 118 ±5 Nm (87 ± 3.7 lbf·ft)
60
67. Correct assembling of the two speed control valve.
60
W3-2-46
TRAVEL DEVICE
E215B
Reassembly of the flushing valve 68. Insert the orifice M5 (15) in the flushing valve (2) and tighten by a torque wrench at 2.5 ±0.5 Nm torque. : 2.5 ±0.5 Nm (1.85 ± 0.35 lbf·ft)
69. Assemble the O-ring seals (14) into its seat in the flushing valve (2).
60
60
70. Assemble the flushing valve (2) to the base plate (17).
60
71. Fix the flushing valve (2) by using nos. 4 socket head screws M10x30 (13), grade 8.8, tightened by a male hex head torque wrench at 58 ±5 Nm torque. : 8 mm : 58 ±5 Nm (42.8 ± 3.7 lbf·ft)
60
W3-2-47
E215B
TRAVEL DEVICE
72. Slide the flushing spool valve (9) inside the flushing valve (2).
60
73. Insert the 1st spring seat (12) on the plunger assy (9).
60
74. Insert the 1st spring (11) on the plunger assy (9).
60
75. By using the tool (G) (XXXXXXXXX), fit the Oring seal in its seat in the plug (10).
*
60
W3-2-48
TRAVEL DEVICE 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)
E215B
60
77. Insert the second spring seat (12) in the opposite side of the plunger assy.
60
78. Insert the second spring (8) on the plunger assy.
60
79. By using the tool (G) (XXXXXXXXX), fit the Oring seal in its seat in the plug (7).
*
W3-2-49
60
E215B
TRAVEL DEVICE
80. Insert the second plug (7) 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)
NOTE - it is suggest to operate like that when motor is completely assembled.
60
81. Slide the poppet (6) inside the flushing valve (2).
60
82. Insert the spring (5) in the flushing valve (2).
60
83. By using the tool (G) (XXXXXXXXX), fit the Oring seal in its seat in the plug (4).
*
60 W3-2-50
TRAVEL DEVICE 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)
E215B
60
85. By using the tool (G) (XXXXXXXXX), fit the Oring seal in its seat in the plug (1).
*
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
NOTE - it is suggested to operate like that when motor is completely assembled.
60
87. Correct assembling of the flushing valve.
60
W3-2-51
E215B
TRAVEL DEVICE
Gearbox reassembling method
Reassembly of the gearbox 1.
Assemble the balls (1) to the plastic supports.
60
2.
Place the bearing inner ring (2) on a spacer (3).
Ɏ
3.
Place the gearbox housing (4) on the bearing inner ring (2).
60
4.
Assemble the bearing inner raceway (2) in the gearbox housing (4).
60
W3-2-52
TRAVEL DEVICE
E215B
Make ready of the lifetime seal: 1.
Carefully clean the seats (A and B) using, if necessary, metallic brushes or solvent (surfaces in contact with or (C) must be perfectly clean and dry).
2.
Make sure that sealing surfaces (D) of metal rings (E) are free from scratches, dinges or foreign substances; metallic ring surfaces (F) must be perfectly clean and dry. We suggest to dip the metallic rings in volatile solvent or industrial degreasing alcohol.
3.
Carefully clean the lapped surface (D) of metal rings (E) and remove dust or fingerprints. Then lubrificate them with a thin oil film, taking care not to oil the other components.
W3-2-53
60
E215B 5.
TRAVEL DEVICE
Fit the 1st half seals (5) on the tool (H) (XXXXXXXXX).
+ 60
6.
By means of the tool (H) (XXXXXXXXX), carry out the assembly of the 1st half seal (5) on the gearbox housing (4).
+
60
7.
Assemble, by using the same tool (H) (XXXXXXXXX), the 2nd half seal on the hydraulic motor (6).
+
60
W3-2-54
TRAVEL DEVICE
E215B
NOTE - Correct lifetime seal assembly check (5).
60
8.
Clean carefully the seal faces (5).
IMPORTANT: Apply a thin oil film on the entire metallic face of one or both seals. Oil must not contact surfaces other than the sealing faces.
60
W3-2-55
E215B
TRAVEL DEVICE
NOTE - By using a tackle, place the hydraulic motor (6) inside the gearbox housing (4).
9.
By using a press and a metal stopper, push the hydraulic motor (6) against the shoulder on the gearbox housing (4) untill assembling of the unit is complete.
60
NOTE: tighten nos. 2 screws M20x100-8.8 ISO 4017 (7) at 180° with nos. 2 washers 22x60x4 ISO 7093 in the thread holes of the gearbox housing (4) to avoid the housing comes out from the hydraulic motor (6) during the movement of the unit. Remove the screws when the unit is positioned.
60
10. Place the ring nut (8).
60
11. By using a tackle place the multiplier (A) (XXXXXXXXX) on the ring nut (8) and tighten by a torque wrench with an input multiplier torque of 143 ±5 Nm (105.5 ± 3.7 lbf·ft) corresponding to an output multiplier torque of 7250 ±250 Nm (5347 ± 184 lbf·ft).
$
60
W3-2-56
TRAVEL DEVICE
E215B
12. Stake the ring nut (8) near 2 seats of the hydraulic motor.
60
NOTE - Stake Ø 4÷5 mm (depth 1÷1,5 mm).
60
13. Assemble correctly the spacers (9) on the pins of the hydraulic motor (6).
60
14. Place the reduction planet assemblies of the 3rd reduction (10) on the pins of the hydraulic motor (6).
60
W3-2-57
E215B
TRAVEL DEVICE
IMPORTANT: Place correctly the reduction planet assemblies checking that the groove is towards the end cover (11).
60
15. By using a rubber hammer and a metal stopper, push the planet assemblies of the 2nd reduction (12) against the hydraulic motor pin shoulders (6).
60
16. By using pliers, assemble the circlips (13) in the hydraulic motor pin seats (6).
60
17. Insert the 2nd reduction assembly (14).
60
W3-2-58
TRAVEL DEVICE 18. Insert the 1st reduction assembly (15).
E215B
60
19. Insert the 1st reduction sun gear (16).
60
20. Assemble the O-ring (17) into its seat in the cover (18).
60
21. Place the end cover (18) on the gearbox housing (4).
60
W3-2-59
E215B
TRAVEL DEVICE
22. Tighten the nos. 13 socket head screws M10x30 (19), grade 12.9, by a torque wrench at 85 Nm torque. : 8 mm : 85 Nm (62.7 lbf·ft)
60
23. Fill the gearbox with the lubricant oil. Insert the washers and the plugs (20) into the oil draing-filling holes of the end cover (18). Tighten the plugs by a torque wrench at 35 ±5 Nm torque. : 35 ±5 Nm (25.8 ± 3.7 lbf·ft)
60
Final Test and Reinstallation Check the product by remounting it to the machine. Check the function of the transmission.
Dismantling and Destroying the Product When dismantling the gearmotor follow the indications given below. 1.
Remove the gearbox from the machine frame and let the lubricant oil flow.
2.
Completely dismount the gearbox and remove all oil and grease from its parts.
3.
Send all dangerous and/or polluted parts to the authorised demolishing centres whilst keeping in line with respective local rules and regulations.
W3-2-60
TRAVEL DEVICE
E215B
MAINTENANCE STANDARD Sprocket
% & '
(
$
60
IMPORTANT: Consult NEW HOLLAND KOBELCO S.p.A. for any inqueries concerning welding procedures. Standard mm (in)
Allowable Limit mm (in)
A
68 (2.67)
60 (2.36)
B
584.7 (22.80)
575 (22.42)
C
PCD644.6 (25.14)
-
D
659 (25.70)
648 (25.27)
E
190 (7.41)
-
W3-2-61
Remedy
Build up and finishing
E215B
TRAVEL DEVICE
NOTES
W3-2-62
TRAVEL DEVICE
E245B
REMOVAL AND INSTALLATION OF 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.
NOTE: be sure to run the vacuum pump continuously while working.
INSTALL ASSY
LQ53D00010F1
No.
NAME
Q'TY
REMARKS
3
CAPSCREW
56
M16x55
4
TRAVEL MOTOR ASSY
2
LQ53D00011F1
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 attachment, and put it on square timbers to float and stabilize.
Removing cover 2.
Remove sems bolt (6) M12x25 and also remove covers (1). : 19 mm
3.
6 1
60
Preparation of oil pan.
Removing hydraulic pipe 4.
Release pressure from travel circuit, and bleed air in hydraulic oil tank, then remove all pipes connecting to travel motor. Then plug up all pipes and joint section to protect them from entry of dust. : 19 mm : 27 mm : 41 mm
60
W3-2-64
TRAVEL DEVICE
E245B
Removing sprocket 5.
Removing thirty (one side) capscrews (3) M16x50. : 24 mm
3 60
Loosening travel motor attaching bolts 6.
Disconnect hoses (A). Apply match marks on travel motor and crawler frame, and remove seventeen (one side) capscrews (3) M20x60.
$
: 24 mm
3
60
Slinging travel motor assy 7.
Sling travel motor with nylon sling applied on the side close to sprocket installing section and remove the motor. Weight of motor: About 262 kg (578 lbs)
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 starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leakage and noise.
NAME
SIZE
TOOLS
No.
TIGHTENING TORQUE (N/m)
Bolts
M12
19
6
83.4 (61.5 lbf·ft)
Capscrew
M16
24
3
279 (206 lbf·ft)
Flareless nut for pipes, sleeve
Ø 10X1.5 Ø 18X2.5 Ø 28
19 32 41
-
49 (36.1 lbf·ft) 147 (108 lbf·ft) 275 (203 lbf·ft)
Hose cap
PF1/4 PF1/2
19 27
-
29.4 (21.7 lbf·ft) 78.5 (57.9 lbf·ft)
Connector
PF1/4 PF1/2 PF1
19 27 41
-
36.3 (26.8 lbf·ft) 108 (79.7 lbf·ft) 255 (188 lbf·ft)
W3-2-66
REMARKS Apply Loctite #262
TRAVEL DEVICE
E245B
DISASSEMBLY PROCEDURE OF TRAVEL DEVICE (E245B) Removing cap 1.
Fix the motor on a stable work bench, loosen eight socket bolts (13) and remove cap (11) with O-ring (12).
2.
Next, remove spring seat (10), spring (9) and spring seat (8).
3.
Then separate plug (15), O-ring (14), spring (34) and ball (33).
14,15,33,34
: 10 mm : 14 mm.
8 9 12
NOTE: cap (11) is pressed out by spring (9). Therefore, do the work, taking care of the following - Loosen socket bolts (13) evenly all round - Loosen socket bolts (13), holding down cap (11).
17
10
11 13
60
Removing double counterbalance plunger 1.
Push the end of plunger (3) lightly so part of plunger (3) comes out of base plate (2). Then, hold the end of plunger (3) by hand and draw out plunger (3) from base plate (2), while turning it by hand.
IMPORTANT: plunger (3) and base plate (2) have a very tight fit. Therefore, do the work, paying attention to the following: - case plunger (3) gets stuck halfway and does not come out, do not try to force it out. If it is pulled out by force, the bore surface of base plate (2) and the outer surface of plunger (3) are scored. - In case the plunger gets stuck halfway, do as follows: Put plunger (3) back into base plate (2) by lightly tapping the end face of it with a plastic mallet. Then make sure that the plunger (3) moves smoothly and draw out the plunger (3) once again, turning it by hand. - Do not disassemble plunger (3) unless it is necessary; the outer surface of it may be scored at disassembly.
W3-2-67
2 3 60
E245B
TRAVEL DEVICE
Removing relief valve assy 1.
Loosen plug (17-6) and remove relief valve assy (17). In that case, poppet seat (17-3) remains in base plate (2).
17-3
: 27 mm IMPORTANT: Relief valve assy (17) is set at certain pressure. The set pressure of it determines the starting power and the braking power of the motor. For this reason, do not do the following: - Do not loosen nut (17-16) and tamper with set screw (17-15). If the set screw is turned, the set pressure of the relief valve changes, making the motor unable to attain required performances. - Do not disassemble the relief valve assy. Otherwise, the set pressure changes and the motor is unable to attain required performances.
17-6
2
17-16 17-15 17 60
Removing poppet seat Separate poppet seat (17-3) from base plate (2), using the poppet seat removing jig. NOTE: Do not separate it unless it is necessary for special reason.
2 17-3 60
W3-2-68
TRAVEL DEVICE
E245B
Removing auto 2-speed select spool 1.
Loosen plugs (22), (25) and take off plugs (22), (25) and spring (21).
2.
Push out part of spool (19) from base plate (2) by pushing the end of spool.
3.
Draw spool (19) out of base plate (2), while holding the end of spool (19) by hand and turning it.
IMPORTANT: Spool (19) and base plate (2) are combined to a very small fit. For this reason, execute the work, paying attention to the following: - Do not disassemble spool (19) unless necessary. - In case the spool gets stuck halfway, do not force it out. If the spool is forced out, the bore surface of base plate (2) and the outer surface of spool (19) are scored. If it gets stuck, do as below: - Put spool (19) into base plate (2) once again by lightly tapping the end face of spool (19) with a plastic mallet. - Then, make certain that spool (19) moves smoothly and draw it out, turning spool (19) by hand.
4.
Do not remove orifice plug (18) unless necessary.
5.
Orifices (28), (29), (30) are caulked so they do not get loose. Do not disassemble them.
W3-2-69
21
25
2 19 22 60
E245B
TRAVEL DEVICE
Removing base plate 1.
Loosen socket bolts (52) and remove base plate (2). : 12 mm
52 2
59
60
NOTE: When removing base plate (2), do the work, taking care of the following: - Base plate (2) is pushed up by the action of spring (59). Therefore, loosen the cap screws evenly all round. - A positioning knock pin (60) is placed between base plate (2) and the main body. When removing base plate (2), do it upright toward the motor shaft center so knock pin (60) is not wrenched. In case it is wrenched, bring knock pin (60) back in place by lightly tapping base plate (2) with a plastic mallet and remove the knock pin. - When removing base plate (2), valve plate (62) comes with base plate (2). Since the moving surface of valve plate (62) tends to be scored, use care so valve plate (62) does not fall.
2
60 60
Removing valve plate 1.
When removing valve plate (62), take care of the following.
62
IMPORTANT: The moving surface of valve plate (62) tends to be scored. If the surface is scored, desired performances are not available; use care so as not to score it.
60
W3-2-70
TRAVEL DEVICE
E245B
Removing O-rings, knock pin and spring 1.
Take off O-rings (63), (64), and knock pin (60).
2.
Then take off spring (59).
59
60 63 64 60
Removing brake piston 1.
Attach a jet air nozzle to the oil path for the parking brake of flange (1), make brake piston (56) afloat by blowing jet air into the parking brake cylinder chamber and remove the brake piston.
2.
After removing brake piston (56), remove disk plate (54) and friction plate (55).
3.
Then separate O-rings (57), (58) from brake piston (56).
56
60
IMPORTANT: When removing brake piston (56), take care of the following: - When blowing in jet air from the parking brake oil path of flange (1), take measures so jet air does not leak. - If the jet air pressure is high when blowing in jet air from the parking brake oil path of flange (1), you may be injured as brake piston (56) pops out. For this reason, keep the air pressure less than 0.29 MPa (43 psi) and do the work, holding down brake piston (56) so brake piston (56) does not jump off.
56
54 54 55
55
54
58
57
60
W3-2-71
E245B
TRAVEL DEVICE
Removing cylinder block 1.
Take out cylinder block (37) from flange (1).
IMPORTANT: When drawing out cylinder block (37), use care of the following: - Hold cylinder block (37) by both hands and take it out slowly, while turning it both ways lightly; - Exercise care so as not to score the moving surface of cylinder block (37) in contact with valve plate (62). If the surface is scored, desired performances will not be attained. - Exercise care so as not to score the moving surface of the shoe of piston assy (38). Desired performances will not be attained if the surface is scored.
37 1
60
Disassembling cylinder block 1.
Give a matching mark to piston assy (38) and cylinder block (37) so they can be reassembled in the same positions.
2.
Then separate piston assy (38) and retainer plate (39) from cylinder block (37).
37
38 39
3.
Give a matching mark to piston assy (38) and retainer plate (39) so they can be reassembled in the same position.
4.
Then remove piston assy (38) from retainer plate (39).
60
39
38
W3-2-72
60
TRAVEL DEVICE 5.
E245B
Separate retainer holder (40) from cylinder block (37). Then take off pin (45) from cylinder block (37).
45
37 40
6.
Fix cylinder block (37) on a manual press bench so the moving surface faces upwards.
7.
Take off snap ring (41), push collar (44) with the jig, bend spring (43) and take off snap ring (41), using snap ring pliers.
60
41
%
37
60
IMPORTANT: When removing snap ring (41), take care as below, so as not to injure yourself: - If snap ring (41) is tight to remove with snap ring pliers, you may injure yourself when the snap ring comes off from the pliers; - Always use the removing jig to remove the snap ring and make certain that the claw of the pliers is set in the hole of the snap ring. 8.
Separate collar (44), spring (43) and spring seat (42) from cylinder block (37).
44 43 42
37
60
W3-2-73
E245B
TRAVEL DEVICE
Removing swash plate 1.
Separate swash plate (46) from flange (1).
IMPORTANT: Use care of the following when removing swash plate (46): - Take care so as not to score the sliding surface of swash plate (46). Desired performances will not be attainted if the surface is scored. - Swash plate (46) comes off with piston assy (38) and steel ball (47) in some cases. On that occasion, use care so piston assy (38) and steel ball (47) do not fall.
46
1
60
Removing travel 2-speed select piston assy and steel ball 1.
Separate piston assy (48) from flange (1).
2.
Then take off spring (61).
3.
Separate steel balls (47) from flange (1).
61
NOTE: Since steel balls (47) are hard to come off, do it as below: - Degrease steel balls (47) fixed in flange (1), using kerosene or thinner; - Separate steel balls (47) from flange (1), using a magnet.
48 47 1
60
Removing shaft 1.
Separate shaft (36) and ball bearing (49) from flange (1).
IMPORTANT: When removing shaft (36), use care of the following Use care so the spline of shaft (36) is not damaged. Exercise care so the sliding part of oil seal (53) in shaft (36) is not scored. If it is scored, oil leakage occurs.
36 49
1
60
W3-2-74
TRAVEL DEVICE
E245B
Draining lube oil from the reduction gear 1.
Next, before disassembling the reduction unit, put a screw in two tapped holes of flange (1) that are in diagonal positions and lift the reduction unit by crane.
2.
Remove two plugs (97) and drain lube oil from the reduction unit.
1
: 12 mm NOTE: Prepare an oil container before doing the work. Do not lift the reduction unit too high, but do the work at as low level as possible (height of your knees).
97
97
60
Removing cover 1.
Loosen bolts (96) and remove them.
2.
Then remove cover (95). : 8 mm
NOTE: Remove the cover as below. Liquid packing is applied between cover (95) and housing (72). For this reason, the cover is hard to come off. Loosen bolts (96) and tap the top and side faces of the removed cover (95) with a plastic mallet. Put a flat-blade screwdriver between cover (95) and housing (72) and take off cover (95).
96
72 95
W3-2-75
60
E245B
TRAVEL DEVICE
Removing thrust plate 1.
Separate thrust plate (94) from the top face of thrust plate (91).
91 94 60
Removing drive gear 1.
Remove drive gear (93).
93 60
Removing the 1st stage holder assy 1.
Remove the 1st stage holder assy that consists of holder B (85), planetary gear B (89), needle bearing (88), inner race (87), thrust plate (86), thrust plate (90), thrust plate (91) and screw (92). 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
Removing the 1st stage holder assy 1.
Fix the 1st stage holder assy in a vise and heat screw (92) with a hair dryer and loosen it.
2.
Separate screw (92), thrust plate (91), thrust plate (90), planetary gear B (89), needle bearing (88), inner race (87) and thrust plate (86), from the holder B, in that order.
92
: 8 mm
85 86
IMPORTANT: When loosening screw (92), exercise care of the following: Screw (92) is coated with Loctite and hard to get slack. If you loosen it by force, it is scored and can not be reused. Heat the screw with a hair dryer before loosening it.
89
88
87
90 91 60
Removing sun gear C 1.
Remove sun gear C (83).
83 60
W3-2-77
E245B
TRAVEL DEVICE
Removing planetary gear C 1.
Fix flange (1), loosen bolt (82) and remove it.
2.
Next, separate thrust plate (81), planetary gear C (80), needle bearing (79), inner race (78) and thrust plate (77), in that order.
1
: 17 mm
79
WARNING Bolt (82) is coated with adhesive Loctite to prevent it from loosening. Fix flange (1) securely for that reason. When loosening bolt (82), use a tool with a sufficiently long extension such as iron pipe. If you do not use it and try to loosen by force, you may injure your waist or other parts.
82
81
80
78
77 60
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
When loosening bolt (76), use care of the followin: Coat bolt (76) with screw locking agent to prevent it from loosening. For that purpose, fix flange (1) securely. 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
99 60
TRAVEL DEVICE
E245B
Separating flange from housing 1.
Attach a jig to the end face on the outer flange of housing and separate flange (1) from housing (72) by pressing flange (1) by press.
&
1
99 72
1
72 60
Removing floating seal 1.
Remove floating seal (70) by pushing up the outer circumference of floating seal (70) with a flat-blade screwdriver.
70 60
Storage of parts This completes disassembly. Clean the disassembled 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. NOTE: If the parts are stored in a hot humid place, they may be rusted even if rust preventive oil is applied. Keep the parts so no dust adheres to them.
W3-2-79
E245B
TRAVEL DEVICE
ASSEMBLING PROCEDURE OF TRAVEL DEVICE (E245B) Assembling floating seal into flange 1.
Confirm the below items concerning floating seal (70). Then assemble floating seal (70) to flange (1), using the floating seal fixing jig.
1 70
' 60
NOTE: Make certain that there is no dust on the surface of flange (1) in contact with floating seal (70). - Thoroughly degrease the surface where floating seal (70) of flange (1) is located. - Make sure that no dust is there on the O-ring of floating seal (70). - Thoroughly degrease the surface of the O-ring in floating seal (70).
71 72 71 (
(
60
2.
Assembling angular bearing (71) to housing (72).
3.
Press angular bearing (71) into housing (72), using a pressing (E) jig and a press.
4.
Make sure of the following as to floating seal (70). Then assemble floating seal (70) into housing (72), using the floating seal (D) fixing jig.
'
70 NOTE: Make certain that there is no dust and foreign matter on the surface on which floating seal (70) in housing (72) is located. - Thoroughly degrease the surface where floating seal (70) in housing (72) is located. - Make sure that there is no dust and foreign matter on the O-ring of floating seal (70). - Thoroughly degrease the surface of the O-ring in floating seal (70).
W3-2-80
72
60
TRAVEL DEVICE
E245B
Assembling housing into flange 1.
Make sure of the below items and assemble housing (72) into flange (1), using a crane, so floating seal (70) of flange (1) matches floating seal (70) of housing (72).
NOTE: Make certain that there is no foreign matter on the moving surface of the seal ring located in floating seal (70). - Apply lubricating oil for the reduction unit or hydraulic oil to all sliding surface of seal ring located in floating seal (70). - When assembling housing (72) into flange (1), make sure that the shaft centers are aligned with each other.
1
72
60
Selecting the thickness of shim 1.
Press the end face of the inner race of angular bearing (71) at a load of 3000 kgf (6600 lbf), using the shim thickness (F) adjusting jig.
2.
In that case, measure the step H between the end face of the inner race of angular bearing (71) and the end face of flange (1).
3.
Measure the step h at holder (74).
4.
Select and combine the repair kit (t=0.05, 0.1, 0.3, 0.5, 1.0) of shims (73) so as to attain shim thickness that matches (H-h).
IMPORTANT: Do not reuse shims (73) that were once used. - Do this work without fail. If pre-load adjustment is not done well, the reduction unit may be broken during operation. - Clean the measuring surface thoroughly.
W3-2-81
74 h Press load: 3000 kgf )
H 71
1 60
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 with holder C (74), using grease, match the pin holes in holder C (74) to the pins and press it in by press.
3.
74 73
Fit washer (75) to holder C (74), coat bolts (76) with Loctite and tighten the bolts to a specified torque.
99
: 17 mm : 539 Nm (397.5 lbf·ft)
1
NOTE: Use care of the assembling direction of washer (75). Check correct direction in the picture on the right.
73 74
NOTE: Confirm that pins (99) are not inclined. - Washer (75) is equipped with a spike to prevent it from getting slack. Fit the spike to the seat of holder C (74). - Thoroughly clean the threads of bolt (76), degrease it and coat it with adhesive Loctite. - Thoroughly clean and degrease the inside of the screw threads of flange (1).
99 76
75
75
60
Assembling planetary gear C 1.
Assemble thrust plate (77) to planetary gear C (80).
2.
Next, fit needle bearing (79) to planetary gear C (80).
3.
Finally, attach inner race (78).
4.
Then install planetary gear C (80) by engaging the bore diameter of inner race (78) with trunnions (four) of holder C (74).
NOTE: Assemble thrust plate (77) to planetary gear C (80) so the draft of the thrust plate (77) is located on holder C (74) side. - When the planetary gears C (80) are installed finally to the holder C (74), mesh the inner gear of housing (72) with gear of planetary gear C (80). - Use care of the assembling direction of planetary gear C (80).
72 74
80 79
78
77
80 77 79 78
74 60
W3-2-82
TRAVEL DEVICE
E245B
Assembling thrust plate 1.
Install planetary gear C (80) so the chamfer side in the bolt hole of thrust plate (81) comes below the neck of bolt (82).
2.
After placing it, coat the screw threads of bolt (82) with Loctite, attach bolt (82) and tighten it to a specified torque. : 8 mm : 539 Nm (397.5 lbf·ft)
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, degrease it and coat it with Loctite. Clean the screw threads in the tapped hole of holder C (74) thoroughly and degrease it thoroughly.
82
81
82
&
NOTE: Place so (C2) chamfer side comes on the seat side.
60
W3-2-83
E245B
TRAVEL DEVICE
Assembling sun gear C 1.
Make sure that snap ring (84) is fitted to sun gear (83).
2.
Then attach sun gear C (83) to four planetary gears C (80).
3.
Engage the teeth of planetary gear C (80) with those of sun gear C (83) and assemble them together.
80
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).
85
83 60
W3-2-84
TRAVEL DEVICE
E245B
Assembling planetary gear B 1.
Assemble thrust plate (86) to planetary gear B (89).
2.
Next, attach needle bearing (88) to planetary gear B (89).
3.
Finally, attach inner race (87), engage the bore with the trunnions (3 places) of holder B (85), and assemble planetary gear B (89) into holder B (85).
86 89 85
NOTE: Attach thrust plate (86) to planetary gear B (89) so the draft side (by press) of thrust plate (86) is located on the holder B side (85). - Finally, when assembling planetary gear B (89) to holder B (85), engage the inner gear teeth of housing (72) with the teeth of planetary gear B (89). - Be careful of the assembling direction of planetary gear B (89).
88
87 89
86 88 87
85 60
Assembling drive gear 1.
Attach thrust plate (90) to planetary gear B (89) and then attach thrust plate (91).
2.
Coat the threads of screw (92) with Loctite and tighten it to a specified torque.
91
90
89
: 8 mm : 58.8 Nm (43.4 lbf·ft) 3.
Assemble drive gear (93) to three planetary gears B (89) by directing the spline of drive gear (93) toward the motor assembling side.
4.
Then engage the teeth of planetary gear B (89) with the teeth of drive gear (93).
NOTE: Be careful about the assembling direction of thrust plate (90). Thoroughly clean and degrease the tapped hole in holder B (85) and the threads of screw (92).
W3-2-85
93
92
60
E245B
TRAVEL DEVICE
Attaching thrust plate 1.
Measure the step between the end face of housing (72) and thrust plate (94), using the thrust plate selecting jig, choose and attach thrust plate (94) according to the table below.
72 91 94
72 7
91 94 60
Unit: mm (in) Step dimension (T)
Thrust plate code
Shim thickness (t)
1.20 ~ 0.67 (0.0472 ~ 0.0264)
20941-62306
2.3
0.66 ~ 0.04 (0.0260 ~ 0.0016)
20941 - 62307
2.8
0.03 ~ -0.16 (0.00122 ~ -0.0063)
20941 - 62308
3.0
-0.174 ~ -0.41 (-0.00685 ~ -0.0161)
20941 - 62309
3.2
-0.42 ~ -0.80 (-0.0165 ~ -0.0315)
B0841 - 23017
3.6
NOTE: Align the hole in the center of thrust plate (94) with the convex part of drive gear (93) and assemble them together.
W3-2-86
TRAVEL DEVICE
E245B
Attaching cover 1.
Remove foreign matter completely from the matching surface between the end face of housing (72) and cover (95).
2.
Next, thoroughly degrease the matching surface between the end face of housing (72) and 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 specified torque.
72 95 96
60
: 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 and the level ports (3 in all) of cover (95), and tighten them to specified torque. : 12 mm : 157 Nm (115.8 lbf·ft)
95
98 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 Fitting oil seal 1.
Make sure that flange (1) is equipped with oil seal (53). If not, press oil seal (53) into flange (1), using the oil seal fixing jig (G).
IMPORTANT: Before attaching oil seal (53), apply grease to the bore surface of flange (1) (where the oil seal is placed) and outer diameter surface of oil seal (53). - Coat the lip of the bore of oil seal (53) with grease and put it in. - Push the oil seal upright. If it is tilted, the outer diameter of oil seal (53) will be scored. - Be careful so as not to score the lip of the bore of oil seal (53) when fixing it. If the lip is scored, oil leakage may occur and break the inside of the reduction gear while the motor is running.
*
1 60
Assembling piston 3 1. 2.
Place spring (61) in the hole where piston assy (48) of flange (1) is located.
48 61
Then, mount piston assy (48) to flange (1).
NOTE: Place spring (61) in the center of the hole. Install piston assy (48) with its cylindrical part facing downward. Before assembling piston assy (48), apply hydraulic oil to the bore of flange (1) and the outer surface of the cylindrical part of piston assy (48). After assembling piston assy (48), confirm that it moves smoothly.
1 60
W3-2-88
TRAVEL DEVICE
E245B
Fitting steel balls 1.
Fit steel balls (47) in the holes in the spherical surface of flange (1).
NOTE: Before fixing steel balls (47), apply hydraulic oil to the bore surface in the spherical part of flange (1) and steel balls (47).
47
1
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 (1).
36 49 ,
1
60
Installing swash plate 1.
Attach flange (1) so the inclined surface of swash plate (46) faces up.
46
NOTE: Assemble swash plate (46) by matching the holes in the rear spherical surface of the swash plate (46) to steel balls (47). After coating steel balls (47) with hydraulic oil and assemble swash plate (46). After assembling swash plate (46), make sure that the swash plate moves smoothly.
1
60
W3-2-89
E245B
TRAVEL DEVICE
Assembling cylinder block 1.
Place cylinder block (37) on a hand press bench so the sliding surface of valve plate (62) faces up.
2.
Assemble cylinder block (37) so the slope of spring seat (42) faces downward.
43
3.
Then mount spring (43) and collar (44) on spring seat (42), in that order.
42
4.
Press in the top face of collar (44), using a jig, and fix snap ring.
44
37
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 (J) and make sure that the claw of the snap ring pliers 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. To press in collar (44), align the center of the cylinder block with that of the press.
60
41
-
60
5.
6.
Place cylinder block (37) on a work bench so the sliding surface of cylinder block (37) in contact with valve plate (62) faces downward.
45
Place three pins (45) into the slanted holes in cylinder block (37).
IMPORTANT: Before placing cylinder block (37) on a work bench, make certain that there is nothing on the work bench. Use care so as not to score the sliding surface of valve plate (62) in cylinder block (37). If the surface is scored, the motor performances are deteriorated which leads to a failure of the motor in an early stage. Before fixing pins (45), coat the pin holes with grease.
W3-2-90
37
60
TRAVEL DEVICE 7.
E245B
Install retainer holder (40) to cylinder block (37).
37 40 60
8.
Attach piston assy (38) [9 pcs.] to retainer plate (39) so the tapered face of retainer plate (39) faces downward.
39
38 60
9.
Install piston assy (38) to cylinder block (37).
NOTE: Coat the piston holes (9 pcs.) in cylinder block (37) with hydraulic oil, before installing piston assy (38). Coat the spherical surface of retainer holder (40) with hydraulic oil, before assembling it.
37
38 60
W3-2-91
E245B
TRAVEL DEVICE
Assembling cylinder block 1.
Engage the inner tooth splines of retainer holder (40) and cylinder block (37) with the outer tooth spline of shaft (36) so the sliding surface of cylinder block (37) in contact with valve plate (62) faces upwards.
2.
Then assemble cylinder block (37) into flange (1).
NOTE: At assy, use care so piston assy (38), retainer plate (39) and retainer holder (40) do not come off from cylinder block (37). Before assy, coat the surface of swash plate (46) and the sliding surface of piston assy (38) with hydraulic oil.
37
1
60
Attaching disk plate 1.
Engage the inner teeth of disk plate (54) with the outer teeth of cylinder block (37) and mount them to flange (1).
2.
Assemble the convex portion of the outer circumference of friction plate (55) with the concavity of flange (1) and install them to flange (1).
3.
In this way attach disk plate (54) and friction plate (55) to the flange, in that order.
54 55 54
55
54
NOTE: Disk plate (54) is a wet type disk. Before assmbly, immerse the disk plate (54) in hydraulic oil so disk plate (54) sucks in sufficient hydraulic oil. 60
W3-2-92
TRAVEL DEVICE
E245B
Installing brake piston 1.
Attach O-rings (57), (58) to brake piston (56).
2.
Next, mount brake piston (56) to flange (1) so the larger diameter side of the brake piston faces upward.
56 IMPORTANT: Coat O-rings (57), (58) with sufficient grease, before fixing them. Align the knock pin hole in flange (1) in contact with base plate with the knock pin hole in brake piston (56), using the positioning jig (K). Then install brake piston (56). Before fitting brake piston (56), coat the outer surface of the brake piston and the bore of flange (1) with grease. Assemble brake piston (56) by pressing it so it does not tilt. If the brake piston is assembled inclined, it develops trouble and tears off O-rings in some cases.
.
57 58
56 1 60
Fitting springs 1.
Fit springs (59) into eight holes in brake piston (56).
59
60
W3-2-93
E245B
TRAVEL DEVICE
Attaching valve plate 1.
Place base plate (2) on a work bench and press bearing (50) in the center of base plate (2), using the bearing fixing jig (L).
2.
Confirm that knock pin (60) is fixed in base plate (2) and attach valve plate (62) to base plate (2).
NOTE: Place valve plate (62) with the copper alloy side facing upward. Coat the matching face between base plate (2) and valve plate (62) with grease to prevent the valve plate from falling off. Use care so as not to score the copper alloy surface of valve plate (62).
W3-2-94
62 /
50
2
60
TRAVEL DEVICE
E245B
Attaching base plate 1.
Fit O-rings (64) and O-rings (63) [4 places] to the top face of flange (1).
2.
Fit knock pin (60) to base plate (2).
3.
Attach base plate (2) to flange (1) so the surface of valve plate (62) in contact with base plate (2) faces downward.
4.
Then tighten them with socket bolts (52).
60
2
52 60
: 12 mm : 205 Nm (151.2 lbf·ft)
63 64
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 circumference.
W3-2-95
60
E245B
TRAVEL DEVICE
Assembling travel 2-speed select spool 1.
Attach spring (21) to spool (19).
2.
Then attach them to base plate (2).
3.
After placing spool (19), make certain that Oring (23) is set in plug (22), fit plug (22) to base plate (2) and tighten it to a specified torque.
4.
25 21 23
Next, make sure that O-ring (23) is fitted to plug (25), install spring guide (24) and washer (26), place plug (25) to base plate (2), and tighten it to a specified torque.
2 19
: 10 mm : 118 Nm (87 lbf·ft)
23 22 60
NOTE: Assemble spool A (19) into base plate (2) so that the pipe port surface of base plate (2) comes toward yourself and that the side of spool A (19) on which spring (21) is placed comes on the right. If the spool is assembled inversely, spool change may get out of order and other trouble may occur in some cases. Coat the outer surface of spool (19) with hydraulic oil, before assembling it. After spool (19) is placed, make certain that it moves smoothly.
W3-2-96
TRAVEL DEVICE
E245B
Assembling relief valve 1.
Make sure that poppet seat (17-3) is placed at the tip of relief valve (17).
2.
Then assemble relief valve (17) to base plate (2) and tighten them to a specified torque. : 27 mm : 373 Nm (275 lbf·ft)
17-17,18 NOTE: Replace O-ring (17-7) with a new one, before assembly. Make sure that O-ring (17-7) and backup ring (1718) are fitted to poppet seat (17-3). Coat O-ring (17-17) and backup ring (17-18) with grease, before assy.
2
17-3 17-7 17
60
Assembling counterbalance valve plunger 1.
Assemble plunger (3) to base plate (2).
NOTE: Assemble the plunger (3) to the base plate, while turning the plunger. Install plunger (3) straight. In case plunger (3) gets stuck, do not force it in, but tap it lightly with a plastic mallet. Coat the outer surface of plunger (3) with hydraulic oil before assmble.
2 3 60
W3-2-97
E245B
TRAVEL DEVICE
Attaching cap 1.
Attach spring seat (8) and spring (9), in that order, 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.
3.
Finally, fasten capscrew (13) to a specified torque.
33,34,14,15
: 10 mm : 108 Nm (79.7 lbf·ft)
8
17
9 10
NOTE: Coat O-ring (12) with grease. Cap (11) is pushed up by the action of spring (9). When tightening up socket bolts (13), hold them down by hand. Tighten four socket bolts (13) evenly all round. If cap (11) is tightened up tilted, O-ring (12) is damaged, resulting in oil leakage.
11,12 13
60
This completes assy of the hydraulic motor.
TOOL TABLE REF.
TOOL NO.
A
XXXXXXXXX
DESCRIPTION Torque multiplier
B
XXXXXXXXX
Stopper back-up ring flanged hub
C
XXXXXXXXX
Stopper O-Rings plugs
D
XXXXXXXXX
Stopper O-Rings flanged plug
E
XXXXXXXXX
Stopper O-Rings relief valve
F
XXXXXXXXX
Stopper O-Rings two speed control
G
XXXXXXXXX
Stopper fitting O-Rings plug
H
XXXXXXXXX
Tool half seal gearbox housing
W3-2-98
TRAVEL DEVICE
E245B
MAINTENANCE STANDARD Sprocket
% & '
(
$
60
IMPORTANT: Consult NEW HOLLAND KOBELCO S.p.A. for any inqueries concerning welding procedures. Standard mm (in)
Allowable Limit mm (in)
A
66 (2.57)
58 (2.26)
B
586 (22.85)
575 (22.42)
C
PCD644.6 (25.14)
-
D
659 (25.70)
649 (25.31)
E
190 (7.41)
-
W3-2-99
Remedy
Build up and finishing
E245B
TRAVEL DEVICE
NOTES
W3-2-100
SWIVEL JOINT
E215B-E245B
REMOVAL AND INSTALLATION OF SWIVEL JOINT 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.
NOTE: Be sure to run the vacuum pump continuously while working.
Removal NOTE: Attach labels or tags to hoses and adapters, to aid in assembly. 1.
Remove tubes (2 and 8) (PF1). : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf·ft)
Remove tube (5 and 6) (PF1/2). : 27 mm : 78.5 ±5 Nm (57.9 ± 3.7 lbf·ft)
2.
3.
4.
Remove tubes (3 and 4) (PF1/4). : 19 mm : 29.4 ±5 Nm (21.7 ± 3.7 lbf·ft)
Remove tubes (1 and 7) (PF1). : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf·ft)
60
W3-3-1
E215B-E245B 5.
SWIVEL JOINT
Remove drain hose (2).
: 27 mm : 78.5 ±5 Nm (57.9 ± 3.7 lbf·ft) 6.
Remove hoses (4 and 6). : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf·ft)
7.
Remove hoses (1 and 3). : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf·ft)
8.
Remove hose (5). : 19 mm : 29.4 ±5 Nm (21.7 ± 3.7 lbf·ft)
60
9.
Loosen the stop nut (7) M20 of swivel joint and remove the screw (8) M20x120.
: 36 mm : 157 Nm (115.8 lbf·ft)
60
10. Remove two adapters (9 and 10). : 19 mm : 36 Nm (26.6 lbf·ft)
60
W3-3-2
SWIVEL JOINT
E215B-E245B
11. Remove six screws (2) M10x25.
: 19 mm : 14.7 Nm (10.8 lbf·ft)
12. Remove clip (1). : 6.8 Nm (5.0 lbf·ft)
13. Remove seal (4).
60
14. Attach eye bolt (5), lift it up temporarily, and remove three screws (6) M12x35. : 19 mm : 108 Nm (79.7 lbf·ft)
NOTE: swivel joint mass: 31 kg (68.4 lbs).
60
Installation NOTE: refer to “Removal” section above for wrench sizes and tightening torque. 1.
Proceed with the re-installation of the centre joint following the operation in reversed order with respect to the removal.
NOTE: swivel joint mass: 31 kg (68.4 lbs).
W3-3-3
E215B-E245B
SWIVEL JOINT
SWIVEL JOINT DISASSEMBLY AND ASSEMBLY
View from X
Section G-G
60
1 2 3 4 5 6
-
Body Stem Thrust plate Cover Seal assy Seal assy
7 8 9 12 13
W3-3-4
-
O-Ring Socket Bolt (M8 x 20) Socket Bolt (M8 x 30) Plug O-ring
SWIVEL JOINT
E215B-E245B
Disassembly The part numbers used in this disassembly procedure 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
3.
Remove cover (4) from body (1) and draw out O-Ring (7) from cover (4).
60
4.
Loosen socket bolt (8) fastening thrust plate (3), in the same manner as the removing of the above-mentioned cover (4).
- When removing thrust plate (3) by fixing body (1), support stem (2) so it may not fall down. : 6 mm
60
W3-3-5
E215B-E245B 5.
SWIVEL JOINT
Place body (1) on a 'V' (A)-block. Put a wooden block against stem (2) via the body so about half of the stem is covered by the wooden block (B) and knock it out using a mallet. By hitting out the stem over about 1/2 from the body, it can be easily pulled out by hand.
%
$
6.
Remove the back-up ring of the seals assemblies (5 and 6) by means of a spatula (E).
60
(
NOTE: Make sure the body (1) is not scored from the tip of the spatula (E).
60
7.
Take off the slip ring (B) of the seals assemblies (5 and 6) by means of pin of screwdriver (A) and remove them from the O-Ring grooves (D). The figure on side shows the use of only one pin of screwdriver, but by using two screwdriver pins, these can be extracted with more sureness.
NOTE: Make sure the body (1) is not scored from the screwdriver (A).
&
% $ '
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 sequence 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 insert it into O-ring groove. Check the twist of Oring.
4.
Slipper ring (B) is assembled, after first inserting the backup ring, by slightly-distorting the shape as shown in figure. Also after inserting all of the seals, be certain that these are installed in the seal groove by use of the spatula.
5.
Assemble seal (5) by the same procedure above mentioned, after removing grease, hydraulic oil and vaseline from the groove of the seal. Seals (5) have no back-up ring.
6.
Lightly coat the outer circumference of stem (2) and the inner surface of body (1) with grease or vaseline and slowly insert stem (2) into body (1).
%
60
NOTE: If stem (2) is pressed in too fast, the seal may be damaged. Do it slowly. The clearance between body (1) and stem (2) is about 0.1 mm. Push stem straight along the shaft center.
60
*A: Push with both hands
W3-3-7
E215B-E245B
SWIVEL JOINT
7.
While holding stem (2) and body (1), match the hole of thrust plate (3) and the stem (2) hole.
8.
Next, after removing any oil from the thread of socket bolt (8), coat it with Loctite 242 and tighten to stem (2).
: 6 mm : 30.4 Nm (22.4 lbf·ft)
60
9.
After installing O-Ring (7) to cover (4) and aligning the matching marks of the cover (4) and body (1), coat socket bolt (9) with Loctite 242 and tighten it which will then complete assembly.
$
: 6 mm : 30.4 Nm (22.4 lbf·ft)
60
W3-3-8
SWIVEL JOINT
E215B-E245B
MAINTENANCE STANDARD Allowable Limit (basis of judgment)
Item Sliding surface and sealed parts
Body, Stem
Sliding surface exception sealed parts
Sliding surface ring
Cover
Sliding surface ring
Remedy
Scored or something hurt it.
Replace
1.
Scored more than 0.1 mm.
Replace
2.
Scored less than 0.1 mm.
Repair with oil stone
1.
Wear more than 0.5 mm deep.
Replace
2.
Wear less than 0.5 mm deep.
Repair
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
3.
Scored less than 0.5 mm and able to repair.
Repair
1.
Protruded excessively from seal groove.
Replace (with back-up ring)
60
2.
Slipper ring narrower than 1.5 mm of seal groove, or narrower than back-up ring.
Replace (with back-up ring)
Slipper ring
PPPD[
60
3.
Worn unevenly more than 0.5 mm.
PPPD[
Replace (with back-up ring)
60
W3-3-9
E215B-E245B
SWIVEL JOINT
Inspection after assembly After completion of assembly, inspection for oil leakage, pressure resistance, etc., using a device as shown in the figure on right. 1. High pressure port (A, B, C, D and F port). Install a directional valve (8) and pressure gauge (1) to the stem side port and body side port respectively, and while watching the pressure gauge (for high pressure) installed on the body side and also by regulating high pressure relief valve (7), gradually increase the pressure. When the pressure has reached 1.5 times the maximum working pressure, close stop valve (3) and lock in the hydraulic oil in the swivel. At this time, keep stop valve (6) on the low pressure relief valve side closed for, at least, 3 minutes and check for any distortions, breakages or loosening. During the first minute, check for oil leakages and, in case of pressure drop, this shoul be the 10% of the pressure trapped. This check should be performed on each circuit. 2.
Low pressure port (E port). Similar to the high pressure port, install a directional valve and pressure gauge on each port of the stem side and body side. Open stop valve (6) on the side of low pressure relief valve (5) and while watching the pressure gauge (for low pressure) connected to the body side and also by regulating low pressure relief valve (5), gradually increase the pressure and check for outside leakage with a color check at a pressure of 0.49 MPa.
60
123456789-
W3-3-10
Pressure Gauge Swivel Joint Stop Valve Hydraulic source Relief Valve for low pressure Stop Valve Relief Valve for high pressure Directional Valve Piping, etc.
TRACK ADJUSTER
E215B-E245B
REMOVAL AND INSTALLATION OF TRACK ADJUSTER (WITH FRONT IDLER) Before removing the track adjuster, the tracks and the front idler must be removed first. For removal and installation of the tracks and the front idler, refer to applicable removal/installation sections. In this section, the procedure starts on the premise that the tracks and the front idler have already been removed. Removal NOTE: Track adjuster assembly weight: 214 kg (472 lbs) (E215B) - 250 kg (551 lbs) (E245B). 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. 1.
After swinging superstructure to 90° related to machine longitudinal centerline for easier access to track components, remove the front idler and track adjuster assembly from track frame by prying it out, using a pry bar shown in figure.
60
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. 1.
As shown in figure, install the front idler and track adjuster into spring guide on track frame.
60
W3-4-1
E215B-E245B
TRACK ADJUSTER
DISASSEMBLY AND ASSEMBLY TRACK ADJUSTER Disassembly Track Adjuster Be sure to thoroughly read "Precautions for Disassembly and Assembly" on page W1-1-1 before starting the disassembly work.
$
Be sure to use special tool (A) (380001029) for assembly / disassembly of the 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 assembly work referring to the procedure below.
60
NOTE: Approximate weight of the track spring holder assembly: 229 kg (505 lbs) (E215B) - 265 kg (584 lbs) (E245B). 1.
Place a jack on the bottom of the track spring holder assembly (380001029).
2.
Loosen four nuts to remove the plate (A).
$
: 46 mm
60
NOTE: Track adjuster weight: 102 kg (225 lbs) (E215B) - 138 kg (304 lbs) (E245B). 3.
Connect the track adjuster to a hoist using a lifting strap. Put the track adjuster in the track spring holder assembly (380001029). Remove the lifting strap.
9
W3-4-2
60
TRACK ADJUSTER 4.
Draw out piston (6) from grease cylinder (1) of the idler adjuster assy.
5.
Removing oil seal (9), O-Ring (8) from grease cylinder (1).
6.
Set the idler adjuster assy on the stand of the jig, with its bracket side facing up.
E215B-E245B
60
7.
Fit retainer plate (A) to bracket (2), tighten holding-down nuts alternately, and secure idler adjuster assy.
: 46 mm
$
60
8.
Remove spring pin (4), press spring (5) lifting it with jack so that nut (3) can be turned freely, and remove nut.
: 46 mm : 75 mm
60
W3-4-3
E215B-E245B 9.
TRACK ADJUSTER
Allow the hydraulic jack to retract slowly till the spring is extended to its free length. Remove the retainer plate and take off bracket (2) and cover (11). : 46 mm
60
10. Hook lifting eye nut (W) to screw M48 on grease cylinder (1) top end and hoist it. Then, remove the set of grease cylinder (1) and spring (5) using crane from the jig. Remove spring (5), collar (7), grease cylinder (1), in that order.
:
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
2.
Install bracket (2) and cover (11) on top of spring (5). Center the rod of grease cylinder (1) and the holes in bracket (2). Attach the retainer plate (13) and four holding-down nuts (12). Fasten the nuts evenly all round and fix the idler adjuster assy to the jig body (380001029).
: 46 mm 3.
Extend the hydraulic jack, compress spring (5) to a set length and screw in nut (3) to the screwed part at the tip of grease cylinder (1). Set length of the spring 432 mm (E215B) 440 mm (E245B)
4.
Tighten nut (3) till the holes for locking spring pins (4) are aligned. Then fit spring pin (4). : 46 mm : 75 mm
W3-4-5
60
E215B-E245B 5.
TRACK ADJUSTER
Remove idler adjuster assy from jig (380001029).
NOTE: Track adjuster weight: 102 kg (225 lbs) (E215B) 138 kg (304 lbs) (E245B).
60
6.
Apply grase on the oil seal (9) and O-Ring (8) then fit them to grease cylinder (1).
7.
Fill up grease in cylinder (1), remove the grease nipple from piston (6) in order to discharge the inside air, and press in the piston by hand.
8.
Direct grease nipple hole downward to make air discharge easier.
9.
Tighten grease nipple (X) to piston (6).
;
: 19 mm : 59 Nm (43.5 lbf·ft)
TOOL TABLE TOOL NO. 380001029
DESCRIPTION
Jig stand track adjuster
W3-4-6
60
FRONT IDLER
E215B-E245B
DISASSEMBLY AND ASSEMBLY FRONT IDLER ASSY Disassembly 1.
Remove plug (8) on the side of collar (3) to drain oil.
: 5 mm
60
2.
To remove pin (5) apply pin push bar (A) (380001051) to the top of pin, and push out striking bar lightly by hammer.
$
60
Put idler on repair stand. Apply push-out jig on shaft (B) (380001052), push out shaft (6) with collar (3), then remove collar (3).
3.
%
60
* : Push with press
W3-5-1
E215B-E245B
If removal of collar (3) on the opposite side is required, turn over front idler and proceed with the procedure described in the previous step.
4.
FRONT IDLER
%
60
* : Push with press 5.
With idler (1) mounted on the stand, tap bushing (C) (380001053) lightly by hammer, while placing the bushing drawing rod against the end face of bushing (2) evenly all round, till it comes out.
6.
Take out floating seals (4) from idler (1), collar (3). If you intend to re-use floating seals (4), confirm that there is no scoring and rusting on the contact surface and store the floating seals in pairs by placing card board between the sealing faces.
7.
Separate O-Ring from shaft.
&
60
W3-5-2
FRONT IDLER
E215B-E245B
Assembly 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 inserted into bushing.
'
1.
60
* : Push with press 2.
Fit O-Ring (7) to O-Ring groove on shaft (6).
3.
Press fit the O-Ring installed side of shaft (6) into collar (3), and drive pin (5).
4.
Fit the half of floating seal (4) on each side of collar (3) and idler (1).
60
5.
6.
Install idler (1) on the shaft (6) with the floating seal (4) fitted into shaft (6) with the toward collar (3).
Fit floating seal (4) on the other side of idler (1).
60
7.
8.
Fit the half of floating seal (4) on the other collar (3), press fit it in shaft (6), and drive pin (5) in with hammer. Fill in 265 cm³ of engine oil AGIP SAE40RCL through the plug hole of collar (3), wind seal tape and tighten plug (8).
: 5 mm NOTE: After installing the idler assy to the idler adjuster assy, make certain that no oil leaks from floating seal and plug (8) and that idler (1) rotates smoothly. 60
W3-5-3
E215B-E245B
FRONT IDLER
MAINTENANCE STANDARD Front Idler
& '
( $ % 60
Unit: mm Standard
Allowable
A
84
66
B
159
-
C
500
482
D
540
-
E
20
-
Remedy
Buildup weld and finishing
IMPORTANT: Consult NEW HOLLAND KOBELCO for any inqueries concerning welding procedures.
Axle and Bushing Unit: mm Standard
Allowable
Axle
Outside Dia
75
74.2
Bushing
Inside Dia
75
76
Bushing
Flange thickness
2
1.2
TOOL TABLE TOOL NO.
DESCRIPTION
380001051
Pin push bar
380001052
Push-out jig
380001053
Punch for upper roller bushes
380001054
Bushing press-fitting jig
W3-5-4
Remedy Replace
UPPER AND LOWER ROLLER
E215B-E245B
REMOVAL AND INSTALLATION OF UPPER ROLLER 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
IMPORTANT: When gravel or mud is packed between sprockets and tracks, remove it before loosening. 1.
Loosen valve (1) to drain grease. : 19 mm
60
WARNING
Insert a piece of non-sliding rag between track frame (5) and hydraulic jack to prevent that the latter slides. 2.
Lift track chains (3) with the hydraulic jack to a height sufficient to remove upper roller (4).
60
3.
Insert a wooden block between tracks (3) and track frame (5).
W3-6-1
60
E215B-E245B 4.
UPPER AND LOWER ROLLER
Remove screws (2) from the support roller (1).
NOTE: Support roller mass 16.5 kg (36.4 lbs).
60
5.
Remove the upper roller (1) from the track frame (3).
NOTE: Support roller mass 16.5 kg (36.4 lbs).
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)
2.
Remove the wooden blocks and the hydraulic jack.
60
W3-6-2
UPPER AND LOWER ROLLER 3.
E215B-E245B
Supply grease to valve (3) throught nipple (4) to adjust tracks tension. Track sag specifications (A): 320 ÷ 350 mm : 19 mm : 59 Nm (43.5 lbf·ft)
NOTE: Check track sag after thoroughly removing soil stuck on the track area by washing.
60
60
4.
Add engine oil via plug (3) hole on cover (4). Apply sealant (Loctite 503 or equivalent) to plug (3). Tighten plug (3). Engine oil quantity: 0.2 kg : 6 mm : 23 Nm (17.0 lbf·ft)
W3-6-3
60
E215B-E245B
UPPER AND LOWER ROLLER
REMOVAL AND INSTALLATION OF LOWER ROLLER Removal
1.
Remove the roller guard and loosen bolts M18 (5). : 27 mm
60
2.
Lift the one side of the track frame high enough to remove the lower roller. Insert wooden blocks under track frame (2).
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
3.
Loosen valve (3) to drain grease enough to permit the roller removal. : 19 mm
W3-6-4
60
UPPER AND LOWER ROLLER
E215B-E245B
NOTE: Lower roller weight: 36.43 kg (80.3 lbs). 4.
Securely hold the lower roller using a fork lift. Remove lower roller (1).
60
Installation 1.
Securely hold the lower roller using a fork lift. Put lower rollers (1) on the tracks as illustration.
60
2.
Lower track frame (2) enough to allow bolts (4) to be installed into track frame (2).
60
3.
Align tapped holes in track frame (2). Tighten bolts M18 (5). : 27 mm : 400 Nm (295 lbf·ft)
60
W3-6-5
E215B-E245B 4.
UPPER AND LOWER ROLLER
Supply grease to valve (3) throught nipple (4) to adjust tracks tension. Track sag specifications (A): 320 ÷ 350 mm : 19 mm : 59 Nm (43.5 lbf·ft)
60
NOTE: Check track sag after thoroughly removing soil stuck on the track area by washing.
60
W3-6-6
UPPER AND LOWER ROLLER
E215B-E245B
UPPER ROLLER DISASSEMBLY 1.
Remove plug (3) and drain out oil.
: 6 mm 2.
Mount the end face inside upper roller (1) on stand jig (A) (XXXXXXXXX) and loosen bolts (12). : 19 mm
3.
Take off cover (9).
4.
Separeate O-Ring (11) from cover (9).
5.
Loosen two trust-washer bolts (13) and draw out trust-washer (10) from roller (1).
$
60
: 15 mm
6.
Put the extrusion jig (B) (XXXXXXXXX) against the end face of shaft (2) and push shaft with collar (8) to floating seals (6, 7) using a press or a hammer.
%
$
60
W3-6-7
E215B-E245B 7.
UPPER AND LOWER ROLLER
Take out floating seals (6, 7) from roller (1).
60
8.
Remove from collar (8) another floating seal (6) that is located on the side on which shaft (2) was disparted.
IMPORTANT: Collar (8) is press fitted into shaft (2) means of press. Therefore do not disassemble it.
60
9.
Since the bushings (4, 5) are thin, machine them on a lathe or scrape them off, exercise care so as not to damage the bore of roller (1). If the bushings are not worn much, mount upper roller (1) on jig (A) (XXXXXXXXX), and push out the bushings (4, 5) with punch (380001053) and hammer.
IMPORTANT: Hammer the surface of roller lightly so as not to damage the surface. Put the extrusion punch (380001053) uniformly over the circumference of bushings and extrude them perpendicularly little by little.
$
60
W3-6-8
UPPER AND LOWER ROLLER
E215B-E245B
UPPER ROLLER ASSEMBLY
&
1.
Assembly of the upper roller is done in the reverse order of disassembly.
2.
Place upper roller (1) on the top end face of jig (A) (XXXXXXXXX), with its floating seal setting side facing down.
3.
Confirm that the outer surface of bushing (5) is not seized and coat the outer surface of the inserting side of the bushing, with molybdenum disulfide grease.
Put jig (C) (XXXXXXXXX) into bushing (5) and press it in, using the bore of the bushing and the bore of the roller as guides.
4.
IMPORTANT: If you fail in this operation by pressing the bushing unevenly, the bushing is distorted and gets unserviceable. In that case, do not re-use the bushing as it may develop malfunctioning after assembly.
$
60
5.
Two floating seals (6) make a pair. Attach one floating seal to retainer fixed in shaft (2), and another to the inside of upper roller (1), placing O-rings (7). - Prior to placing floating seals (6), apply engine oil lightly to seal surface.
60
60
W3-6-9
E215B-E245B
UPPER AND LOWER ROLLER
6.
Coat shaft (2) with a thin film of oil and insert it into upper roller (1).
7.
Mount upper roller (1) on the stand jig (A) (XXXXXXXXX) and attach thrust-washer to the end face of the shaft (10) with bolt (13).
$
: 15 mm : 114.7 Nm (84.6 lbf·ft) 8.
Fit O-Ring (9) to the groove of cover (11). - Apply grease to O-Ring.
9.
Fit cover (9) to upper roller (1) and fix it with bolts (12).
: 19 mm 10. Fill in 0.2 cm3 of engine oil SAE40 through the plug hole in cover (3). 11. Wind seal tape around plug (3) and screw it into the plug hole of the upper roller (1). : 6 mm : 23 Nm (17.0 lbf·ft) - After assembling the upper roller, confirm that oil is not leaking from it and that it rotates smoothly by.
W3-6-10
60
UPPER AND LOWER ROLLER
E215B-E245B
LOWER ROLLER DISASSEMBLY
60
1.
Plug (Q.ty 2)
5.
Floating Seal (Q.ty 2)
2.
Collar (Q.ty 2)
6.
Bushing (Q.ty 2)
3.
Elastic pin (Q.ty 2)
7.
Roller
4.
O-Ring (Q.ty 2)
8.
Axle
W3-6-11
E215B-E245B
UPPER AND LOWER ROLLER
Disassembly Lower Roller Be sure to thoroughly read “Precautions for Disassembly and Assembly” on page W1-1-1 before starting the disassembly work. 1.
Remove plug (1) and elastic pins (3) from collars (2), and drain oil. : 6 mm
: 14 mm
60
2.
Press down axle (8) until O-Ring (4) comes out of collar (2). Remove collar (2) from axle (8).
3.
Remove O-Ring (4) from axle (8). Remove axle (8) from roller (7).
4.
Remove floating seal (5) from roller (7) and collar (2).
5.
Press out axle (8), and remove collar (2) and ORing (4) from axle (8).
60
6.
In case of replacing bushings (6), remove the bushings using a press and the special tool. Special Tool (380001030) (9).
60
W3-6-12
UPPER AND LOWER ROLLER
E215B-E245B
LOWER ROLLER ASSEMBLY
60
1.
Plug (Q.ty 2))
5.
Floating Seal (Q.ty 2)
2.
Collar (Q.ty 2)
6.
Bushing (Q.ty 2)
3.
Elastic pin (Q.ty 2)
7.
Roller
4.
O-Ring (Q.ty 2)
8.
Axle
W3-6-13
E215B-E245B
UPPER AND LOWER ROLLER
Assembly Lower Roller 1.
2.
Install bushings (6) (Q.ty 2) onto roller (7) using a press. Take care not to dent the flange surface of bushings. Apply a coat of grease to ORing (4) and install onto axle (8).
Install collar (2) onto axle (8), aligning the pin holes. Secure them using elastic pin (3). Take care not to damage O-Ring (4).
60
IMPORTANT: The elastic pin (3) has to be fitted with the slit oriented to the internal side of the roller.
IMPORTANT: For handling of floating seal (4), refer to the section “Precautions for floating seal handling” on page W1-1-3.
60
3.
Install floating seal (5) to roller (7) and to collar (2).
Insert axle (8) into roller (7). Install the other floating seal (5) to roller (7) and to collar (2). Install O-Ring (4) the other collar (2). Secure them using elastic pin (3).
IMPORTANT: The elastic pin (3) has to be fitted with the slit oriented to the internal side of the roller.
60
4.
Add engine oil via plug (1) hole on collar (2). Apply 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)
W3-6-14
60
UPPER AND LOWER ROLLER
E215B-E245B
MAINTENANCE STANDARD Upper Roller
&
$ %
60
Unit: mm Standard
Allowable Limit
A
84
-
B
150
-
C
140
130
Remedy Replace
Lower Roller
'
$ %
&
&
60
Unit: mm Standard
Allowable Limit
A
172
181.5
B
218
-
C
23
11.5
D
150
132
W3-6-15
Remedy Buildup weld and finishing
E215B-E245B
UPPER AND LOWER ROLLER
Upper roller axle and bushing Unit: mm Standard
Allowable Limit
Axle
Outside Dia.
45
44.7
Bushing
Inside Dia.
45
45.3
Remedy Replace
Lower roller axle and bushing Unit: mm Standard
Allowable Limit
Outside Dia.
65
64.2
Bushing
Inside Dia.
65
66
Bushing
Flange Thickness
2
1.2
Axle
TOOL TABLE DESCRIPTION
TOOL NO. 380001053
Punch for upper roller bushings
XXXXXXXXX
Stand jig upper roller
XXXXXXXXX
Stopper shaft upper roller
XXXXXXXXX
Stopper bushings upper roller
380001030
Push-out jig bushings lower roller
W3-6-16
Remedy Replace
TRACKS
E215B-E245B
REMOVAL AND INSTALLATION OF TRACKS 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
1.
Move the tracks so that master pin (3) is positioned over front idler (4). Put a wooden block under track shoes (5), as shown.
60
2.
To loosen the track tension, slowly turn valve (1) counterclockwise one turn; grease will escape from grease outlet. : 19 mm
W3-7-1
60
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
3.
Remove master pin (5) by using a special tool.
60
A: 380001008 B: 380001009 C: 380001013 (E215B); 380001010 (E245B) D: 380001012 (E215B); 380001011 (E245B) E: 380001015 (E215B); 380001016 (E245B) G: 380001019 5: MASTER PIN
' &
*
%
(
$ 60
4.
Slowly drive the machine in reverse until the whole length of the removing track comes on the ground.
60
5.
Rotate the upperstructure 90 degrees toward the removing track side, perpendicular to the tracks. Operate the boom and arm so that the angle between them is 90 to 110 degrees. Lower the boom with the bucket rolled-in to jack up the machine as illustrated.
60
W3-7-2
TRACKS
E215B-E245B
Installation 1.
O OO
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
2.
Lift the track, and place it on sprocket (1).
60
3.
Slowly turn the sprocket in forward direction.
60
4.
Turn sprocket (1) until end of track (4) comes on front idler (3). Lower the machine and put a wooden block as illustrated.
60
W3-7-3
E215B-E245B
TRACKS
IMPORTANT: hole surfaces, link holes and counterbore surfaces, bushing ends, shall be free from dust and rust. 5.
Install master pin (5), using a hammer and special tool. A: 380001008 B: 380001009 C: 380001013 (E215B); 380001010 (E245B) D: 380001012 (E215B); 380001011 (E245B) E: 380001015 (E215B); 380001016 (E245B) G: 380001019 5: MASTER PIN
60
IMPORTANT: inject rust preventive protective (ex. TECTYL165 G) between pin and bushing clearance.
IMPORTANT: if any links have been removed from the track, be sure to charge the grease into the clearance between the pin and bushing when reconnecting the links. Also, apply a coat of grease tothe ends of the bushing. Grease Charging Method: - Stand the bushing on a flat plate. - Fill the bushing bore with the grease. - Insert the pin into the bushing while pushing the bushing onto the plate (so that the bushing end stays on the plate). - Wipe off excess grease.
6.
' &
*
%
(
$ 60
Supply grease to the cylinder through the grease fitting to adjust the track tension. : 19 mm
When proper track sag is obtained, turn value clockwise and tighten.
60
Track sag specifications (A): 320 to 350 mm : 19 mm : 59 Nm (43.5 lbf·ft)
IMPORTANT: check track sag after thoroughly removing soil stuck on the track area by washing.
60
W3-7-4
TRACKS
E215B-E245B
MAINTENANCE STANDARD Link Pin and Track Bushing • •
Measure the length of four links, as illustrated, with the tension on the track. Do not measure the master-pin included part of the track.
$ 60
Unit: mm Standard A
Allowable Limit
E215B
E245B
E215B
E245B
761
760
774
778
Remedy Replace
Master Pin
(%
%
(%
$ 60
60
Unit: mm Standard E215B
Allowable Limit
E245B
E215B
E245B
A
207
220
200
-
B
38
39.7
36.5
37
W3-7-5
Remedy Replace
E215B-E245B
TRACKS
Master Bushing
%
&
$ 60
Unit: mm Standard
Allowable Limit
E215B
E245B
A
129.2
135
B
38
C
58.7
E215B
Remedy
E245B
-
-
40 ++00.87
39.5
42.8
60
54.1
57
Replace
Grouser Shoe
& % $ 60
Unit: mm Standard
Allowable Limit
E215B
E245B
E215B
E245B
A
220
222.5
-
-
B
9.5
12.5
-
-
C
25.5
28
15
14
W3-7-6
Remedy
Replace
TRACKS
E215B-E245B
TOOL TABLE DESCRIPTION
TOOL NO. 380001008
Tool fitting/pushing-out master pin
380001009
Tool fitting/pushing-out master pin
380001010
Tool fitting/pushing-out master pin (E245B)
380001011
Tool fitting/pushing-out master pin (E245B)
380001012
Tool fitting/pushing-out master pin (E215B)
380001013
Tool fitting/pushing-out master pin (E215B)
380001015
Tool fitting/pushing-out master pin (E215B)
380001016
Tool fitting/pushing-out master pin (E245B)
380001019
Tool fitting/pushing-out master pin
W3-7-7
E215B-E245B
TRACKS
NOTES
W3-7-8
SECTION 4
FRONT ATTACHMENT
CONTENTS Group 1 - Front attachment Front attachment removal and installation W4-1-1 Monoblock version ............................ W4-1-1 Maintenance ..................................... W4-1-6 Triple articulation version .................. W4-1-7 Maintenance ..................................... W4-1-12 Standard dimensions for arm and bucket connection............................................. W4-1-13 Replacement of bucket .......................... W4-1-14 Removing the bucket ....................... W4-1-14 Installing the bucket ......................... W4-1-14 Bucket play adjustment..................... W4-1-14 Bucket teeth replacement ................. W4-1-15 Cylinders removal and installation ......... W4-1-16 Bucket Cylinder removal ................... W4-1-16 Bucket Cylinder installation............... W4-1-18 Arm cylinder removal ........................ W4-1-19 Arm cylinder installation .................... W4-1-20 Boom cylinders removal ................... W4-1-21 Boom cylinders installation .............. W4-1-22 Positioner cylinder removal............... W4-1-23 Positioner cylinder installation .......... W4-1-24 Cylinders assembly and disassembly .... W4-1-25 Bucket cylinder ................................. W4-1-25 Arm cylinder ...................................... W4-1-28 Positioner cylinder ............................ W4-1-31 Boom cylinders ................................. W4-1-34 Special tools ..................................... W4-1-37 Maintenance standard: rod ............... W4-1-38
E215B-E245B
FRONT ATTACHMENT
E215B-E245B
FRONT ATTACHMENT REMOVAL AND INSTALLATION Monoblock version 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.
2.
Disconnect lubrication hoses (1) from boom cylinder rod end. : 17 mm
3.
Loosen lock nuts (2), remove bolt (3) and stopper (4) from boom cylinder rod end. Carry out the same procedure for the other boom cylinder. : 24 mm
SM0200
5
4.
Attach each boom cylinder to a crane.
1
3
NOTE: boom cylinder weight: 176 kg Remove cylinder rod end pin (5) and shims (6) using a hammer and bar.
4 2 SM0201
3
5 4 2 2 6 4 3
W4-1-1
SM0202
E215B-E245B
FRONT ATTACHMENT
5.
Slowly lower the boom cylinder using the crane onto the wooden block.
6.
Press the valve located on the hydraulic oil tank to bleed the residual pressure inside the tank itself. Complete the bleeding of the residual pressure from the hydraulic system, making reference to "Procedure for the bleeding of the pressure from the hydraulic system" at page T2-1-47.
7.
Disconnect hoses (7) and (8) of bucket cylinder and arm cylinder.
SM0203
9
9
10
NOTE: if the machine is equipped with the hammer/ crusher, bucket rotation or anti-drop valves variants, disconnect the relevant hoses (9), (10) and (11). 8
11
11
: 41 mm
7
7 8
Bucket (7) and arm (8) cylinder hoses:
10
: 36 mm Hammer/crusher hoses (9): : 41 mm
SM0204
: 12 mm Bucket rotation hoses (10): : 27 mm
12
Anti-drop valves hoses (11): : 22 mm Close all openings with plugs to keep clean.
8.
Disconnect centralised lubrication hoses (12) located between the boom cylinders. : 17 mm
SM0205
14
9.
Remove panel (13) by removing securing screws (14). : 19 mm
13
SM0206
W4-1-2
FRONT ATTACHMENT
E215B-E245B
10. Remove work light and bracket by removing securing screws (15). : 17 mm
16 18
11. Disconnect fuel transfer pump hose (16). : 41 mm 15
12. Loosen lock nuts (17) and remove bolt (18). : 30 mm
17
SM0207
13. Sling the boom to a hoist. Slightly lift the boom. NOTE: approximate mass of the front equipment: 3450 kg.
SM0208
14. Pull out the boom lower pivot pin (20) to the frame using the appropriate puller (XXXXXXXX).
20
15. Lift the front attachment. Move the machine away from the front attachment and the hoist.
W4-1-3
SM0209
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 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. 2. 3.
18
15
Install boom foot pin (20) using a hammer and bar.
20 17
Install bolt (18) and tighten lock nuts (17). SM0210
: 30 mm : 200 Nm 4.
14
Install fuel transfer pump hose (16).
13
: 41 mm : 30 Nm 5.
Install work light and bracket by removing securing screws (15). : 17 mm : 15 Nm
6.
Install panel (13) by tightening securing screws (14).
SM0206
: 19 mm : 80 Nm 7.
Connect hoses (7) and (8) of bucket cylinder and arm cylinder.
NOTE: if the machine is equipped with the hammer/ crusher, bucket rotation or anti-drop valves variants, connect the relevant hoses (9), (10) and (11).
9
9
10
8 11
Bucket (7) and arm (8) cylinder hoses:
7
7 8
10
11
: 41 mm : 206 ± 21 Nm : 36 mm SM0204
: 177 ± 18 Nm Bucket rotation hoses (10):
Hammer/crusher hoses (9):
: 27 mm
: 41 mm
: 78 ± 5 Nm
: 206 ± 21 Nm
Anti-drop valves hoses (11):
: 12 mm
: 22 mm
: 150 ± 10 Nm
: 49 ± 5 Nm
W4-1-4
FRONT ATTACHMENT 8.
E215B-E245B
Attach the boom cylinder to a crane.
NOTE: boom cylinder weight: 176 kg Lift the boom cylinder and align the boom cylinder rod with the pin hole on the boom. NOTE: for easy alignment, start the engine and use the boom control lever.
9.
Install shims (6) and insert pin (5).
10. Install stopper (4), tighten bolts (3) and lock nuts (2):
SM0211
: 24 mm : 147 Nm
3
11. Connect lubrication hoses (1) to boom cylinder rod.
5 4 2
: 17 mm : 20 Nm
2 6
12. Connect centralised lubrication hoses (12) located between the boom cylinders.
4 3
: 17 mm
SM0202
: 20 Nm Using a grease gun, inject grease via nipples (21) (boom) and (22) (boom cylinders).
5 1
3
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.
4
IMPORTANT: bleed air from hydraulic circuit.
2 SM0201
12
22
21
22
SM0212
W4-1-5
E215B-E245B
FRONT ATTACHMENT
Maintenance: monoblock version
A
B
H
G
E
F
J
C
D
K
I SM0213
Unità di misura: mm Standard
Allowable limit
Pin
90
89
Bushing
90
91.5
Pin
85
84
Boss (Main Frame)
85
86.5
Bushing (Boom Cylinder)
85
86.5
Pin
85
84
Parts name A
B
C
D
E
F
G
H
I J K
Bushing (Boom Cylinder)
85
86.5
Foro (Boom)
85
86.5
Pin
90
89
Bushing
90
91.5
Pin
85
84
Boss (Arm)
85
86.5
Bushing (Arm Cylinder)
85
86.5
Pin
85
84
Boss (Boom)
85
86.5
Bushing (Arm Cylinder)
85
86.5
Pin
80
79
Boss (Arm)
80
81.5
Bushing (Bucket Cylinder)
80
81.5
Pin
80
79
Bushing
80
81.5
Bushing (Bucket Cylinder)
80
81.5
Pin
70
69
Bushing
70
71.5
Pin
80
79
Bushing
80
81.5
Pin
80
79
Bushing
80
81.5
IMPORTANT: be sure to install front attachment bushings using a press.
W4-1-6
Remedy
Replace
FRONT ATTACHMENT
E215B-E245B
Triple articulation version 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.
2.
Disconnect lubrication pipes (1) from boom cylinder rod end. : 17 mm
3.
Loosen lock nuts (2), remove bolt (3) and stopper (4) from boom cylinder rod end. Carry out the same procedure for the other boom cylinder. : 24 mm
SM0215
3
4.
Attach each boom cylinder to a crane.
1
5
NOTE: boom cylinder weight: 176 kg Remove cylinder rod end pin (5) and shims (6) using a hammer and bar.
2
4
SM0216
3
5 4 2
2 6 4 3
W4-1-7
SM0217
E215B-E245B
FRONT ATTACHMENT
5.
Slowly lower the boom cylinder using the crane onto the wooden block.
6.
Press the valve located on the hydraulic oil tank to bleed the residual pressure inside the tank itself. Complete the bleeding of the residual pressure from the hydraulic system, making reference to "Procedure for the bleeding of the pressure from the hydraulic system" at page T2-1-47.
7.
Disconnect hoses (12), (7) and (8) of positioner cylinder, bucket cylinder and arm cylinder.
NOTE: if the machine is equipped with the hammer/ crusher, bucket rotation or anti-drop valves variants, disconnect the relevant hoses (9), (10) and (11).
SM0218
9
10
9
Positioner cylinder hoses (12) (from the control valve): : 30 mm
8
Bucket (7) and arm (8) cylinder hoses:
8 11
: 41 mm : 36 mm
7
7
11 12
12 SM0219
Hammer/crusher hoses (9): : 41 mm : 12 mm
13
Bucket rotation hoses (10): : 27 mm Anti-drop valves hoses (11): : 22 mm Close all openings with plugs to keep clean. SM0220
8.
9.
Disconnect centralised lubrication hoses (13) located between the boom cylinders. : 17 mm
15 14
Remove panel (14) by removing securing screws (15). : 19 mm
SM0221
W4-1-8
FRONT ATTACHMENT
E215B-E245B
10. Remove work light and bracket by removing securing screws (16). : 17 mm
17 19
11. Disconnect fuel transfer pump hose (17). : 41 mm 16
12. Loosen lock nuts (18) and remove bolt (19). : 30 mm
18
SM0222
13. Sling the boom to a hoist. Slightly lift the boom. NOTE: approximate mass of the front equipment: 4100 kg.
SM0223
14. Pull out the boom lower pivot pin (21) to the frame using the appropriate puller (XXXXXXXX).
21
15. Lift the front attachment. Move the machine away from the front attachment and the hoist.
W4-1-9
SM0224
E215B-E245B
FRONT ATTACHMENT
Installation 1.
Lift the front attachment.
NOTE: approximate mass of the front equipment: 4100 kg 16
Install dust seals to boom foot. Align the boom foot boss with the main frame boss. Insert a 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. 2.
Install boom foot pin (20) using a hammer and bar.
3.
Install bolt (18) and tighten lock nuts (17).
18
15
20 17
: 30 mm SM0210
: 200 Nm 4.
Install fuel transfer pump hose (16).
14
: 41 mm
13
: 30 Nm 5.
Install work light and bracket by removing securing screws (15). : 17 mm : 15 Nm
6.
Install panel (13) by tightening securing screws (14). : 19 mm : 80 Nm
7.
SM0206
Connect bucket cylinder hoses (7), positioner cylinder hoses (12) and arm cylinder hoses (8).
NOTE: if the machine is equipped with the hammer/ crusher, bucket rotation or anti-drop valves variants, connect the relevant hoses (9), (10) and (11).
9
10
9
Positioner cylinder hoses (12) (from the control valve): : 30 mm
8
: 83 ± 5 Nm
8
Bucket (7) and arm (8) cylinder hoses:
11
: 41 mm : 206 ± 21 Nm
11 12
: 36 mm
Bucket rotation hoses (10):
: 177 ± 18 Nm
: 27 mm
Hammer/crusher hoses (9):
: 78 ± 5 Nm
: 41 mm
Anti-drop valves hoses (11):
: 206 ± 21 Nm
: 22 mm
: 12 mm
: 49 ± 5 Nm
: 150 ± 15 Nm
W4-1-10
7
7
12 SM0219
FRONT ATTACHMENT 8.
E215B-E245B
Attach the boom cylinder to a crane.
NOTE: boom cylinder weight: 176 kg Lift the boom cylinder and align the boom cylinder rod with the pin hole on the boom. NOTE: for easy alignment, start the engine and use the boom control lever.
9.
Install shims (6) and insert pin (5).
10. Install stopper (4), tighten bolts (3) and lock nuts (2): : 24 mm : 147 Nm
3
11. Connect lubrication hoses (1) to boom cylinder rod.
5 4 2
: 17 mm : 20 Nm
2
12. Connect centralised lubrication hoses (12) located between the boom cylinders. : 17 mm
6 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. IMPORTANT: bleed air from hydraulic circuit.
2
4
SM0216
12
22
21
22
SM0212
W4-1-11
E215B-E245B
FRONT ATTACHMENT
Maintenance: triple articulation version
E
F
A
B
L
C
G
M
H
D
N
J
K
I SM0238
Unità di misura: mm Standard
Allowable limit
Pin
90
89
Bushing
90
91.5
Pin
90
89
Boss (Main Frame)
90
91.5
Bushing (Boom Cylinder)
90
91.5
Pin
85
84
Parts name A-D-N
B
C
E
F
G
H
I J-K
L
M
Bushing (Boom Cylinder)
85
86.5
Boss (Boom)
85
86.5
Pin
90
89
Boss (Positioner)
90
91.5
Bushing (Positioner Cylinder)
90
91.5
Pin
90
89
Boss (Boom)
90
91.5
Bushing (Positioner Cylinder)
90
91.5
Pin
80
79
Boss (Arm)
80
81.5
Bushing (Bucket Cylinder)
80
81.5
Pin
80
79
Bushing
80
81.5
Bushing (Bucket Cylinder)
80
81.5
Pin
70
69
Bushing
70
71.5
Pin
80
79
Bushing
80
81.5
Pin
85
84
Boss (Positioner)
85
86.5
Bushing (Arm Cylinder)
85
86.5
Pin
85
84
Boss (Arm)
85
86.5
Bushing (Arm Cylinder)
85
86.5
IMPORTANT: be sure to install front attachment bushings using a press. W4-1-12
Remedy
Replace
FRONT ATTACHMENT
E215B-E245B
STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION o
q
p
g h
k
i j Section A d
l m
B c
n
e b
a
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
→
(*) Arm: 2940 mm
Unit: mm
W4-1-13
E215B-E245B
FRONT ATTACHMENT
MAINTENANCE TO BE PERFORMED WHEN REQUIRED 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. Removing the bucket • Place the machine on a firm and flat surface and rest the bucket on the ground in a stable position. • Place O-rings (1) out of the relevant seats. Remove the pins and the retaining rings of the pins. • Remove pin (E) and pin (B); then remove the bucket.
Installing the bucket • Using a suitable hoist, place the bucket on the same level as the tracks. • Position the O-Rings (1)outside their seats. • Using the arm cylinder control and boom cylinder control make small vertical and horizontal movements to insert pivot pin (B) connecting the bucket to the arm into hole (A). • Use the bucket cylinder control to align the connecting rod (C) to hole (D)and insert pivot pin (E). • Secure pivot pins using lock pins and retaining rings and reposition the O rings into their seats.
IMPORTANT: during the removal of the bucket, take care that the pin are not contaminated by dirt, sand etc. After the reinstallation of the bucket, provide grease to the pins through the appropriate fittings.
Bucket play adjustment Bucket play (g) is adjusted by opportunely changing total shims installed. NOTE: bucket play (g) should be 0.5 to 1.5 mm. If bucket play (g) exceeds the specified value, increase adjust shims as follows: • loosen the three bolts (2) taking care to retrieve the washers. Slide out the ring (1); • Add adjust shims (3) until compensating the play (g); • Install the ring (1), and tighten securing bolts (2).
W4-1-14
FRONT ATTACHMENT Bucket teeth replacement
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.
• Ensure the machine is parked on a level surface. • Rest the bucket to the ground. • Switch off the Auto-Idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the safety lever in the locked position (LOCK). • Use a hammer and punch to push lock pin (1) out of its seat and remove the tip of bucket tooth (2). NOTE: to push lock pin (1) out of its seat, strike it with a punch on its upper side. • Install a new rubber insert (3) inside lock pin (1). • Clean the surface of bucket tooth (4) and insert a new tip. • Insert lock pin (1) into its seat using a punch and hammer, until it is fully mounted.
W4-1-15
E215B-E245B
E215B-E245B
FRONT ATTACHMENT
CYLINDERS REMOVAL AND INSTALLATION 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.
Bucket Cylinder removal 1.
Park the machine on firm, level ground. Position the front attachment as illustated and lower the bucket to the ground.
2.
Press the valve located on the hydraulic oil tank to bleed the residual pressure inside the tank itself.
3.
Insert wooden block (3) between bucket cylinder (1) and arm (2). SM0200
4.
Complete the bleeding of the residual pressure from the hydraulic system, making reference to "Procedure for the bleeding of the pressure from the hydraulic system" at page T2-1-47.
1
3
IMPORTANT: Pin (6) end of the link will drop when pin is removed, possibly resulting in personal injury. Be sure to secure the link using a wire before removing pin (6).
2
SM0226
5.
Loosen lock nuts (4) and remove bolt (5). Pull-out pin (6) with the help of a mallet and a bar so that the end of the cylinder is free, then remove adjusting shims (7).
7
4
6
: 24 mm 5
SM0227
W4-1-16
FRONT ATTACHMENT 6.
E215B-E245B
Disconnected hoses (8) from bucket cylinder (1).
9
12
: 10 mm
11
: 36 mm Put plugs on cylinder pipes and hoses.
10 1
NOTE: bucket cylinder weight: 153 kg
7.
Using a hoist, slightly lift bucket cylinder (1). Loosen locking nuts (9) remove screw (10) and pull-out pin (11) with the help of a mallet and a bar so that the end of the cylinder is free, then remove adjusting shims (12).
8
8
: 24 mm
8.
Remove bucket cylinder (1).
SM0228
W4-1-17
E215B-E245B
FRONT ATTACHMENT
Bucket Cylinder installation NOTE: bucket cylinder weight: 153 kg
9
12
1.
2.
11
Connect bucket cylinder (1) to a crane using a sling belt. Align the hole of the bucket cylinder with the pin hole on the arm-tip bracket. Install adjusting shims (12) and insert pin (11). Install screw (10) and tighten lock-nuts (1).
10 1
: 24 mm
8
: 147 Nm 3.
Connect two hoses (8) to bucket cylinder (1).
8
: 10 mm : 83 ± 5 Nm : 36 mm : 177 Nm 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. 4.
SM0228
Align the bucket cylinder rod with bucket links (13) and (14). Install shims (7) and pin (6).
NOTE: for easy alignment, start the engine and use the arm control lever. 7
5.
4
6
Install bolt (5) onto pin (6) then tighten lock nuts (4). : 24 mm
5
: 147 Nm
14
IMPORTANT: if link (13) has been disconnected from the arm, be sure to insert shims (7) when connecting it. Bleed air from hydraulic circuit.
13
SM0229
W4-1-18
FRONT ATTACHMENT
E215B-E245B
Arm cylinder removal 1.
Insert a wooden block (3) between arm cylinder (1) and boom (2). 1
2.
3.
Press the valve located on the hydraulic oil tank to bleed the residual pressure inside the tank itself. Complete the bleeding of the residual pressure from the hydraulic system, making reference to "Procedure for the bleeding of the pressure from the hydraulic system" at page T2-1-47.
3 2 SM0230
Loosen lock nuts (4), remove bolt (5) and pullout pin (6) with the help of a mallet and a bar so that the end of the cylinder is free, then remove adjusting shims (7).
7
6
4
: 24 mm 5
4.
Disconnected hoses (8) and (9) from arm cylinder. Put plugs on cylinder pipes and hoses. : 10 mm : 36 mm SM0231
5.
Disconnect lubrication hose (10). : 17 mm
8
NOTE: arm cylinder weight: 255 kg
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 and a bar so that the end of the cylinder is free, then remove adjusting shims (14).
10
9
: 24 mm
7.
SM0232
14
Remove arm cylinder (1).
11
13
12
SM0233
W4-1-19
E215B-E245B
FRONT ATTACHMENT
Arm cylinder installation NOTE: arm cylinder weight: 255 kg 1.
Using a crane, align the hole of the arm cylinder with the pin hole on the boom-tip bracket.
2.
Install adjusting shims (14), pin (13), install screw (12) onto pin (13) and tighten lock-nuts (11).
14
13
11
: 24 mm : 147 Nm 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
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. 4.
Slightly lift arm cylinder and align the arm cylinder rod with the pin hole on the arm.
NOTE: for easy alignment, start the engine and use the arm control lever. 5.
8
10
9
Install adjusting shims (7), pin (6), install screw (5) onto pin (6) and tighten lock-nuts (4).
SM0232
: 24 mm : 147 Nm
7
4
6
IMPORTANT: bleed air from hydraulic circuit. 5
SM0231
W4-1-20
FRONT ATTACHMENT
E215B-E245B
Boom cylinders removal 1.
2.
Park the machine on firm, level surface and lower the bucket teeth and arm top to the ground with the arm and bucket cylinders fully retracted.
5 1
3
Disconnect lubrication hoses (1). : 17 mm
3.
Loosen lock nuts (2), remove bolt (3) and stopper (4) from boom cylinder rod end. : 24 mm
4 2 SM0201
NOTE: boom cylinder weight: 176 kg 3
4.
Attach boom cylinder to a crane.
5.
Slowly lower the boom cylinder using the crane onto the wooden block.
6.
Press the valve located on the hydraulic oil tank to bleed the residual pressure inside the tank itself. Complete the bleeding of the residual pressure from the hydraulic system, making reference to "Procedure for the bleeding of the pressure from the hydraulic system" at page T2-1-47.
7.
5 4 2 2 6 4 3
SM0202
Disconnect hoses (7) of boom cylinder. Put plugs on cylinder pipes and hoses. : XX mm
: 30 mm 7
8.
Disconnect centralised lubrication hoses (10) located between the boom cylinders. : 17 mm
9.
9 8
Remove securing screws (8) complete with washers, then remove pin (9) and adjusting shims (10).
SM0234
: 24 mm 10. Using a hoist, lift boom cylinder. Remove the other boom cylinder following the same procedure.
10
10
SM0235
W4-1-21
E215B-E245B
FRONT ATTACHMENT
Boom cylinders installation NOTE: boom cylinder weight: 176 kg 1.
Using a crane, install the boom cylinders to the main frame.
2.
Install adjusting shims and pin (9), then tighten securing screws (8) complete with washers.
7
: 24 mm : 540 Nm 3.
4.
9 8
Connect lubrication hose (7) to boom cylinder. : 30 mm
: 36 mm
: 137 Nm
: 206 Nm
SM0234
Connect centralised lubrication hoses (10) located between the boom cylinders.
10
10
: 17 mm : 20 Nm 5.
Install shims (6) and insert pin (5).
6.
Install stopper (4), tighten bolts (3) and lock nuts (2): : 24 mm : 147 Nm
7.
SM0235
Connect lubrication hoses (1) to boom cylinder rod.
3
: 17 mm : 20 Nm 5 4 2
8.
Using a grease gun, inject grease via nipples (10).
2
Install the other boom cylinder following the same procedure. 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.
6 4 3
SM0202
5
IMPORTANT: bleed air from hydraulic circuit.
1
3
4 2 SM0201
W4-1-22
FRONT ATTACHMENT
E215B-E245B
Positioner cylinder removal 1.
Insert a wooden block (3) between positioner cylinder (1) and boom (2).
2.
Press the valve located on the hydraulic oil tank to bleed the residual pressure inside the tank itself. Complete the bleeding of the residual pressure from the hydraulic system, making reference to "Procedure for the bleeding of the pressure from the hydraulic system" at page T2-1-47.
1
3 2
3.
Loosen lock nuts (4), remove bolt (5) and pullout pin (6) with the help of a mallet and a bar so that the end of the cylinder is free, then remove adjusting shims (7).
SM0236
7
6
4
: 24 mm 5
4.
Disconnected hoses (8) and (9) from arm cylinder. Put plugs on cylinder pipes and hoses. : 10 mm : 36 mm SM0237
5.
Disconnect lubrication hose (10). : 17 mm
8
NOTE: positioner cylinder weight: 220 kg
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 and a bar so that the end of the cylinder is free, then remove adjusting shims (14).
10
9
: 24 mm
7.
SM0232
14
Remove positioner cylinder (1).
11
13
12
SM0233
W4-1-23
E215B-E245B
FRONT ATTACHMENT
Positioner cylinder installation NOTE: positioner cylinder weight: 220 kg 1.
Using a crane, align the hole of the positioner cylinder with the pin hole on the boom-tip bracket.
2.
Install adjusting shims (14), pin (13), install screw (12) onto pin (13) and tighten lock-nuts (11).
13
11
14
: 24 mm : 147 Nm 12
3.
Connect lubrication hoses (10) and hoses (8) and (9) to positioner cylinder. : 10 mm : 83 ± 5 Nm : 36 mm
SM0233
: 177 Nm 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. 4.
8
Slightly lift positioner cylinder and align the positioner cylinder rod with the pin hole on the arm.
NOTE: for easy alignment, start the engine and use the arm control lever.
10
9
SM0232
5.
Install adjusting shims (7), pin (6), install screw (5) onto pin (6) and tighten lock-nuts (4). 7
: 24 mm
4
6
: 147 Nm IMPORTANT: bleed air from hydraulic circuit.
5
SM0237
W4-1-24
FRONT ATTACHMENT
E215B-E245B
CYLINDERS ASSEMBLY AND DISASSEMBLY Bucket cylinder
13 20
19 15
16 18 19
17 16 20 21
24 23
22 11
12 1 2 8
3 4 7
5 6 9 10
SM0240
12345678-
Wiper Ring Backup Ring Seal Seal Bushing Snap Ring Cylinder Head Socket Bolt (q.ty 12)
9 - Backup Ring 10 - O-Ring 11 - Cylinder Rod 12 - Cylinder Tube 13 - Cushion Bearing 15 - Piston 16 - Backup Ring (q.ty 2) 17 - Seal Ring
W4-1-25
18 - O-Ring 19 - Slide Ring (q.ty 2) 20 - Slide Ring (q.ty 2) 21 - Shim 22 - Set Screw 23 - Steel Ball 24 - Nut
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): - bucket cylinder: 90 mm (XXXXXXXX)
7.
Remove seal ring (17), slide rings (19) and (20), O-ring (18) and backup rings (16) from piston (15).
8.
Remove cylinder head (7) from cylinder rod (11).
9.
Remove O-Rings (10), backup rings (9) and (2) from cylinder head (7), then remove wiper ring (1), seal (3), buffer ring (4), snap ring (6), and bushing (5).
Be sure to thoroughly read all the precautions for disassembly/assembly work on page W1-1-1 before starting the disassembly procedure. The disassembly procedure below starts on the premise that the hydraulic lines and the line securing bands have been removed. NOTE: bucket cylinder mass: 153 kg 1.
2.
Lift and securely place the cylinder on a workbench using a crane. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.
Fully extend cylinder rod (11). Secure the rod end using a crane. Remove socket bolts (8) from cylinder head (7). : 14 mm
IMPORTANT: be sure to pull cylinder rod (11) straight so as not to damage the sliding surfaces.
3.
Pull out cylinder head (7) from cylinder tube (12) by tapping with a plastic hammer.
4.
Secure cylinder rod (11) on special tool (xxxxxxxxx). Put matching marks between cylinder rod (11) and nut (24).
5.
Remove set screw (22) and steel ball (23). : 10 mm
NOTE: cut away its mushroomed portion using a drill first, as set screw was mushroomed with a punch and hammer at two places after it had been screwed in.
W4-1-26
FRONT ATTACHMENT 9.
Bucket cylinder assembly 1.
Install bushing (5) to cylinder head (7) using a press. Special tools for bushing installation (5): - Bucket cylinder: Ø 80 mm (XXXXXXXX)
IMPORTANT: be sure that the rings are installed correctly.
2.
Install seal (3), back-up ring (2), elastic ring (6) and seal (4) on the cylinder front sleeve (7).
3.
Install wiper ring (1) to cylinder head (7) using a plastic hammer.
4.
Install O-Rings (10) and backup ring (9) to cylinder head (7).
E215B-E245B
Align the holes on cylinder rod (11) and nut (24). Insert steel ball (23) into the hole, and tighten set screw (22) into the hole. Mushroom the head of set screw (22) at two places using a punch and hammer. : 10 mm : 56.9 ± 10.7 Nm
IMPORTANT: be sure to align cylinder rod (11) with the center of cylinder tube (12) when inserting, in order to avoid damaging the rings.
10. Secure cylinder tube (12) horizontally using a work bench. Insert cylinder rod (11) into cylinder tube (12).
11. Install cylinder head (7) to cylinder tube (12). Tighten socket bolts (8). : 14 mm : 267 Nm
5.
Install O-Ring (18), backup ring (16) (Q.ty 2), seal ring (17), slide ring (19) (Q.ty 2), (20) (Q.ty 2) to piston (15). Special tools for seals assembly: - Bucket cylinders: (XXXXXXXX)
6.
Install cylinder head (7) to cylinder rod (11). Special tools: - Bucket cylinders: (XXXXXXXX)
IMPORTANT: be sure that the cushion seal slit faces toward the piston and that the cushion bearing oil groove faces the correct direction.
7.
Install cushion bearing (13) to cylinder rod (11). Install piston (15) to cylinder rod (11).
8.
Install shim (21) to cylinder rod (11). Tighten nut (24) using special tool (xxxxxxxxx). Be sure to align the machine mark on the rod with that on the nut. Socket to tighten nut (24): - bucket cylinder: 90 mm (XXXXXXXX) : 7280 Nm
W4-1-27
E215B-E245B
FRONT ATTACHMENT
Arm cylinder
14 13 19 20 15 23 17 16 20 19 27
22 16 18 11
25 26 28
12
1 2 8
3 4 7
5 6 9 10
SM0241
12345678-
Wiper Ring Backup Ring Seal Seal Bushing Snap Ring Cylinder Head Socket Bolt (q.ty 12) 9 - Backup Ring
10 - O -Ring 11 - Cylinder Rod 12 - Cylinder Tube 13 - Cushion Bearing 14 - Cushion Seal 15 - Piston 16 - Backup Ring (q.ty 2) 17 - Seal Ring 18 - O -Ring
W4-1-28
19 - Slide Ring (q.ty 2) 20 - Slide Ring (q.ty 2) 22 - Set Screw 23 - Steel Ball 25 - Snap Ring 26 - Cushion Seal 27 - Cushion Bearing 28 - Stopper
FRONT ATTACHMENT Arm cylinder disassembly
7.
Remove seal ring (17), slide rings (19) and (20), O-ring (18) and backup rings (16) from piston (15).
8.
Remove cylinder head (7) from cylinder rod (11).
9.
Remove O-Rings (10), backup rings (9) and (2) from cylinder head (7), then remove wiper ring (1), seal (3), buffer ring (4), snap ring (6), and bushing (5).
Be sure to thoroughly read all the precautions for disassembly/assembly work on page W1-1-1 before starting the disassembly procedure. The disassembly procedure below starts on the premise that the hydraulic lines and the line securing bands have been removed. NOTE: arm cylinder mass: 251 kg 1.
2.
Lift and securely place the cylinder on a workbench using a crane. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.
10. Remove stopper (28) from cylinder rod (11) using a screw driver. Remove cushion bearing (27), cushion seal (26), and snap ring (25).
Fully extend cylinder rod (11). Secure the rod end using a crane. Remove socket bolts (8) from cylinder head (7). : 14 mm
IMPORTANT: be sure to pull cylinder rod (11) straight so as not to damage the sliding surfaces.
3.
Pull out cylinder head (7) from cylinder tube (12) by tapping with a plastic hammer.
4.
Secure cylinder rod (11) on special tool (xxxxxxxxx). Put matching marks between cylinder rod (11) and piston nut (15).
5.
Remove set screw (22) and steel ball (23). : 10 mm
NOTE: cut away its mushroomed portion using a drill first, as set screw was mushroomed with a punch and hammer at two places after it had been screwed in.
6.
E215B-E245B
Loosen piston (15) using special tool (xxxxxxxxx). Remove shim (21) cushion bearing (13) and cushion seal (14). Piston nut (15) Turning Special Tool: - 110 mm (XXXXXXXX)
W4-1-29
E215B-E245B
FRONT ATTACHMENT 9.
Arm cylinder assembly 1.
Install bushing (5) to cylinder head (7) using a press. Special tools for bushing installation (5): (XXXXXXXX)
IMPORTANT: be sure that the rings are installed correctly.
2.
3.
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. Mushroom the head of set screw (22) at two places using a punch and hammer. : 10 mm : 56.9 ± 10.7 Nm
IMPORTANT: be sure that the cushion seal slit faces toward the piston and that the cushion bearing oil groove faces the correct direction.
Install seal (3), back-up ring (2), elastic ring (6) and seal (4) on the cylinder front sleeve (7).
Install wiper ring (1) to cylinder head (7) using a plastic hammer.
4.
Install O-Rings (10) and backup ring (9) to cylinder head (7).
5.
Install O-Ring (18), backup ring (16) (Q.ty 2), seal ring (17), slide ring (19) (Q.ty 2) and (20) (Q.ty 2) to piston (15). Special tools for seals assembly: (XXXXXXXX)
10. Install snap ring (25) and cushion seal (26) to cylinder rod (11). Install cushion bearing (27) and stopper (28) to cylinder rod (11). IMPORTANT: be sure to keep cylinder rod (11) aligned with the center of cylinder tube (12) when inserting, in order to avoid damaging the rings.
11. Secure cylinder tube (12) horizontally using a vise. Insert cylinder rod (11) into cylinder tube (12).
12. Install cylinder head (7) to cylinder tube (12). Tighten socket bolts (8). 6.
Install cylinder head (7) to cylinder rod (11). Special tools for cylinder head installation: (XXXXXXXX)
IMPORTANT: be sure that the cushion seal slit faces toward the piston and that the cushion bearing oil groove faces the correct direction.
7.
Install cushion seal (14) to cylinder rod (11). Install cushion bearing (13) and piston (15) to cylinder rod (11).
8.
Install shim (21) to cylinder rod (11). Tighten piston nut (15) using special tool (xxxxxxxxx). Be sure to align the machine mark on the rod with that on the nut. Nut Turning Special Tools (24): -110 mm (XXXXXXXX) : 10280 Nm
W4-1-30
: 14 mm : 367 Nm
FRONT ATTACHMENT
E215B-E245B
Positioner cylinder (triple articulation version)
20
19 15
16 18 19
17 16 20 21
24 23
22 11
12 1 2 8
3 4 7
5 6 9 10
SM0242
12345678-
Wiper Ring Backup Ring Seal Seal Bushing Snap Ring Cylinder Head Socket Bolt (q.ty 12)
9 - Backup Ring 10 - O -Ring 11 - Cylinder Rod 12 - Cylinder Tube 15 - Piston 16 - Backup Ring (q.ty 2) 17 - Seal Ring 18 - O -Ring
W4-1-31
19 - Slide Ring (q.ty 2) 20 - Slide Ring (q.ty 2) 21 - Shim 22 - Set Screw 23 - Steel Ball 24 - Nut
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 (1), seal (3), buffer ring (4), snap ring (6), and bushing (5).
The disassembly procedure below starts on the premise that the hydraulic lines and the line securing bands have been removed. NOTE: positioner cylinder mass: 220 kg 1.
Lift and securely place the cylinder on a workbench using a crane. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.
2.
Fully extend cylinder rod (11). Secure the rod end using a crane. Remove socket bolts (8) from cylinder head (7). : 17 mm
IMPORTANT: be sure to pull cylinder rod (11) straight so as not to damage the sliding surfaces.
3.
Pull out cylinder head (7) from cylinder tube (12) by tapping with a plastic hammer.
4.
Secure cylinder rod (11) on special tool (xxxxxxxxx). Put matching marks between cylinder rod (11) and nut (24).
5.
Remove set screw (22) and steel ball (23). : 12 mm
NOTE: cut away its mushroomed portion using a drill first, as set screw was mushroomed with a punch and hammer at two places after it had been screwed in.
6.
Loosen nut (24) using special tool (xxxxxxxxx). Remove piston (15) and shim (21). Socket to loosen nut (24) -110 mm (XXXXXXXX)
7.
Remove seal ring (17), slide rings (19) and (20), O-ring (18) and backup rings (16) from piston (15). W4-1-32
FRONT ATTACHMENT
E215B-E245B
Positioner cylinder assembly 1.
Install bushing (5) to cylinder head (7) using a press. Special tools for bushing installation (5): (XXXXXXXX)
IMPORTANT: be sure that the rings are installed correctly.
2.
Install seal (3), back-up ring (2), elastic ring (6) and seal (4) on the cylinder front sleeve (7).
IMPORTANT: be sure to align cylinder rod (11) with the center of cylinder tube (12) when inserting, in order to avoid damaging the rings.
10. Secure cylinder tube (12) horizontally using a work bench. Insert cylinder rod (11) into cylinder tube (12).
11. Install cylinder head (7) to cylinder tube (12). Tighten socket bolts (8). : 17 mm : 520 Nm
3.
Install wiper ring (1) to cylinder head (7) using a plastic hammer (7).
4.
Install O-Rings (10) and backup ring (9) to cylinder head (7).
5.
Install O-Ring (18), backup ring (16) (Q.ty 2), seal ring (17), slide ring (19) (Q.ty 2), (20) (Q.ty 2) to piston (15). Special tools for seals assembly: (XXXXXXXX)
6.
Install cylinder head (7) to cylinder rod (11). Special tools: (XXXXXXXX)
7.
Install piston (15) to cylinder rod (11).
8.
Install shim (21) to cylinder rod (11). Tighten nut (24) using special tool (XXXXXXXX). Be sure to align the machine mark on the rod with that on the nut. Nut Turning Special Tools (24): - 110 mm (XXXXXXXX) : 9900 Nm
9.
lign the holes on cylinder rod (11) and nut (24). Insert steel ball (23) into the hole, and tighten set screw (22) into the hole. Mushroom the head of set screw (22) at two places using a punch and hammer. : 12 mm : 56.9 ± 10.7 Nm
W4-1-33
E215B-E245B
FRONT ATTACHMENT
Boom cylinders
13 20
19 15
16 18 19
17 16 20 21
24 23
22 11
12 1 2 8
3 4 7
5 6 9 10
SM0240
12345678-
Wiper Ring Backup Ring Seal Seal Bushing Snap Ring Cylinder Head Socket Bolt (q.ty 12)
9 - Backup Ring 10 - O-Ring 11 - Cylinder Rod 12 - Cylinder Tube 13 - Cushion Bearing 15 - Piston 16 - Backup Ring (q.ty 2) 17 - Seal Ring
W4-1-34
18 - O-Ring 19 - Slide Ring (q.ty 2) 20 - Slide Ring (q.ty 2) 21 - Shim 22 - Set Screw 23 - Steel Ball 24 - Nut
FRONT ATTACHMENT Boom cylinders disassembly
7.
Remove seal ring (17), slide rings (19) and (20), O-ring (18) and backup rings (16) from piston (15).
8.
Remove cylinder head (7) from cylinder rod (11).
9.
Remove O-Rings (10), backup rings (9) and (2) from cylinder head (7), then remove wiper ring (1), seal (3), buffer ring (4), snap ring (6), and bushing (5).
Be sure to thoroughly read all the precautions for disassembly/assembly work on page W1-1-1 before starting the disassembly procedure. The disassembly procedure below starts on the premise that the hydraulic lines and the line securing bands have been removed. NOTE: boom cylinder mass: 176 kg 1.
Lift and securely place the cylinder on a workbench using a crane. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.
2.
Fully extend cylinder rod (11). Secure the rod end using a crane. Remove socket bolts (8) from cylinder head (7). : 14 mm
IMPORTANT: be sure to pull cylinder rod (11) straight so as not to damage the sliding surfaces.
3.
Pull out cylinder head (7) from cylinder tube (12) by tapping with a plastic hammer.
4.
Secure cylinder rod (11) on special tool (xxxxxxxxx). Put matching marks between cylinder rod (11) and nut (24).
5.
Remove set screw (22) and steel ball (23). : 10 mm
NOTE: cut away its mushroomed portion using a drill first, as set screw was mushroomed with a punch and hammer at two places after it had been screwed in.
6.
E215B-E245B
Loosen nut (24) using special tool (xxxxxxxxx). Remove piston (15), shim (21) cushion bearing (13). Socket to loosen nut (24): - boom cylinder: 90 mm (XXXXXXXX)
W4-1-35
E215B-E245B
FRONT ATTACHMENT 9.
Boom cylinders assembly 1.
Install bushing (5) to cylinder head (7) using a press. Special tools for bushing installation (5): - Boom cylinders: Ø 85 mm (XXXXXXXX)
IMPORTANT: be sure that the rings are installed correctly.
2.
Install seal (3), back-up ring (2), elastic ring (6) and seal (4) on the cylinder front sleeve (7).
3.
Install wiper ring (1) to cylinder head (7) using a plastic hammer (7).
4.
Install O-Rings (10) and backup ring (9) to cylinder head (7).
Align the holes on cylinder rod (11) and nut (24). Insert steel ball (23) into the hole, and tighten set screw (22) into the hole. Mushroom the head of set screw (22) at two places using a punch and hammer. : 10 mm : 56.9 ± 10.7 Nm
IMPORTANT: be sure to align cylinder rod (11) with the center of cylinder tube (12) when inserting, in order to avoid damaging the rings.
10. Secure cylinder tube (12) horizontally using a work bench. Insert cylinder rod (11) into cylinder tube (12).
11. Install cylinder head (7) to cylinder tube (12). Tighten socket bolts (8). : 14 mm : 267 Nm
5.
Install O-Ring (18), backup ring (16) (Q.ty 2), seal ring (17), slide ring (19) (Q.ty 2), (20) (Q.ty 2) to piston (15). Special tools for seals assembly: - Bucket cylinders: (XXXXXXXX)
6.
Install cylinder head (7) to cylinder rod (11). Special tools: - Boom cylinders: (XXXXXXXX)
IMPORTANT: be sure that the cushion seal slit faces toward the piston and that the cushion bearing oil groove faces the correct direction.
7.
Install cushion bearing (13) to cylinder rod (11). Install piston (15) to cylinder rod (11).
8.
Install shim (21) to cylinder rod (11). Tighten nut (24) using special tool (xxxxxxxxx). Be sure to align the machine mark on the rod with that on the nut. Socket to tighten nut (24): - Boom cylinder: 90 mm (XXXXXXXX) : 5470 Nm
W4-1-36
FRONT ATTACHMENT Special tools Piston nut socket wrench: XXXXXXXXX for boom cylinders (90 mm) XXXXXXXXX for bucket cylinder (90 mm) XXXXXXXXX for arm cylinder (110 mm) XXXXXXXXX for positioner arm cylinder (110 mm) (triple articulation version) Use nut loosening/tightening workbench: XXXXXXXXX Tools kit seals installation: XXXXXXXXX for boom cylinders XXXXXXXXX for bucket cylinder XXXXXXXXX for arm cylinder XXXXXXXXX for positioner arm cylinder (triple articulation version)
Tool for the installation and removal of the rod guide bushing: XXXXXXXXX for boom cylinders (Ø 85 mm) XXXXXXXXX for bucket cylinder (Ø 80 mm) XXXXXXXXX for arm cylinder (Ø 95 mm) XXXXXXXXX for positioner arm cylinder (Ø 90 mm) (triple articulation version) Head installation tool: XXXXXXXXX for boom cylinders XXXXXXXXX for bucket cylinder XXXXXXXXX for arm cylinder XXXXXXXXX for positioner arm cylinder (triple articulation version)
W4-1-37
E215B-E245B
E215B-E245B
FRONT ATTACHMENT
Maintenance standard: rod
A
SM0243
Cylinders
STANDARD (A)
Boom
85 ± 0.03
Arm
95 ± 0.03
Bucket
80 ± 0.03
Positioning (*)
90 ± 0.03
(*) Triple articulation version
Remedy
Replace or plate with chromium
Unit: mm
W4-1-38