New Holland KOBELCO E215B E245B Workshop Manual

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
This manual is written for an experienced - If you have any questions or comments, or if you
technician to provide technical information found any errors regarding the contents of this
needed to maintain and repair this machine. manual, please contact:
- Be sure to thoroughly read this manual for NEW HOLLAND KOBELCO

correct information concerning the service CONSTRUCTION MACHINERY S.p.A.
procedures. Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 0077357
ADDITIONAL REFERENCES
Please refer to the materials listed below in

addition to this service manual:
- Operation and Maintenance Instruction

Manual
- Parts Catalog
WORKSHOP MANUAL COMPOSITION
The Workshop Manual consists of five parts: - The Operational Performance Test part includes
- Safety Precautions the information needed to carry out the machine
operational performance test.
- Operational Principle
- Operational Performance Test
- The Troubleshooting part includes the technical
- Troubleshouting
information needed for troubleshooting and
- Repair Instructions malfunction detection.
- The Safety Precaution part includes the - The Repair Instruction part includes information
recommended procedures that, if followed, can needed for maintenance and repair of the
avoid the risk of accident for operator and for staff machine, tools and devices needed for
related to the work and maintenance machine maintenance and repair, maintenance standards,
operations. removal/installation and assembly/disassembly
procedures.
- The Operational Principle part includes the
technical information concerning the operation of
main devices and systems.
IN - 1
E215B-E245B INTRODUCTION
PAGE NUMBER
Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:
Example: T 1-2-3
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 Into Multiply by Quantity To convert from Into Multiply by
(SI) (Others) (SI) (Others)
Lenght mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power 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 Flow rate L/min US gpm 0.2642
Torque N.m kgf.m 0.10197 mL/rev cc/rev 1.0
N.m lbf.ft 0.7375
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 Specifications................................................................................. T1-1
Group 2 Component Layout ........................................................................ T1-2
Section 2 SYSTEM
Group 1 Mechatro control system................................................................ T2-1
Group 2 Hydraulic System........................................................................... T2-2
Group 3 Electrical System ........................................................................... T2-3
Section 3 COMPONENT OPERATION

Group 1 Hydraulic Pump Assy..................................................................... T3-1
Group 2 Pilot Valve ...................................................................................... T3-2
Group 3 Control Valve ................................................................................. T3-3
Group 4 Swing Device ................................................................................. T3-4
Group 5 Travel Device ................................................................................. T3-5
Group 6 Swivel Joint.................................................................................... T3-6
Group 7 Cylinders........................................................................................ T3-7
Group 8 Air Conditioner system................................................................... T3-8
OPERATIONAL PERFORMANCE TEST

Section 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction ................................................................................... T4-1
Group 2 Standard Performances ................................................................. T4-2
Group 3 Test Procedures ............................................................................ T4-3
Group 4 Mechatro Controller ....................................................................... T4-4
TROUBLESHOOTING
Section 5 TROUBLESHOOTING
Group 1 Troubleshooting (by error codes)................................................... T5-1
Group 2 Troubleshooting (by trouble) .......................................................... T5-2
Group 3 Troubleshooting (trouble diagnosis mode)..................................... T5-3
E215B-E245B INDEX
REPAIR INSTRUCTIONS
Section 1 GENERAL INFORMATION

Group 1 Precautions for Disassembly and Assembly.................................W1-1
Group 2 Tightening Torque ........................................................................W1-2
Section 2 UPPERSTRUCTURE
Group 1 Upperstructure ..............................................................................W2-1
Group 2 Pump Device.................................................................................W2-2
Group 3 Control Valve ................................................................................W2-3
Group 4 Swing Device ...............................................................................W2-4
Group 5 Pilot Valve .....................................................................................W2-5
Section 3 UNDERCARRIAGE
Group 1 Swing Bearing ..............................................................................W3-1
Group 2 Travel Device ...............................................................................W3-2
Group 3 Swivel Joint ..................................................................................W3-3
Group 4 Track Adjuster ..............................................................................W3-4
Group 5 Front Idler .....................................................................................W3-5
Group 6 Upper and Lower Roller ...............................................................W3-6
Group 7 Tracks ...........................................................................................W3-7
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
Read the Operation and Maintenance Instruction Do not leave the machine until it has come to a
Manual carefully before starting, operating, complete stop.
maintaining, fuelling or servicing the machine. Always check height, width and weight limitations
Carefully read the explanation to each and all safety which may be encountered in the working site and
signs in the special section of this Manual before ensure the machine does not exceed them.
starting, operating, maintaining, fuelling or servicing Assess exact paths of gas ducts, water mains,
the machine. telephone lines, sewers, overhead and underground
Machine-mounted safety plates are colour coded electric lines and all other possible obstacles.
yellow with black borders when they refer to points Such paths should be opportunely defined by
where special ATTENTION must be paid and failure competent Authorities. If necessary, require that the
to observe them may cause a serious DANGER to service is interrupted or said installations are moved
the integrity of machine operators. They are white prior to starting the work.
with red borders and black lettering when they refer
You must know the working capacity of the machine.
to a FORBIDDEN practice.
Define the rear upperstructure swing area and
It is fundamental that all machine operators know
provide for opportune barriers to prevent access into
very well the meaning of each safety plate as this
it.
considerably decreases operating hazards and
accidents. Never exceed machine lifting capacity.
Do not allow unauthorised personnel to operate or Remain within the limits shown in the loading
service this machine. capacity chart which located on the machine.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get STARTING
caught in moving parts. Wear certified safety clothes Never start or operate a failed machine. Walk all
such as: hard hat, no-slip footwear, heavy gloves, ear around the machine before mounting.
protection, safety glasses, reflector vests, respirators Before operating the machine, make sure that any
every time the job requires it. Ask your employer possible dangerous condition has been properly
about safety regulations in force and protective removed. Before starting machine, check that
equipment. steering and attachment controls are in the neutral
Always keep the operators compartment, step position and the safety lever is in the LOCK position.
plates, grab-rails and handles clean and clear of Immediately report any malfunction of parts or
foreign objects, oil, grease, mud or snow to minimise systems to the maintenance managers for proper
the danger of slipping or stumbling. Remove mud or action.
grease from your shoes before operating the Prior to starting the engine, check, adjust and lock the
machine. drivers seat for maximum riding comfort and control
Do not jump on or off the machine. Always keep both accessibility. Prior to operating the machine and/or
hands and one foot, or both feet and one hand in its attachments, check that bystanders are outside
contact with steps and/or grab rails. the machine operating range. Sound the horn.
Do not use controls or hoses as hand holds. Hoses Obey all hand signals, safety indications and signs.
and controls are movable parts and do not provide Due to the presence of flammable fluids, never
solid support. Besides, controls may be inadvertently check fuel level, refuel, charge the batteries in the
moved and cause unexpected movement of the presence of smoking materials, open flames or
machine or its attachments. sparks.
Never operate the machine or its attachments from Ensure that nobody is within the excavator operating
any position other than sitting in the drivers seat. area before starting the machine, swinging the upper
Keep head, body, limbs, hands and feet inside the structure or moving in any direction.
operators compartment at all times to reduce Adjust all rear-view mirrors for maximum visibility of
exposure to external hazards. the area behind the machine.
Be careful of possible slippery conditions of the steps Ensure that engine speed is appropriate to the job to
and hand rails as well as of the ground around the be carried out.
machine. Wear protective boots or shoes with the
soles made of highly no-slip rubber
S1 - 1
E215B-E245B GENERALITIES
If any hydraulic control or system exhibits erratic properly protected against possible backlash in
performance or responds abnormally, have the case of cable or chain failure or detachment.
machine checked for air in the system. Be alert of soft ground conditions close to newly
Air in these circuits may cause incorrect movements constructed walls. The fill material and machine
with consequent accident hazard. Refer to the weight may cause the wall to collapse under the
Operation and Maintenance Instruction Manual machine.
about corrective action to be taken. In darkness, check area of operation carefully before
moving in with the machine. Use all lights provided.
Do not move into low visibility areas.
OPERATING If the engine tends to slow down and stall for
whatever reason under load or at idle, immediately
report this problem to the maintenance managers for
Do not run the engine of this machine in closed proper action.
buildings without proper ventilation capable to
Do not operate the machine until this condition is
remove harmful exhaust gases which concentrate in
corrected. Regularly check all exhaust system
the air.
components, as exhaust fumes are toxic for the
Keep the operators compartment free of foreign operator.
objects, especially if not firmly secured. Never use
Operators must know the performance of the
the machine to transport objects, unless proper
machine they are driving. When working on slopes or
securing points are provided.
near sudden level drops in the terrain, pay attention
Do not carry riders on the machine. Study and not to lose adherence and avoid loose soft ground
familiarise with escape routes alternative to normal since overturn or loss of machine control could result.
exit routes. For your personal safety, do not climb on
If noise level is high and exceeds 90 dB (A) over 8
or off the machine while it is in motion.
hours at the operators ear, wear approved ear
Make sure that bystanders are clear of the machine protection in compliance with local regulations.
operating range before starting the engine and
Do not operate the machine if you are extremely tired
operating the attachment. Sound the horn.
or feel ill. Be especially careful towards the end of the
Obey all hand signals, safety indications and signs. working shift.
When backing, always look to where the machine is Where removable counterweights are provided, do
to be moved. not operate the machine if they have been removed.
Be alert of the position of bystanders. Should When operating the machine, keep in mind height
someone enter the work area, stop the machine. limits of overhead doors, arches, overhead cables
Maintain a safe distance from other machines or and lines as well as width limits of corridors, roads
obstacles to ensure required visibility conditions. and narrow passages.
Always give way to loaded machines. Also, get to know load limits of the ground and
Maintain a clear vision of the surroundings of the paving type of the ramps you are to work on.
travel or work area at all times. Keep cab windows Beware of fog, smoke or dust that obscure visibility.
clean and repaired.
Always inspect the working area to identify potential
When pulling loads or towing through a cable or risks such as: inclines, overhangs, trees, demolition
chain, do not start suddenly at full throttle. Take-up rubble, fires, ravines, steep slopes, rough terrain,
slack carefully. Avoid kinking or twisting chains or ditches, crowns, ridge trenches,diggings in traffic
cables. areas, crowded parking lots, crowded service areas,
Carefully inspect the towing items for flaws or fenced zones. In such conditions, proceed with
problems before proceeding. Do not pull through a extreme care.
kinked chain or cable as the high anomalous stresses Whenever possible, avoid crossing over obstacles
existing in this condition may induce failures in the such as very rough terrain, rocks, logs, steps,
kinked portion. ditches, railroad tracks.
Always wear heavy gloves when handling chains or When obstructions must be crossed, do so with
cables. extreme care and at a square angle, if possible. Slow
Chains and cables should be securely anchored down.
using suitable hooks. Anchor points should be strong Ease up to the break-over point, pass the balance
enough to withstand the expected load. point slowly and ease down the other side also using
Keep anyone clear of anchor points and cables or the attachment, if necessary.
chains. To overcome deep trenches or sinking ground, place
Do not pull or tow unless the operators the machine perpendicular to the obstacle, drastically
compartments of the machines involved are reduce ground speed and start crossing using also
S1 - 2
the attachment if necessary, only after assessing that The load must always be properly arranged in the
ground conditions allow the traverse safely and bucket; move with extreme care when transporting
without risks. oversize loads.
The gradient you may attempt to overcome is limited Do not lift and move the bucket overhead where
by factors such as ground conditions, load being persons are standing or working, nor downhill when
handled, machine type and speed, and visibility. working on a slope as this would decrease machine
There is no substitute for good judgement and stability. Load the bucket from the uphill side.
experience when working on slopes. Loads to be raised using the machine should be
Avoid operating the attachment too close to an exclusively hooked to the hitch specially provided.
overhang or high wall, either above or below the The excavator is no lifting and transportation means,
machine. Beware of caving edges, falling objects therefore it should not be used to position loads
and landslides. Remember that such hazards are accurately. Should it be exceptionally used to lift and
likely to be concealed by bushes, undergrowth and lay building components, special caution must be
such. taken as follows:
Avoid faggots, bushes, logs and rocks. Never drive
over them, nor over any other surface irregularities
- The machine must be equipped compulsorily with
that discontinue adherence or traction with the
the appropriate variant provided upon request.
ground, especially near slopes or drop-offs.
- Secure the loads to be raised using cables or
Be alert to avoid changes in adherence conditions
chains fastened with appropriate hooking
that could cause loss of control. Work with extreme
mechanisms.
care on ice or frozen ground and on stepped slopes
or near drop-offs. - Nobody should be allowed to remain under the
raised load or within the excavator operating range
The word bulldozing generally refers to work in
for any reason whatever.
virgin rough terrain, characterised by the presence of
all the perils and risks listed above. We emphasise
the danger represented in these conditions by large Never exceed specified loading capacity. Incorrect
tree limbs (possibly falling on the machine) and large fastening of slings or chains may cause boom/arm
roots (which may act as a leverage under the failure or failure of the lifting means with consequent
machine when up-rooted and cause the unit to bodily injuries and even death.
overturn). Always ensure that slings and chains used for lifting
Position the machine dependent upon the loading are adequate to the load and in good condition.
and unloading areas in order to swing leftwards to All loading capacities are referred to the machine
load to obtain best visibility. on a level surface and should be disregarded
Never use the bucket or attachment as a man lift when working on a slope.
or carry riders. Never use the machine as a work Avoid travelling across slopes. Proceed from uphill
platform or scaffolding. The machine must not be downhill and vice-versa. If machine starts slipping
improperly used for works not consistent with its sideways when on a slope, lower the bucket and
features (such as pushing railway cars, trucks or thrust bucket teeth into the ground.
other machines).
Working on slopes is dangerous. Grade the working
Always pay attention to people within the machine area if possible. Reduce work cycle time if it is not
operating range. possible to grade the working area.
Never move or stop the bucket, other loads or the Do not move full bucket or a load from uphill downhill
attachment above ground personnel or truck cabs. as this would reduce machine stability. Do not work
Ensure the truck driver is in a safe place before with the bucket turned to the uphill side.
loading the truck. Do not work with the bucket turned uphill as
Load trucks from side or rear. counterweights protruding downhill would reduce
Use only the type of bucket recommended machine stability on the slope and increase risk of
considering machine type, materials to be handled, overturning.
material piling up and loading characteristics, ground We recommend to work on slopes with the bucket
type and other typical conditions of the work to be downhill, after checking machine stability with the
performed. bucket empty and attachment retracted, by slowly
When transporting a loaded bucket, keep it as swinging the upper structure by 360.
rolled-back as possible. Keep boom and arm as low Position the carriage at a right angle relative to
as possible. slopes, hanging walls, etc. to exit the working area
Ground speed should be adequate to the load and easily.
ground conditions. Standard use, provides for the travel controls at the
front and travel motors at the back. Should travel
S1 - 3
motors be positioned at the front with regard to the - Look up the in the telephone directory.
actual travel direction. Remind relative to travel - Define together with the Company representative
direction that controls are reversed. which precautions should be taken to guarantee
Always check travel motor position before moving off. work safety.
Properly judge ground conditions with particular - All electric lines should be considered as operative
attention to consistency of the area you are going to live lines even though it might be well known that
work on. the line in question is out of work and visibly
Keep the machine sufficiently far from the ditch connected to the ground.
edge. - The Electric Power Company, if previously advised
Never dig under the machine. and involved in the work, as well as machine
Operator, Owner and/or any natural person or legal
Should it be necessary to dig under the machine,
entity having rent orleased the machine or being
always ensure that digging walls are opportunely
responsible at the time by contract or by law, are
propped up against landslide to prevent the machine
liable for the adoption of the necessary
from falling into the trench.
precautions.
Do not swing the upperstructure, raise the load or
- Decrease work speed. Reaction time could be too
brake abruptly if not required. This may cause
slow and distance evaluation wrong.
accidents.
- Warn all ground personnel to keep clear of the
Prior to beginning the work near gas distribution
machine and/or load at all times. If the load has to
mains or other public utilities:
be guided down for laying, consult the Electric
- Contact the company owner of the gas mains or its Power Company to know which precautions should
nearest branch before starting the work. Look up be taken.
the number in the telephone directory.
- Appoint a person in charge of signalling duties.
- Define together which precautions should be taken This person will have the responsibility of observing
to guarantee work safety. the machine, any part of it and/or the load
- Decrease work speed. Reaction time could be too approaching the electric lines from a standpoint
slow and distance evaluation wrong. more favourable than the Operators. This signal
- When working near gas mains or other public man (flag-man) must be in direct communication
utilities installations, appoint a person in charge of with the Operator and the Operator must pay
signalling duties. This person will have the undivided attention to the signals supplied.
responsibility of observing the machine, any part of When working in or near pits, in ditches or very high
it and/or the load approaching the gas mains from walls, check that the walls are sufficiently propped up
a standpoint more favourable than the Operators. to avoid cave-in hazards.
This signal man (flag-man) must be in direct Pay the utmost attention when working near
communication with the Operator and the Operator overhang walls or where landslides may take place.
must pay undivided attention to the signals Make sure that the support surface is strong enough
supplied. to prevent landslides.
- The gas distributing Company, if previously When digging, there is the risk of cave-ins and
advised and involved in the work, as well as landslides.
machine Operator, Owner and/or any natural
Always check ground conditions and conditions of
person or legal entity having rent or leased the
the material to be removed. Support everywhere it is
machine or being responsible at the time by
required to prevent possible cave-ins or landslides
contract or by law, are liable for the adoption of the
when:
necessary precautions.
- Digging near previous trenches filled with material.
Working near electric lines can be very dangerous,
therefore some special precautions must be - Digging in bad ground conditions.
observed. - Digging trenches subject to vibration from
Within this Manual, work near electric lines means railroads, working machines or highway traffic.
when the attachment or load raised by the excavator
(in any position) may reach the minimum safety
distance established by local or international Safety
STOPPING
Regulations.
To work without risks, keep maximum possible
distance from electric lines and never trespass When the machine is to be stopped for whatever
minimum safety distance. reason, always check that all controls are in the
neutral position and that the safety lever is on the lock
- Contact the Company owner of the electric lines or
position to guarantee risk-free start-up.
its nearest branch before starting the work.
S1 - 4
Never leave the machine unattended with the engine Read all safety plates mounted on the machine and
running. observe instructions they contain before starting,
Prior to leaving the drivers seat, and after making operating, repairing, fuelling or servicing the
sure that all people are clear of the machine, slowly machine.
lower the attachment until resting it safely to the Do not allow unauthorised personnel to repair or
ground. Retract possible auxiliary tools to the closed service the machine.
safety position. Follow all recommended maintenance and service
Check that all controls are in the neutral position. procedures.
Move engine controls to the shut-down position. Do not wear rings, wrist watches, jewellery, loose or
Switch off the key-start switch. Consult the Operation hanging garments, such as ties, torn clothing,
and Maintenance Instruction Manual. scarves, unbuttoned or unzipped jackets that can get
Park the machine in a non-operating and no-traffic caught in moving parts. Wear certified safety clothes
area. Park on firm level ground. If this is not possible, such as: hard hat, no-slip footwear, heavy gloves, ear
position the machine at a right angle to the slope, protection, safety glasses, reflector vests, respirators
making sure there is no danger of uncontrolled when required. Ask your employer about safety
sliding. regulations in force and protective equipment.
If parking in traffic lanes cannot be avoided, provide Do not use controls or hoses as hand holds. Hoses
appropriate flags, barriers, flares and other signals as and controls are movable parts and do not provide
required to adequately warn the oncoming drivers. solid support. Besides, controls may be inadvertently
Always switch off the key-start switch before moved and cause unexpected movement of the
cleaning, repairing, or parking the machine to prevent machine or its attachments.
accidental unauthorised start-up. Do not jump on or off the machine. Always keep both
Never lower the attachment or auxiliary tools other hands and one foot, or both feet and one hand in
than from sitting in the operators seat. Sound the contact with steps and/or grab rails.
horn. Make sure that nobody is within the machine Never service the machine with someone sitting in
operating range. Lower the attachment slowly. the drivers seat, unless this person is an authorised
Securely block and lock the machine every time you operator assisting in the maintenance being carried
leave it unattended. Return keys to the safe place out.
previously agreed upon. Perform all necessary Keep the operators compartment, step plates, grab
operations for stopping as detailed in the Operation rails and handles clear of foreign objects, oil, grease,
and Maintenance Instruction Manual. mud orsnow to minimise the danger of slipping or
Drive the machine far from pits, trenches, rocky stumbling.
hanging walls, areas with overhead electric lines, and Clean mud or grease from your shoes before
slopes before stopping it at the end of the working climbing on the machine or driving it.
day. Never attempt to operate the machine or its
Align the upperstructure to the tracks in order to allow attachments from any position other than sitting in the
to easily get on and off the drivers compartment. operators seat.
Move all controls to the position specified for machine Keep the drivers seat free from foreign objects,
stopping. Refer the Operation and Maintenance especially if these are not secured.
Instruction Manual. Should it be necessary to move the attachment for
Never park on an incline without accurately blocking maintenance purposes, do not raise or lower the
the machine to prevent unexpected movement. attachment from any other position than sitting in the
Follow stopping instructions contained in the operators seat. Before starting the machine or
Operation and Maintenance Instruction Manual. moving its attachment, sound the horn and require
that nobody remains near the machine.
Raise the attachment slowly.
Always lock all moving components or parts of the
machine that must be lifted for maintenance
MAINTENANCE purposes using adequate external means as
required by local and national regulations. Do not
allow anyone to pass or stay near or below a raised
GENERALITIES
attachment. If you are not absolutely sure about your
safety, do not stay or walk under a raised attachment.
Carefully read the Operation and Maintenance Do not place head, body, limbs, hands, feet or fingers
Instruction Manual before starting, operating, near articulated cutting edges deprived of the
maintaining, fuelling or servicing the machine in any necessary guards, unless they are suitably and
manner. safely locked.
S1 - 5
Never lubricate, repair or adjust the machine with the flammable fluids to clean parts. Use proprietary
engine running, except when this is specifically certified non-flammable, non-toxic solvents only.
required by the Operation and Maintenance When using compressed air to clean parts, wear
Instruction Manual. safety glasses with side shields. Limit pressure to
Do not wear loose clothing, jewellery near rotating max. 2 bars, in accordance with local and national
parts. safety regulations in force.
When service or maintenance require access to Do not run the engine of this machine in closed
areas that cannot be reached from the ground, use a buildings without proper forced ventilation capable to
ladder or step platform conforming to local or national remove toxic exhaust gases concentrating in the air.
regulations to reach the working area. If such means Do not smoke, nor allow open flames or sparks
are not available, use machine grab rails and steps. nearby while refuelling the unit or handling highly
Always perform all service or maintenance work with flammable materials.
the greatest care and attention.
Do not use open flames as light sources to look for
Shop and/or field service platforms or ladders should leaks or inspect anywhere on the machine.
be manufactured and maintained in accordance with
Make sure that all mechanical tools provided are in
local or national safety regulations in force.
good condition at all times. Never use tools with
Disconnect batteries and label all controls to warn mushroomed or damaged heads. Always wear eye
that service work is in progress, according to local protections with side shields.
and national safety regulation requirements.
Move with extreme care when working under, on or
Block the machine and all attachments to be raised near the machine or its attachments.
according to local and national safety regulation
In case of attachment tests during which the engine
requirements.
should be kept running, a qualified operator must sit
Do not check or fill fuel tanks or install batteries near in the drivers seat at all times while the mechanic is
burning or smoking materials and open flames due to at work.
the presence of flammable vapours.
Keep hands and clothes far off moving parts.
The fuel filler pipe nozzle must be constantly kept in
Stop the engine and move the safey lever to the lock
contact with the filler neck and this even before fuel
position before starting adjusting or repairing an
starts flowing in. Keep this contact from the beginning
assembly.
to the end of the fuelling operation to avoid possible
generation of sparks due to static electricity. Do not carry out any work on the attachment without
prior authorisation. Observe maintenance and repair
Use a truck or trailer to haul a failed machine. Should
procedures.
it be necessary to tow it, provide for suitable danger
signals as required by the local norms and In case of field service, move the machine to level
regulations and observe recommendations given in ground and block it. If work on an incline cannot be
the Operation and Maintenance Instruction Manual. avoided, securely block the machine and its
Load/unload the machine on firm level ground attachments. Move the machine to level ground as
providing safe support to the wheels of the truck or soon as possible.
trailer. Use strong access ramps, with adequate Do not twist chains and cables. Never use a twisted
height and angle. Keep the trailer flatbed free of mud, chain or cable for lifting or pulling. Always wear safety
oil or slippery materials. Tie the machine securely to gloves to handle chains or cables.
the trailer and block carriages and upperstructure. Be sure chains and cables are firmly fastened and
Never align holes or slots using your fingers; that the anchor point is strong enough to withstand
alwaysuse appropriate aligning tools. the expected load.
Remove all sharp edges and burrs from re-worked Keep all bystanders clear of the anchor point, cables
parts. or chains. Do not pull or tow unless the operators
Use only approved and effectively grounded auxiliary compartments of the machines involved are
power sources for heaters, battery chargers, pumps fitted with proper guards against cable or chain
and similar equipment to reduce electrical shock backlash.
hazard. Keep the maintenance area clean and dry at all
Lift and handle heavy components using hoisting times.
devices of appropriate capacity. Ensure the parts are Clean immediately all water and oil spillage.
supported by appropriate straps and hooks. Do not pile up oily or greasy rags as they represent a
Use lifting eyes provided to this aim. major fire hazard. Always store them in closed metal
Pay attention to bystanders near the lifting area. containers.
Never pour gasoline or diesel fuel into open Before starting the machine or its attachment, check,
containers. Never use gasoline, solvents or other adjust and lock the operators seat. Also ensure that
nobody is within the machine or attachment
S1 - 6
operating range before starting or operating the injuries are most likely to occur. Pay attention to
machine and/or its attachments. prevent possible part movements by means of
Sound the horn. blocks or by keeping clear of such zones when
motion may take place during maintenance or repair.
Rust inhibitors are volatile and flammable.
Move the hydraulic system lock safety lever to the
Prepare parts in well ventilated areas. Keep open
lock position when stopping the machine for
flames away.
whatever reason.
Do not smoke.
Always install the safety stays for the hood and other
Store containers in a cool well ventilated place where hinged covers before performing any maintenance or
they could not be reached by unauthorised people. repair work in the engine compartment.
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
TRANSFERS AND TRANSPORTATION
safety shoes and gloves, safety glasses when
splinters or other particles may be ejected.
Wear the appropriate welders equipment such as Before moving or transporting the machine, block
dark safety glasses or mask, hard hat, protective upperstructure swing to prevent accidental
clothing, safety gloves and footwear always while movement.
welding or arc-cutting. Wear dark safety glasses Pay particular attention during transfer on inclines,
when you are near a welding in progress. both uphill and downhill. Keep the bucket in a position
Do not look the welding arc without proper eye to provide a possible anchor point into the ground in
protection. case of slipping.
Become acquainted with all your jacking equipment During transfers on inclines, both uphill and downhill,
and their capacity. keep the upperstructure aligned with the carriages.
Do not travel across the slope.
Ensure that the jacking point on the machine is
appropriate for the load applied. Also, be sure the Never transfer the machine in the working site, in a
supports under the jack and between the jack and the crowded area, or near people without having at least
machine are appropriate and stable. one person charged with hand-signals who could
guide the Operator.
Any equipment supported by a jack represents a
possible hazard. Always support the load onto Sound the horn to inform that you are about to move
appropriate blocking means as a safety measure off.
before proceeding with service or maintenance work, It is necessary to know load limits of bridges and
in compliance with local or national safety dimensional limits of tunnels. Such limits must never
regulations. be exceeded. You should also know machine height,
Metal cables produce steel splinters. Always wear width, and weight. Have a signal-man help you when
certified protection clothes such as safety gloves and clearances are limited.
glasses while handling them. Check distance between boom/arm and dimensional
Do not use makeshift jacks to adjust track sag. Follow limits during transfer or transportation.
instructions given in the Repair Manual. Rough terrain may cause the machine to sway and
Handle all parts carefully. Keep hands and fingers roll to such an extent that boom/arm could get to
away from gaps, gears, and similar. Always use and contact electric lines or other obstacles. Cross
wear certified safety clothes such as safety glasses, obstacles at a right angle at low speed. Pay attention
gloves and footwear. to machine shaking when the centre of gravity
overcomes the obstacle.
The attachment is kept constantly in position by an oil
column trapped into the high pressure circuit. Lower Keep the bucket down at all times during transfers.
the attachment to the ground and relieve pressure Drive with the lights on and use appropriate signals
from all circuits prior to carrying out any type of and flags.
maintenance or repair work. Get to know and respect local and national
Do not service or repair the machine if it is parked regulations.
downhill. If this is unavoidable, in case of emergency, Consider boom/arm and upperstructure dimensions
block the carriages to prevent unexpected while turning.
movement, particularly if the work is to be carried out
Use a ramp to load the machine on a trailer. If a ramp
on the final reduction units or travel motors.
is not available, fabricate one using blocks. The ramp
Consult the Operation and Maintenance Instruction should be sufficiently strong to support machine
Manual for correct maintenance procedure. weight. Always load and unload on level surface.
Areas near articulated cutting edges where
mechanical parts are in motion are where personal
S1 - 7
Tow the machine following the instructions contained Before any maintenance or repair, make sure that
in the Operation and Maintenance Instruction there are no fuel or electrolyte leaks from the
Manual. batteries. If any, correct prior to proceeding with
further work. Do not recharge batteries in confined
spaces. Ensure proper ventilation is provided to
avoid accidental explosions due to build-up of
ENGINE explosive gas released during charging.
Disconnect batteries before working on the electrical
Do not run the engine in closed buildings without system or carrying out any other type of work.
proper ventilation capable to remove harmful exhaust
fumes.
Do not place head, body, limbs, feet, hands or fingers
HYDRAULIC SYSTEM
near rotating fans or belts. Be especially careful near
blower fans.
Loosen the radiator cap very slowly to relieve system Pressure fluid escaping from a very small hole can be
pressure before removing it. Always top-up coolant almost invisible and still have sufficient force to
level with the engine off or idling if hot. See the penetrate the skin. Always check any suspected
Operation and Maintenance Instruction Manual. pressure leaks using a piece of cardboard or wood.
Keep the exhaust manifold and tube free from Do not use hands. If injured by escaping fluid, obtain
combustible matters. Fit the machine with shields medical attention immediately or serious infection or
and guards when working in the presence of reaction may develop.
combustible matter free in the air. Stop the engine and ensure pressure is relieved from
Do not refuel with the engine running, especially if all systems before removing side panels, housings,
hot, as this increases fire hazard in case of fuel guards and covers. See the Operation and
spillage. Maintenance Instruction Manual.
Never attempt to check or adjust fan belt tensions Always use gauges of adequate capacity for
when the engine is running. pressure testing. Refer to the Operation and
Maintenance Instruction Manual or Repair Manual.
Do not adjust the fuel injection pump when the
machine is operating.
Do not lubricate the machine with the engine running.
Do not run the engine with the air intakes open and
not protected. If this cannot be avoided for service
reasons, place protection meshes on all intakes TOOLS
before servicing the engine.
Always keep head, body, limbs, feet, hands, and

ELECTRICAL SYSTEM fingers away from the bucket and attachments, when
in the raised position.
Pay attention to connect connecting cables to correct Prior to any maintenance or repair work, install all
poles (+ to +) and (- to -) at both ends. Do not short- supports necessary to this aim according to local and
circuit terminals. Thoroughly follow instructions given national safety regulations.
in Operation and Maintenance Instruction Manual. In case the attachment is to be operated for
Always move the key-start switch in the lock position maintenance or repair purposes, do so exclusively
before servicing or repairing the machine. while sitting in the drivers seat. Sound the horn
Batteries contain SULPHURIC ACID. Protect the before starting the machine or moving the
eyes when working near the batteries against attachment. Require that nobody remain near the
possible sprays of the acid solution. Should acid machine. Raise the attachment slowly.
contact skin, eyes, or clothes, RINSE IMMEDIATELY Do not use the machine to transport loose objects,
IN WATER FOR AT LEAST 15 MINUTES. unless proper securing devices are provided.
Immediately seek medical attention. Never use gases other than nitrogen to charge the
Battery released gas is highly flammable. Leave accumulators.
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
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.
These words are always accompanied by the safety DANGER
alert symbol.
DANGER: indicates an imminent hazardous

situation which, if not avoided, will result in death or
WARNING
serious injury.
WARNING: indicated a potential hazardous

situation which, if not avoided, could result in death
CAUTION
or serious injury.
CAUTION: indicates a potential hazardous situation IMPORTANT

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.
S2 - 1
E215B-E245B SAFETY PRECAUTIONS
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.
S2 - 2
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 work-

shift by an attentive visual inspection of machine
outside prior to starting it to prevent damages and
personal injuries.
S2 - 3
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.
S2 - 4
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.
S2 - 5
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 operators 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 operators
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.
S2 - 6
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.
S2 - 7
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.
S2 - 8
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.
S2 - 9
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.
S2 - 10
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.
S2 - 11
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.
S2 - 12
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.
S2 - 13
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.
S2 - 14
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
persons 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.
S2 - 15
SAFE MAINTENANCE
To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Keep the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it
is in motion.
- Keep hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
4. Switch off the Auto-Idle.
5. Let the engine idle with no load for at least
five minutes until it has cooled down.
6. Move the key-start switch to the OFF
position to stop the engine.
7. Remove the ignition key from the start
switch.
8. Apply the "Maintenance in progress" tag
(see SAFETY PLATE in this Chapter).
This tag can be applied o the left-hand
control lever, safety lever or cab door.
9. Let the engine cool down.
- Do not leave the machine unattended if
servicing requires the engine running.
- If the machine is to be raised, place boom and
arm at an angle 90 to 110. Lock machine
components which should be raised for
maintenance or repair using suitable supporting
means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or
replace as necessary. Refer to the Chapter
MAINTENANCE in this Manual.
- Keep all components in good condition and
properly install. Immediately repair any fault.
- Immediately repair any damage.Replace worn
or failed components. Remove grease, oil,
debris build-ups.
- Disconnect the negative cable (-) from the
battery before carry out any work on he
electrical sysem or arc-welding on he machine.
S2 - 16
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.
S2 - 17
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.
S2 - 18
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.
S2 - 19
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 drivers
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.
S2 - 20
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.
S2 - 21
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 connections before applying

pressure.
- Search for leaks with a piece of cardboard; take

care to protect hands and body from high-
pressure 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.
SP0047
- As pieces may fly off, be sure to keep body and
face away from air release plug to avoid injury.
Reduction gear oil is hot. Wait for gear oil to cool
down, then gradually loosen the air release plug
to release pressure.
S2 - 22
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
PREVENT FIRES
Check for Oil Leaks:
- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts
which may cause oil leaks.
- Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil-
cooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts:
- Short circuits can cause fires.
- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10)
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
Check Key-start Switch:
- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF
position to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.
Check Heat Shields:
- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S2 - 24
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
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
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
NOTE:
S2 - 28
SAFETY PLATES E215B-E245B
SAFETY PLATES
Triple articulation version
1. Attachment operating range safety plate.

2. Track adjuster plate.
S3 - 1
E215B-E245B SAFETY PLATES
3. Counterweight operating range safety plate. 9. Controls lock/unlock plate (safety lever).
4. Read-your-manual plate. 10. Hydraulic oil pressurised tank warning plate.
5. Boom and arm movement warning plate 11. Burns warning plate.
(Triple articulation version). 12. Safety distance plate.
6. Open windscreen warning plate aperta 13. No-stepping warning plate.
(inside the cab).
14. Special equipment movement warning plate
7. Tag indicating maintenance in progress.
8. Engine hood warning plate.
S3 - 2
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
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
S3 - 3
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
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
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
S3 - 4
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
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
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
S3 - 5
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
11 - Burns danger plate
It indicates that a burns danger exists, since

the zone is characterised by high temperature.
Background: yellow
12 - Safety distance plate
It instructs to keep at a safe distance from a

zone dangerous for personal safety.
Background: yellow
S3 - 6
13 - No-stepping warning plate
It instructs not to step on the zone where this

decal is attached.
Background: yellow
Cross: red
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
S3 - 7
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 Mechatro Control System
Group 2 Hydraulic System
Group 3 Electrical System

Group 1 Hydraulic Pump Assy
Group 2 Pilot Valve
Group 3 Control Valve
Group 4 Swing Device
Group 5 Travel Device
Group 6 Swing Joint
Group 7 Cylinders
Group 8 Air Conditioner
SECTION 1 E215B-E245B
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
Bucket applications as a function
of the arms E215B ............................. T1-1-13
Digging data E245B
Digging data E245B
Bucket applications as a function
of the arms E245B ............................. T1-1-18
SPECIFICATIONS E215B-E245B
MAIN COMPONENTS
1- Bucket 11 - Swing motor 21 - Track link

2- Bucket link 12 - Fuel tank 22 - Batteries
3- Idler link 13 - Hydraulic oil tank 23 - Upper roller
4- Bucket cylinder 14 - Control valve 24 - Track guide
5- Arm 15 - Engine muffler 25 - Lower roller
6- Arm cylinder 16 - Hydraulic pump 26 - Air cleaner
7- Boom 17 - Engine 27 - Crawler adjuster
8- Boom cylinder 18 - Counterweight 28 - Front idler
9- Cab 19 - Engine radiator 29 - Shoe plate
10 - Swivel joint 20 - Travel motor
T1-1-1
E215B-E245B SPECIFICATIONS
Main Components Upper Structure
2
6
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
Main Components Under Carriage
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
Main Components Front Attachment
2 7
1
3
4 6 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 8- Positioner (Triple Articulation Version)
Version)
T1-1-4
HYDRAULIC COMPONENTS
HYDRAULIC PUMP
Item Main pump Gear pump for pilot

Pump K3V112DTP1KMR-YTOK-HV ZX10LPRZ7-07G
Variable displacement plunger Fixed displacement type gear
Type
pump: regulator attached type pump
Max. displacement capacity cm3 110 x 2 10
rpm
(Clockwise
Revolution Rated
seen from
2000
shaft end)
Rated 34.3
Pressure MPa 5.0
ATT boost 37.8
Max. flow L/min 220 x 2 at 7.8 MPa 20
Max. input Power
kW 118 3.4
(at 2000 rpm)
Max. input torque
Nm 665 14.7
(at 1200 rpm)
Model KR3G-YTOK-HV
Control Electric flow control, positive flow control, total power control at
Regulator function emergency mode and power shift control
With solenoid proportional reducing valve (KDRDE5K-31/
Others
30C50)
Mass 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 L/min 220 x 2
Main relief valve set pressure MPa 34.3 at 70 x 2 L/min
When power boost pressure 37.8 at 60 x 2 L/min
Over load relief valve set pressure MPa
Boom H, Bucket H, Arm R 39.7 at 30 L/min
Boom R, Bucket R, Arm H 37.8 at 30 L/min
Mass kg 232
Item OPT VALVE

Model KADV22Y / 501103A03
Over load relief valve set pressure MPa
Positioner R 39.7 at 30 L/min
Positioner H 37.7 at 30 L/min
Mass kg 2.8
T1-1-5
PILOT VALVE
ATTACHMENT TRAVEL
Model PV48K2004 6TH6NRZ
Primary pressure 5.0 MPa 4.9 MPa
Secondary pressure 0.6 ~ 3.2 MPa 0.54 ~ 2.35 MPa
Rated flow 20 L/min 25 L/min
Mass Approx. 2 kg Approx. 8 kg
SWING MOTOR UNIT

Model M5X130CHB10A41C/295
Swash-plate type, fixed-displacement plunger
Type
motor
Displacement cm3 129.2
Hydraylic motor
Working pressure MPa 32.4

Max. flow L/min 220
Braking torque Nm 655
Release pressure MPa 2.5~5.0
Relief set pressure MPa 29
Mass kg 49
Antireaction Type 2KAR6P72/240-712

valve block Mass kg 2.5
Hydraulic motor assy mass kg 51.5
Speed reduction type Planetary 2-stage
Reduction ratio 15.38
Reduction unit
Lubicate oil Gear oil SAE90 (API class GL4 grade)

Lubicate oil volume L 3.0
Grease Extreme pressure lithium base # 2 grease
Grease volume kg Approx. 1.0
Mass kg 145
Total mass kg Approx. 197
T1-1-6
TRAVEL DEVICE
Item E215B E245B
Reduction gear unit Epicycloidal, three-stage planetary type
Model 710 C3 K
Gearbox ratio 1 : 55.2 1 : 43.2
Travel motor Two speed, axial piston swash plate type
Model MAG 170 VP MAG 170 VP
high speed 81.2 cm3/rev 112.6 cm3/rev
Displacement
low speed 129.3 cm3/rev 181.3 cm3/rev
Max. flow 220 L/min 246 L/min
Max. gearbox output high speed 38949 Nm 42827 Nm

torque low speed 24469 Nm 25600 Nm
static 32060 Nm 25000 Nm
Parking brake torque
dynamic 26707 Nm 20900 Nm
Min. pressure parking brake release 11 bar
cracking 311 bar at 1.2 L/min
Relief valve set pressure
total flow 353 bar at 40 L/min
Mass 235 kg 262 kg
CYLINDERS
Center distance
Cylinder bore / of pins
Use Rod Dia. Stroke Full extend B / Cushion Mass
Full retract A
(mm) (mm) (mm) (kg)
With cushion
Boom 120 / 85 1345 3200 / 1855 176
on rod side
With cushion
Arm 135 / 95 1558 3637 / 2079 255
on both sides
With cushion
Bucket 120 / 80 1080 2684 / 1604 153
on rod side
Positioning 145 / 90 992 2662 / 1670 Without cushion 220
T1-1-7
EXCAVATOR PERFORMANCE
GRADEABILITY ......................................................................................................................................... 70%
TRAVEL SPEED
Excavator
E215B E245B
Speed
First speed 3.6 km/h 3.2 km/h
Second speed 6.0 km/h 5.2 km/h
ENGINE DATA
MAIN SPECIFICATIONS
- Manufacturer ................................................................................................................................. CNH U.K.
- Model .........................................................................................................................................667TA/MEB
- Type ..................................................................................... Diesel, 4 stroke, direct injection, turbocharged
- Number of cylinder ...........................................................................................................................6 in-line
- Bore ................................................................................................................................................. 104 mm
- Stroke............................................................................................................................................... 132 mm
- Total displacement .........................................................................................................................6728 cm3
- Compression ratio ............................................................................................................................... 17.5:1
- Net power at flywheel (at 2000 rpm) (ISO 14396)............................................................................. 118 kW
- Torque (at 1200 rpm) ........................................................................................................................670 Nm
- Engine idle at no-load ...................................................................................................................... 800 rpm
INJECTION PUMP
- Type .................................................................................................................................VE6/12 F 1000 LV
- Injection order ............................................................................................................................. 1-5-3-6-2-4
BATTERY
- Voltage - Capacity............................................................................................................. 2 x 12 V - 100 Ah
STARTER MOTOR
- Manufacturer .................................................................................................................................... BOSCH
- Voltage - Output .......................................................................................................................... 24V - 4 kW
ALTERNATOR
- Manufacturer .................................................................................................................................... BOSCH
- Type .................................................................................................................................NCB1 28V 35-70A
- Voltage - Output ............................................................................................................................ 28V - 55A
T1-1-8
SPECIFICATIONS E215B
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
TRANSPORTING DIMENSIONS E215B

(Monoblock Version)
VERSIONS A B C D E F G H I L
(1) 9617 (1) 3133
(2) 9580 (2) 3044
E215BEL 3656 4451 1035 2800 2503 3027 948 471
(3) 9493 (3) 2884
(4) 9568 (4) 3044
(1) 9617 (1) 3133
(2) 9580 (2) 3044
E215BL 3656 4451 1035 2800 2503 3027 948 471
(3) 9493 (3) 2884
(4) 9568 (4) 3044
(1) 9617 (1) 3133
(2) 9580 (2) 3044
E215BLC 3656 4451 1035 2800 2503 3027 948 471
(3) 9493 (3) 2884
(4) 9568 (4) 3044
Arm: (dimensions in mm)
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 mm
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 (kg) 20590 20850 21120 20920 21190 21460 21730 20940 21210 21480 21750
Spec. ground pres. (bar) 0.55 0.47 0.40 0.47 0.41 0.36 0.32 0.47 0.41 0.36 0.32
(*) With arm 2940 mm and bucket 1.3 m3
T1-1-11

G E
D
H
F
I C
L
M A
N B NH0148
(1) 9683 (1) 3062
(2) 9665 (2) 3014
E215BEL 3656 4451 1035 2800 2503 3027 948 471
(3) 9643 (3) 2954
(4) 9631 (4) 3237
(1) 9683 (1) 3062
(2) 9665 (2) 3014
E215BL 3656 4451 1035 2800 2503 3027 948 471
(3) 9643 (3) 2954
(4) 9631 (4) 3237
(1) 9683 (1) 3062
(2) 9665 (2) 3014
E215BLC 3656 4451 1035 2800 2503 3027 948 471
(3) 9643 (3) 2954
(4) 9631 (4) 3237
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 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 (kg) 21220 21490 21760 21560 21830 22100 22360 21580 21850 22120 22390
Spec. ground pres. (bar) 0.57 0.48 0.42 0.48 0.42 0.37 0.33 0.48 0.42 0.37 0.33
(*) With arm 2940 mm and bucket 1.3 m3
T1-1-12
BUCKET APPLICATIONS AS A FUNCTION

OF THE ARMS E215B
E215B Monoblock
BUCKETS E215BEL E215BL E215BLC
Capacity Arm (mm) Arm (mm) Arm (mm)

Width (dm3) Mass
(mm) SAE J296 (kg) 2080 2400 2940 3500 2080 2400 2940 3500 2080 2400 2940 3500
(ISO 7451)
750 525 503
850 625 537
1000 789 634
1200 1000 651
1300 1105 698
1500 1315 760
E215B Triple Articulation
BUCKETS E215BEL E215BL E215BLC
Capacity Arm (mm) Arm (mm) Arm (mm)

Width (dm3) Mass
(mm) SAE J296 (kg) 2080 2400 2940 3500 2080 2400 2940 3500 2080 2400 2940 3500
(ISO 7451)
750 525 503
850 625 537
1000 789 634
1200 1000 651
1300 1105 698
1500 1315 760
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
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
DIGGING DATA E245B

(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

(Monoblock Version)
(1) 9617 (1) 3141
(2) 9577 (2) 3050
E245B 3840 4645 1053 2800 2503 3045 970 486
(3) 9487 (3) 2886
(4) 9564 (4) 3044
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 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

G E
D
H
F
I C
L
M A
N B NH0148
(1) 9684 (1) 3067
(2) 9665 (2) 3014
E245B 3840 4645 1053 2800 2503 3045 970 486
(3) 9641 (3) 2957
(4) 9634 (4) 3235
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 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
BUCKET APPLICATIONS AS A FUNCTION

OF THE ARMS E245B
E245B Monoblock
BUCKETS E245B
Capacity (dm3) Arm(mm)

Width (mm) SAE J296 Mass (kg)
(ISO 7451) 2080 2400 2940 3500
750 525 503
850 625 537
1000 789 634
1200 1000 651
1300 1105 698
1500 1315 760
E245B Triple Articolation
BUCKETS E245B
Capacity (dm3) Arm (mm)

Mass
Width (mm) SAE J296 (kg) 2080 2400 2940 3500
(ISO 7451)
750 525 503
850 625 537
1000 789 634
1200 1000 651
1300 1105 698
1500 1315 760
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
SYSTEM
CONTENTS
Group 1 - Mechatro Control System 5 Positioning circuit (triple articulation

version) .............................................. T2-2-8
1 Preface .............................................. T2-1-1
6 Color coding standard for hydraulic
2 Summary of Mechatro control system T2-1-2 circuits................................................ T2-2-10
2.1 Mechatro control system in 7 Neutral circuit .................................... T2-2-10
general ..................................... T2-1-2
8 Travel circuit ...................................... T2-2-12
2.2 Unload valve control ................. T2-1-4
9 Bucket circuit ..................................... T2-2-14
2.3 Positive control & P-Q control... T2-1-5
10 Boom circuit ...................................... T2-2-16
2.4 Boom up conflux control ........... T2-1-7
11 Swing circuit ...................................... T2-2-20
2.5 Arm in recirculation & conflux
12 Arm circuit ......................................... T2-2-22
control....................................... T2-1-8
13 Combined circuit ............................... T2-2-28
2.6 Arm-in anti-cavitation control .... T2-1-10
14 Pressure draining (releasing) circuit . T2-2-32
2.7 Arm-out conflux control............. T2-1-11
2.8 Bucket digging (dump) conflux Group 3 - electrical system
control....................................... T2-1-12
2.9 Bucket digging anti-cavitation Electrical system main components........ T2-3-1
control....................................... T2-1-13 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
Electrical system diagram (No. 5) ...... T2-3-21
3 Mechatro controller ............................ T2-1-21
Wiring harness ........................................ T2-3-22
3.1 Summary of multi display ......... T2-1-21
Cluster gauge wiring harness
3.2 Self diagnosis display ............... T2-1-27
assembly................................... T2-3-23
3.3 Service diagnosis display
Platform wiring harness assembly .... T2-3-25
function ..................................... T2-1-29
Upper frame wiring harness assembly . T2-3-27
3.4 Trouble history diagnosis.......... T2-1-39
Engine wiring harness (KSB & STOP) . T2-3-29
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
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 MECHATRO CONTROL SYSTEM
2 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
PILOT VALVE FOR TRAVEL
FOR ATT
SE-9
SE-10
SE-11
LOW PRESSURE SENSOR
SE-4
(4)
SE-3
(3) L2
GAUGE CLUSTER L3
SENSOR BLOCK
SE-2
(2)
LCD DISPLAY
SE-1
FOR SELECTION (1)
FUEL GAUGE
COOLANT TEMP. GAUGE SE-8
(8)
SWITCH
SCREEN CHANGE SE-7
(7)
BUZZER STOP
L4
MODE (6)
WASHER
WIPER SE-5
(5)
OUTPUT VOLTAGE
TRAVEL
AUTO-IDLE
PSV-R
SERIAL COMMUNICATION
SERIAL COMMUNICATION
SHORT-CIRCUIT PROPORTIONAL
ACCEL DIAL VALVE VALVE
SE-16
SE-23
HIGH PRESSURE SENSOR
C-1 SE-22 L5
MECHATRO CONTROLLER ENGINE A1 A2 A3
GOVERNOR
MOTOR
SPEED SENSOR
M-2 SE-13
PSV -P1
P1 PUMP PROPORTIONAL VALVE
: HIGH PRESSURE SENSOR
(FOR P1,P2 : 2pcs) PSV -P2
: GOVERNOR MOTOR P2 PUMP PROPORTIONAL VALVE
: E/G SPEED SENSOR L6

: LOW PRESSURE SENSOR
(ATT : 7pcs, TRAVEL : 2pcs) L7
VOLTAGE 24V
PROPORTIONAL COMMAND CURRENT
SM0116
T2-1-2
MAIN CONTROL VALVE

L1
SE-29
ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT

(8) (2) (4) (3) (6) (8) SV-13
P1 UNLOAD
ATTACHMENT BOOST
SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
N&B
BUCKET
P2 UNLOAD
OPTION
STRAIGHT
SWING
TRAVEL
PL1
SOL
P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM IN
L2 SOLENOID VALVE
L3
L4
SWING MOTOR PARKING RELEASE
TRAVEL MOTOR 1,2 SPEED SELECT
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE
SAFETY LOCK LEVER

ATTACHMENT BOOST
TRAVEL 1,2 SPEED

TRAVEL STRAIGHT
ARM IN 2 SPEED
L5
P1 UNLOAD
P2 UNLOAD
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV SV
-A -D -C -B -2 -3 -1 -4
(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
SM0117
T2-1-3
2.2 UNLOAD VALVE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
TRAVEL
P2 UNLOAD
P2 P1
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS 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
2.3 POSITIVE CONTROL & P-Q CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
(LEFT) (RIGHT) PILOT PILOT

VALVE VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2
pi
pi
P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0119
T2-1-5
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.
POSITIVE CONTROL P-Q CONTROL
PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS

SECONDARY PRESSURE
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
PILOT PRESSURE PUMP DELIVERY PRESSURE
SM0120
T2-1-6
2.4 BOOM UP CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
BOOM UP PILOT SECONDARY PRESSURE 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.
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
2.5 ARM IN RECIRCULATION & CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7
CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM IN PILOT SECONDARY PRESSURE
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D
pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE
P2 PUMP PRESSURE MECHATRO pi : PROPORTIONAL VALVE

CONTROLLER SECONDARY PRESSURE
SM0122
T2-1-8
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 arm-
in 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
2.6 ARM-IN ANTI-CAVITATION CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi PILOT SIGNAL
PROCESS REVERSE PROPORTIONAL
VALVE CONTROL PROCESS
FOR ARM 2 SPOOL PSV-Bpi

pi
VALVE FOR ARM VALVE FOR ARM 2 SPOOL
2 SPOOL COMMAND PSV-A pi
ENGINE SPEED (COMMAND VALUE) MECHATRO

CONTROLLER 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
2.7 ARM-OUT CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM OUT PILOT SECONDARY PRESSURE

pi
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
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.
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
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
2.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
LOW
PRESSURE
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

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

pi
PILOT SIGNAL
PROCESS TRAVELSTRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE SM0125
SECONDARY PRESSURE
1. On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches
bucket spool and is input to low pressure sensor.
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.
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
2.9 BUCKET DIGGING ANTI-CAVITATION CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
ACCEL VALVE PSV-B
POTENTIO
pi PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C

PILOT SIGNAL
pi PROCESS
BUCKET ATT BOOST
ANTI-CAVITATION SOLENOID VALVE
PROCESS SV-2
ENGINE SPEED (COMMAND VALUE)
MECHATRO
CONTROLLER
P1 PUMP PRESSURE pi : PROPORTIONAL VALVE
T2-1-13
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.
valves, P1 and P2 unload proportional valves and travel straight proportional valve.
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
2.10 SWING PRIORITY CONTROL
BOOM UP CONFLUX
P1 UNLOAD
PILOT
TRAVEL RIGHT
VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
LOW
PRESSURE
SENSOR
SE-5 SE-7
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
MECHATRO pi : PROPORTIONAL VALVE

SWING PILOT SECONDARY PRESSURE CONTROLLER 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.
valves, P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve
for arm 2 spool.
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
2.11 TRAVEL STRAIGHT CONTROL
BOOM UP CONFLUX
P1 UNLOAD
OPTIONAL
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL
SOLENOID SHORT CIRCUIT

VALVE
LOW
SE-10 SE-9 SE-11 PRESSURE
SENSOR
VALVE SIGNAL
TRAVEL STRAIGHT SIGNAL
pi
PILOT SIGNAL PROPORTIONAL
PROCESS VALVE PSV-R
IN SHORT-CIRCUIT
VALVE
PILOT
SECONDARY PRESSURE
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C
PILOT
SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
PILOT
SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
PILOT
T2-1-16
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 Bucket Swing Option

Right travel operation (P1)
Left travel operation (P2)
T2-1-17
2.12 PRESSURE RELEASE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1
SE-23 SE-22
ENGINE
(M-2)
PRESSURE
RELEASE
CONTROL ENGINE SPEED
CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
pi
PILOT SIGNAL
P1 UNLOAD
VALVE PSV-D
MECHATRO
pi : PROPORTIONAL VALVE SM0130
CONTROLLER SECONDARY PRESSURE
1. Change mechatro controller to PRESSURE DRAING MODE by operating switch on gauge cluster.
For detail of changing mode method, refer to Pressure draining (releasing) circuit on GROUP 2 -
HYDRAULIC CIRCUIT.
2. Once mechatro controller decides it as pressure release control, regardless of each input signal (operating
pilot, accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to
minimum tilt angle.
2) Outputs command of pressure release to control step-by step motor (M2) and fixes engine speed to
pressure release control speed.
3) Outputs maximum command to P1 and P2 unload proportional valves and each pilot secondary
pressure fixes P1 and P2 unload valves to the maximum opening.
3. Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump
pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
4. Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure)
to be released by operating each control lever and switching spool with the unload valve opened.
T2-1-18
2.13 N&B SWITCH CONTROL (OPTION)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR
BUCKET
OPTION
SE-29 VALVE
SWING
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
A MODE
B MODE
GAUGE CLUSTER
pi
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
2.14 OPTION CONFLUX CONTROL (OPTION)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
PILOT VALVE
P2 UNLOAD
TRAVEL
P2 P1
SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
P1 UNLOAD
VALVE PSV-D

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE SM0132
OPTION PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
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.
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
3. MECHATRO CONTROLLER
3.1 SUMMARY OF MULTI DISPLAY
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
1. Controls
SWING PARKING
BRAKE RELEASE
GAUGE SWITCH
CLUSTER
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.
FUSE &
STARTER SWITCH RELAY BOX
ACCEL DIAL
DETAIL A
SM0133
A
2. Gauge cluster
11
No. Name
22:00 1 Engine coolant temperature gauge
2 Fuel level gauge
H 3 Screen change switch
4 Buzzer stop switch
1 5 Work mode select switch
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 Select switch
10
6 11 Multi display (LCD)
4 9 8 5 7
SM0134
T2-1-21
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 Contents
S mode
10:25 "S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.

H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.

B mode
10:25 For the work with breaker, select "B mode" without fail.

A mode
10:25 For the work with crusher (nibbler), select "A mode".

T2-1-22
1) Pump flow rate adjustment (A mode /B mode) 1 2 3 4

No. Switches
1 Screen change switch
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 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 130 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m
Enter
H A A
(a) (b) (d)
Increase/Decrease
In Breaker mode (B mode)
Flow Flow Flow

rate 130 L/m rate 100 L/m rate 100 L/m
Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 130 L/m rate 130 L/m
A B
(b) (c) SM0141
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
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
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
Warning table
These descriptions indicate error codes stored as trouble history code
W009 W005 W011
CAUTION ATTACHMENT LOW ENG OIL PRESS. PREHEAT
W006
POWER BOOST ON HIGH ENG WATER TEMP. CHARGE ERROR
CPU W004
DATA COMMUNICATION LOW ENG WATER LEVEL LOW FUEL LEVEL

ERROR
W001 W010
SWING BRAKE DRAIN WATER AUTO WARMING UP

DISENGAGED SEPARATOR
W008
ENG LOW PRESSURE CLOGGED AIR FILTER CHANGE ENG OIL

(ENGINE STOP)
NOTE: Error codes were stored as trouble history, and displayed on the monitor by the
trouble history display function.
T2-1-26
Warning Condition
Trouble
Level Buzzer sounds
Priority Screen Condition Only Engine History
(*) Type Auto Manual Code
Key ON Run
(**) Stop Stop
Data from Mechatro controller
1 DATA COMMUCATION ERROR O O 3 x O
is not received
The swing parking brake
1 SWING BRAKE DISENGAGED O O 2 O O W001
switch is turned ON
Engine is stopped after engine
A 1 ENGINE STOP O 1 O x
oil pressare low warning
Impossible to drain hyd.
2 FAIL DRAIN HYD. PRESSURE O O 1 x O
Pressure
2 DRAINING HYD. PRESS. Possible to drain hyd. Pressure O 4 x O
The selector valve (OPT) is

1 CAUTION ATTACHMENT O 2 x O W009
malfunction
2 POWER BOOST ON The power boost switchis turn ON O O -
After finishing warming up

2 FINISH WARM-UP O 2 O x
control
Low engine oil pressure O 2 x O W005
3 LOW ENG OIL PRESS.
Disconnection O
The engine water is more than

3 HIGH ENG. WATER TEMP. O O 3 x O W006
105 C
Water in water separator filter
3 DRAIN WATER SEPA O O 3 x O W010
is increased
B 3 CLOGGED AIR FLTR The air filter is clogged O O 3 x O W008
According to the self diagnosis

3 (SELF DIAGNOSIS SCREENS) O O 3 x O
control
The heater relay contact is
3 PREHEAT O O 3 O W011
faulty
4 CHARGE ERROR No signal from the alternator O -
4 LOW FUEL LEVEL The fuel level is less than 10 % O O -
The warter engine coolant

4 LOW ENG WATER LEVEL O - W004
reservoir is low
The auto warming up control is
5 AUTO WARMING UP O -
activated
The remaining time is reached
5 CHANGE ENG OIL O O -
zero Huors
(*) 1: these extremely influence safety and the machine (**) 1: Continuation
performance 2: Beep ON 0.2 sec. OFF 0.3 sec.
2: these warn the machine control mode is switched 3: Beep ON 0.5 sec. OFF 0.5 sec.
3: fatal failure 4: Beep ON 0.5 sec. OFF 1.0 sec.
4: normal priority warning
5: low priority message
3.2 SELF DIAGNOSIS DISPLAY

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
CONTROL
Pressure sensor, Governor motor SERIAL COMMUNICATION

INPUT Proportional valve, Battery relay
Gauge cluster
Selector valve (SOL) (Buzzer sound)
SM0147
T2-1-27
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 Last 2nd and 3rd digits: Specifies failed section.
B013
Last 1 digit: Specifies failure type.
This failure symbol is displayed simultaneously with error code during failure diagnosis.
ERROR CODE SM0148
ALPHABET
A B C D E F G H I K R
Controller Low pressure High pressure Proportional Proportional Potentiometer
valve for valve for Solenoid valve Speed sensor Communication Battery relay Relay output
memory sensor sensor etc.
nd rd
2 AND 3 DIGIT
Engine Wiper ark
01 adjust data
Boom up P1 pump P1 unload P1 pump ATT boost Step motor Throttle Battery relay prevention
Torque adjust Swing parking Wiper ark

02 data
Boom down P2 pump P2 unload P2 pump
brake
Step motor forward
Unload Travel 1,2 Wiper ark

03 adjust data
Arm out Boom head Travel straight
speed reverse
Option
04 Arm in
selector
Washer motor
Bucket
05 digging
Arm 2 spool for

06 Bucket dump
arm in
07 Swing
09 Travel right Fuel sensor
10 Travel left
Selector
11 position
13
14
PSV-R Short
15 Cricuit valve
16 P1 side option AIS relay2
Engine stop
17 P2 side option
relay
Safety lock
18 lever relay
Adjustment
21 data sector 1
Safety relay
Adjustment
22 data sector 2
Hourmeter
23 sector 1
Hourmeter
24 sector 2
Proportional
25 valve adjust
Cluster
31 communication
LAST DIGIT
Larger than Larger than
0 normal range normal range
Transistor
1 - OFF failure/
Transistor ON Transistor ON
2 - Wrong output Wrong output
failure failure
Over run
Transistor ON
3 - Disconnection Disconnection Disconnection Disconnection failure / Disconnection Disconnection Time is over
Power source Power source Power source Contact point Power source
4 -
short circuit short circuit short circuit is melted and short circuit
adhered
Obnormal
5 data
T2-1-28
3.3 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.2No.3No.4...)
Wiper switch: Screen loses by 1 in order. (No.24No.23No.22...)
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns
to No.1. (No.1No.2No.3No.1...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then
returns to No.3. (No.3No.2No.1No.3...)
4) Turn key switch OFF and the display of service diagnosis mode is closed.
T2-1-29
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. Displays Contents No. Displays Contents

1 4
NO.1 NO.4 RELAY
MAIN CONT. P/N
YN22E00207F1 P/No. indication K-1 AIS RELAY 2 ON Indicated value
PROGRAM VERSION K-2 SAFETY RLY ON Indicated value
1-VER 2.00 Program version indication K-3 ENG STOP OFF Indicated value
2-VER 0.00 KEY SWITCH ON Key switch
START SWITCH OFF Starter switch
SERVICE DIAG 1 Service diagnosis mode CHARGE LIVE Alternator
K-4 LOCK LEVER OFF Indicated value
SWITCH ON Switch
2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 1000 No load setting rpm B-1 BOOM RAISE
MEAS 1000 Actual rpm 0.4 V 0.0 M Sensor voltage / Pressure converted value
G-5 ENG PRS. LIVE Engine oil pressure B-2 BOOM LOWER
WATER TEMP 20 C OFF Coolant temperature sensor / Coolant tempreature switch 0.4 V 0.0 M Sensor voltage / Pressure converted value
B-3 ARM OUT
MODE H Work mode 0.4 V 0.0 M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 0.3 V Potentiometer voltage B-4 ARM IN
POS. 0% Voltage % indication 0.4 V 0.0 M Sensor voltage / Pressure converted value
G-1 MOTOR STEP 30 Number of step B-5 BUCKET DIG
POS. 0% Step % indication 0.4 V 0.0 M Sensor voltage / Pressure converted value
COIL A 1.5 A A phase current B-6 BUCKET DUMP
COIL B 1.5 A B phase current 0.4 V 0.0 M Sensor voltage / Pressure converted value
G-2 LIMIT SW. OFF Limit switch
3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. OFF Set value in computer 0.4 V 0.0 M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-9 TRAVEL (R)
SWITCH OFF Switch 0.4 V 0.0 M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL (L)
COMP. ON Set value in computer 0.4 V 0.0 M Sensor voltage / Pressure converted value
MEAS. ON Measured value B-16 P1 OPT.
RELEASE SW OFF Switch 0.4 V 0.0 M Sensor voltage / Pressure converted value
F-3 1/2-TRAVEL B-17 P2 OPT.
COMP. OFF Set value in computer 0.5 V 0.0 M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-18 DOZER 1
SWITCH OFF Switch 0.0 V 0.0 M Sensor voltage / Pressure converted value
B-19 DOZER 2
0.0 V 0.0 M Sensor voltage / Pressure converted value
SM0149
T2-1-30

7 16
NO.7 P.SENSOR PROPO-V NO.16 PRESS.SENSOR
C-1 PUMP P1 B-11
0.4 V 0.3 M Sensor voltage / Pressure converted value 0.4 V 0.0 M Sensor voltage / Pressure converted value
C-2 PUMP P2 B-12
0.4 V 0.0 M Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
0.0 V 0.0 M
C-3 BOOM-HEAD
B-13
0.5 V 0.9 M
Sensor voltage / Pressure converted value 0.0 V 0.0 M Sensor voltage / Pressure converted value
C-4 BOOM-ROD
0.0 V 0.0 M B-14
PROPO-VALVE Sensor voltage / Pressure converted value 0.0 V 0.0 M Sensor voltage / Pressure converted value
E-3 OPT RELIEF 1 B-15
COMP. 0 mA 2.0 M Set value in computer / Converted value from pressure 0.0 V 0.0 M Sensor voltage / Pressure converted value
MEAS. 0 mA 2.0 M Measured value / Converted value from pressure B-20
E-4 OPT RELIEF 2 0.0 V 0.0 M Sensor voltage / Pressure converted value
COMP. 0 mA 2.0 M Set value in computer / Converted value from pressure
MEAS. 0 mA 2.0 M Measured value / Converted value from pressure
8 18
NO.8 PROPO-VALVE NO.18 DIGITAL INPUT
D-1 P1 UN-LOAD(BP-CUT) DI1 OFF ON/OFF indication
COMP. 750 mA 3.0 M Set value in computer / Converted value from pressure DI2 ON ON/OFF indication
MEAS. 750 mA 3.0 M Measured value / Converted value from pressure DI3 OFF ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) DI4 OFF ON/OFF indication
COMP. 750 mA 3.0 M Set value in computer / Converted value from pressure DI5 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 --- ON/OFF indication
Mechatro
COMP. 350 mA 0.6 M Set value in computer / Converted value from pressure DI8 OFF ON/OFF indication
controller
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
COMP. 750 mA 0.0 M Set value in computer / Converted value from pressure DI11 --- ON/OFF indication
MEAS. 750 mA 0.0 M Measured value / Converted value from pressure DI12 --- ON/OFF indication
DI13 ON ON/OFF indication
DI14 --- ON/OFF indication
9 19
NO.9 PROPO-VALVE NO.19 DIGITAL INPUT
E-1 P1 PUMP DI15 --- ON/OFF indication
COMP. 417 mA 1.0 M Set value in computer / Converted value from pressure DI16 ON ON/OFF indication
MEAS. 417 mA 1.0 M Measured value / Converted value from pressure DI17 ON ON/OFF indication
POWER SHIFT 0 mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 30 L Flow rate of pump P1 DI19 --- ON/OFF indication
E-2 P2 PUMP DI20 OFF ON/OFF indication
COMP. 417 mA 1.0 M Set value in computer / Converted value from pressure DI21 --- ON/OFF indication
MEAS. 417 mA 1.0 M Measured value / Converted value from pressure DI22 --- ON/OFF indication
POWER SHIFT 0 mA Power shift DI23 ON ON/OFF indication
FLOW RATE 30 L Flow rate of pump P2 DI24 OFF ON/OFF indication
DI25 ON ON/OFF indication
DI27 OFF ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
1.2 V 77% Fuel level DI30 --- ON/OFF indication
H-10 HYD.OIL TEMP DI31 --- ON/OFF indication
0.0 V 0 Hydraulic oil temperature DI32 --- ON/OFF indication
GLOW --- Glow switch DI33 ON ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 --- ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 --- ON/OFF indication
ENG OIL FILTER --- Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 --- ON/OFF indication
DOUBLE FLOW ON Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW --- Command from grid heater DI39 --- ON/OFF indication
HEATER OFF Engine oil level DI40 OFF ON/OFF indication
ENG OIL LEVEL OK Coolant level DI41 --- ON/OFF indication
COOLANT LEVEL OK DI42 ---
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH NIB Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. --- Set value in computer MEAS. OFF Measured value
MEAS. --- Measured value DO5 COMP. --- Set value in computer
F-6 MEAS. --- Measured value
COMP. --- Set value in computer DO6 COMP. --- Set value in computer
MEAS. --- Measured value MEAS. --- Measured value
DO7 COMP. OFF Set value in computer
15 22
NO.15 PROPO-VALVE NO.22 DIGITAL OUTPUT
D-11 P1 I-TRAVEL DO8 COMP. ON Set value in computer
COMP. 0 mA 0.0 M Set value in computer / Converted value from pressure MEAS. ON Measured value
MEAS. 0 Ma 0.0 M Measured value / Converted value from pressure DO9 COMP. OFF Set value in computer
D-12 P2 I-TRAVEL MEAS. OFF Measured value
COMP. 0 mA 0.0 M Set value in computer / Converted value from pressure DO10 COMP. --- Set value in computer
MEAS. 0 mA 0.0 M Measured value / Converted value from pressure MEAS. --- Measured value
D-15 P1 BY PASS VALVE DO11 COMP. OFF Set value in computer
COMP. 347 mA 0.6 M Set value in computer / Converted value from pressure MEAS. OFF Measured value
MEAS. 347 mA 0.6M Measured value / Converted value from pressure DO12 COMP. --- Set value in computer
D-16 P2 BY PASS VALVE MEAS. --- Measured value
COMP. 0 mA 0.0 M Set value in computer / Converted value from pressure DO13 COMP. --- Set value in computer
MEAS. 0 mA 0.0 M Measured value / Converted value from pressure MEAS. --- Measured value
DO14 COMP. --- Set value in computer
MEAS. --- Measured value
SM0150
T2-1-31
No. Displays Contents

23
NO.23 DIGITAL OUTPUT
DO16 COMP. ON Set value in computer
MEAS. ON Measured value
DO21 COMP. ON Set value in computer
24
NO.24 DIGITAL OUTPUT
25
NO.25 WIPER SYSTEM
WIPER SW OFF Wiper switch
RISEUP SW ON Wiper rise-up switch
REVERSE SW ON Wiper reverse rotation switch
PREVENT ARC OFF Wiper motor ark prevention
CW MOTOR RLY OFF relay
CCW MOTOR RLY OFF Wiper normal rotation relay
WASHER SW OFF Wiper reverse rotation relay
MOTOR RELAY OFF Washer switch
Washer motor relay
SM0151
T2-1-32

1 33
NO.1 NO.33 BUCKET
MAIN CONT. P/N C-1 P1 PUMP 0.2 M Pump pressure sensor
YN22E00207F1 P/No. indication C-2 P2 PUMP 0.0 M Pump pressure sensor
PROGRAM VERSION E-1 P1-PSV 417 mA Command current
1-VER 2.00 Program version indication E-2 P2-PSV 417 mA Command current
2-VER 0.00 MERIT controller program version D-1 P1-UL(BPC) 750 mA Command current
D-2 P2-UL(BPC) 750 mA Command current
SERVICE DIAG 2 Service diagnosis mode 2 D-3 S-TRAVEL 350 mA Command current
B-5 BUCKET DIG 0.0 M Bucket digging pressure sensor
B-6 BUCKET DUMP 0.0 M Bucket dump pressure sensor
G-3 ENG SPEED 1000 Engine actual speed
POWER SHIFT 0 mA Power shift current
31 34
NO.31 BOOM NO.34 TRAVEL
C-1 P1 PUMP 0.2 M Pump pressure sensor C-1 P1 PUMP 0.2 M Pump pressure sensor
E-1 P1-PSV 417 mA Command current E-1 P1-PSV 417 mA Command current
D-1 P1-UL(BPC) 750 mA Command current D-1 P1-UL(BPC) 750 mA Command current
B-1 BOOM RAISE 0.0 M Boom up pressure sensor D-3 S-TRAVEL 350 mA Command current
B-2 BOOM LOWER 0.0M Boom down pressure sensor B-9 TRAVEL(R) 0.0 M Travel right pressure sensor
G-3 ENG SPEED 1000 Engine actual speed B-10 TRAVEL(L) 0.0 M Travel left pressure sensor
POWER SHIFT 0 mA Power shift current Pi-P1 0.0 M Pilot pressure at travel straight (P1 side)
Pi-P2 0.0 M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0 mA Power shift current
32 35
NO.32 ARM,SWING NO.35 OPT
D-3 S-TRAVEL 350 mA Command current D-3 S-TRAVEL 350 mA Command current
D-6 ARM-IN-2 750 mA Command current E-3 OPT RELIEF 110 mA Command current
B-3 ARM OUT 0.0 M Arm out pressure sensor B-16 P1 OPT 0.0 M P1 side option pressure sensor
B-4 ARM IN 0.0 M Arm in pressure sensor B-17 P2 OPT 0.0 M P2 side option pressure sensor
B-1 BOOM RAISE 0.0 M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 0.0 M Swing pressure sensor DOUBLE FLOW SW OFF Conflux/ Single selector switch
G-3 ENG SPEED 1000 Engine actual speed G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0 mA Power shift current POWER SHIFT 0 mA Power shift current
SM0152

1 43
NO.1 NO.43 MACHINE-INFORM.
MAIN CONT. P/N HOUR METER 3550 Hour meter of controller
YN22E00207F1 P/No. indication TRIP METER 3500 Trip meter of controller
PROGRAM VERSION OPERATION 3300 All accumulated operating time
1-VER 2.00 Program version indication TRAVEL 300 All accumulated traveling time
2-VER 0.00 MERIT controller program version SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker operating time
SERVICE DIAG 3 Service diagnosis mode 3 CRANE 100 All accumulated high-reach crane operating time
STARTER 1200 All accumulated starter operating time
41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2230 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 515 mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
7 mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 35.0 M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 930 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 565 mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 565 mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 0 0 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 0 0 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 0 0 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 0 0 Angle adjustment
SM0153
T2-1-33
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 Operation No.2 : No operation

H mode Hi idle 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
D-1 P1-UL(BPC) 750 mA D-1 P1-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 1970~2030 G-3 ENG SPEED 1770~1830
POWER SHIFT 0 mA POWER SHIFT 0 mA
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
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
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
T2-1-34
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 1970~2060
POWER SHIFT 0 mA
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
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
T2-1-35
Operation No.8 : Operation No.9 :

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
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
* Measure the values after a lapse of 5 minutes or * Measure the values after a lapse of 5 minutes or
after release of low temperature mode after release of low temperature mode

Swing in full lever operation & relief Swing in full lever operation & in operation
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-2 P2-PSV 528~750 mA E-2 P2-PSV 750 mA
T2-1-36

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
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-1 P1-PSV 650~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 540~563 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

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 6.0~15.0 M
C-2 P2-PRES 33.0~35.8 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
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
T2-1-37

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
A mode Hi idle 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
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 NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
* Conflux switch is ON. Relief set pressure is value * Conflux switch is OFF. Relief set pressure is value
of shipping. of shipping.

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
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
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
T2-1-38
3.4 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) Display trouble history screen.
2) Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
3) When "NO ERROR" is displayed, the deletion is completed.
4) Turn starter switch off.
NOTE: all the stored items are erased. It is impossible to erase data partially.
T2-1-39
3.5 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
3.6 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.
Screen change Buzzer stop KPSS work mode
NOTE: interval of replacement of parts is mentioned switch switch select switch
below.
Washer
Engine oil : 500 Hr switch
Fuel filter : 500 Hr
Hydraulic filter : 1,000 Hr
Select Wiper
Hydraulic oil : 5,000 Hr switch switch
Auto accel Travel speed
switch select switch
SM0155
Procedure Operating Procedure Display on Multidisplay
After several seconds,

NEW HOLLAND display is changed to 10:25
1 Turn starter key switch on. KOBELCO clock autmatically.
H
Press " " switch press once display

change switch on the switch panel once. And 10:25 Press screen change 250 Hr
2
the clock display changes to the display of switch once more. ENGINE OIL
remaining time for coming engine oil change. H H
Press " " switch press once select

switch once and the display for the engine 250 Hr Press select switch 250 Hr
3
oil change reverses. ENGINE OIL once more. ENGINE OIL
H
When required to adjust the interval to the coming

Replacing interval is
4
change time by 10 hours, press " " switch 250 Hr changed with each 500 Hr
and the time to the coming engine oil change is ENGINE OIL ENGINE OIL
pressing of switch.
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. 500 Hr To set the desired interval, 500 Hr
5 Press " " select switch once and the set ENGINE OIL press the select switch ENGINE OIL
time is stored. H
SM0156
NOTE:
1. After displaying the display for setting by pressing the display change switch, set the respective
maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does
not sound.
T2-1-41
3.7 ADJUSTING PROCEDURE OF DISPLAY

1. For operator
1) Clock Adjustment Switches 1 2 3 4

No. 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 5
7 Auto Accel Switch 8 7 6 SM0140
8 Select Switch
Main screen (a)

SWITCH STATUS
10:25 CLOCK/CONTRAST 13:15
H H
(a) (b)
(c) (d) (e)

SWITCH STATUS ADJUST CLOCK Y M D H M Enter
CLOCK/CONTRAST ADJ CONTRAST 06 04 01 13 15
Select Year/Month/Day/Hour/Minute 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 "YMDHM" in operation of FEED (4) and FEED (5) and vary the values in
operations of FEED (6) and FEED (7).
5) After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting
is completed, and then the screen returns to main screen (a).
T2-1-42
2) Contrast Adjustment Switches 1 2 3 4

No. 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 5
7 Auto Accel Switch 8 7 6 SM0140
8 Select Switch
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
(c) (d) (a)

SWITCH STATUS ADJUST CLOCK
CLOCK/CONTRAST ADJ CONTRAST 10:25
H
(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555
Adjustable range
11111~99999 Increase/Decrease
(Default 55555) SM0158
1) Turn starter key switch on and display main screen (a), and press select switch (8) and display
"SWITCH STATUS CLOCK CONTRAST" select screen (b).
2) In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.
3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and
then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4) Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5) Vary the values by pressing the desired figure in operations of FEED (4) and FEED (5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) 99999 (clear) * The initial set value is 55555.
6) Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).
T2-1-43
2. Function for service

Following items are provided for adjustment of service function.
LANGUAGE/LOGO
Function Explanation Note Range Default
All language data is stored in 15
LANGUAGE To change language ISO
one gauge cluster languages
LOGO To change Company Logo 5 Logos NHK
ADJUSTING MODE 1
Function Explanation Note Range Default
To change wiper control, when special
RISE-UP WIPER CAB is installed on demolition OFF is for special CAB ON/OFF ON
machine
P1 OPT SENSOR To activate the self-diagnosis when P1 Switch to ON when 2PB is
ON/OFF OFF (*)
ACTIVE OPT pressure sensor is failed installed
P2 OPT SENSOR To activate the self-diagnosis when P2 Switch to ON when N&B
ON/OFF OFF (*)
ACTIVE OPT pressure sensor is failed option is installed
Only for EU, to activate the priority
PRIORITY MODE ON/OFF OFF
valve
To use P1 option pedal for P4-rotation
LEFT PEDAL
circuit, releasing auto accel. And not ON/OFF OFF
ACTIVE
activating unload valve
1:No selector valve
SELECT OPT Switch to ON when N&B
2:Selector Valve + Mechanical relief 1 or 3 1 or 3 (*)
SYSTEM option is installed
3:Selector Valve + Electrical relief
ADJ OVERLOAD To change the pressure for overload
10 - 27 18
PRESS alarm in EU
ENG SPEED To activate the engine speed
ON/OFF OFF
DISPLAY information for customer
6, 8, 10, 12,
AUTO ACCEL To change auto accel control type 18
14, 16, 18
To change the starting MODE X: return to default MODE
START MODE S, H, B, A, X S
(S,H,B,A) when key sw is ON
To cancel the low temp. mode to
CANCEL LOW OFF = Low Temp. Mode
prevent hydraulic hunching at low ON/OFF OFF
TEMP MODE ACTIVE
temp.
DRAIN HYD. To activate the drain hydraulic When switch is ON, this
ON/OFF OFF
PRESS pressure function function starts.
20 - 35
15 Mpa (at
To adjust Pressure and Flow for Pressure
ADJ OPT HAMMER Follow setting procedure 220 L/min)
Hammer (9set) 30 - 220
220 L/min
Flow rate
20 - 35
15 Mpa (at
To adjust Pressure and Flow for Pressure
ADJ OPT NIBBLER Follow setting procedure 220 L/min)
Nibbler (9set) 30 - 220
220 L/min
Flow rate
(*) Autodetect
T2-1-44
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 S
screen shows display (B).
3. Press SELECT button (2); the screen shows
display (C) indicating the symbol of the language 1
previously set, for example: ENG (English).
4. Press WIPER button (3) or WINDSHIELD
4
WASHER button (4), once or more until the
symbol of the desired language is displayed, for 5
example FRA (French); the screen shows
display (D). 2 3
5. Press SELECT button (2) to memorize the
language selected, the screen shows display SM0069
(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. NO. 1
MAIN CONT. P/N
(A) YN 22E 00207 F1

PROGRAM VERSION
1 VER 2.00
2 VER 0.00
SERVICE DIAG 1
List of the languages available:

1 2
EU (ISO icons only)
LANGUAGE/LOGO
ITA ADJUSTING MODE 1
PRESET BY FACTORY
USA (B)
CHN
IDN
THA SELECT LANGUAGE
ESP ENG
FRA (C)
FEED
DEU
VNM
4
MYS
MMR 3
TAM SELECT LANGUAGE
POR FRA
(D)
ENG
FEED
JPN
SELECT LANGUAGE
FRA
(E)
FEED
SM0070
T2-1-45
2.2 Setting Adjusting Mode 1

NO. 1
To enter the displays Adjusting Mode 1 proceed as MAIN CONT. P/N
YN 22E 00207 F1
follows: (A) PROGRAM VERSION

1 VER 1.00
2 VER 0.00
SERVICE DIAG 1
1. Keep BUZZER CUT-OFF button (1) pressed
x3
and, at the same time, move the STARTER 1 2
SWITCH onto ON; the screen shows display
LANGUAGE/LOGO
(A) ADJUSTING MODE 1
PRESET BY FACTORY
2. Keep BUZZER CUT-OFF button (1) pressed, (B)
then press SELECT button (2) three times; the
screen shows display (B).
3
3. Press WINDSHIELD WASHER button (3) to get
ADJUSTING MODE 1, the screen shows display LANGUAGE/LOGO
(C). ADJUSTING MODE 1
4. By pressing SELECT button (2) you enter the (C) PRESET BY FACTORY
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 11
RISE-UP WIPER
WASHER button (4), to return back. (D) ON
FEED
2.3Adj. Overload Press (tip-over momentum 4 3

device) SM0071
To modify the value of the pressure at which the

pressure sensor goes ON to operate the tip-over LANGUAGE/LOGO
momentum device, proceed as follows: ADJUSTING MODE 1
1. In function Adjusting Mode 1, display (C), press (C) PRESET BY FACTORY
SELECT button (2) to enter the functions and

use WIPER button (3), to select function 63 -
2
ADJ OVERLOAD PRESS on display (E).
2. Press SELECT button (2) to choose the number 3
relative to the setting pressure, display (F).
63
18 = 180 bar
ADJ OVERLOAD PRESS
3. Press WINDSHIELD WASHER button (4), to (E) 18
increase the pressure, or WIPER button (3), to FEED
decrease it.
4. Set the desired pressure value (for example: 11),
display (G), press SELECT button (2) to 63
memorise it. ADJ OVERLOAD PRESS
By pressing SCREEN CHANGE button (5) you

(F) 18
FEED
return to display (C).
To exit the program, move the STARTER
SWITCH onto OFF. 4 3
63
ADJ OVERLOAD PRESS
(G) 11
FEED
63
ADJ OVERLOAD PRESS
11
FEED
5
SM0073
T2-1-46
2.4 Drain Hyd. Press
To drain the hydraulic pressure from the system,

LANGUAGE/LOGO
proceed as follows: ADJUSTING MODE 1
1. In function Adjusting Mode 1, display (C), press (C) PRESET BY FACTORY
SELECT button (2) to enter the functions and

using WIPER button (3), select on the display
function DRAIN HYD. PRESS, display (H). 2 3
2. Press SELECT button (2) to show the writing
OFF, display (I). DRAIN HYD PRESS
(H)
3. Press WINDSHIELD WASHER button (4) to OFF
FEED
activate function ON, display (L).
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 (I)
DRAIN HYD PRESS
OFF
pressure is drained from all the actuators.
FEED
The function is automatically deactivated by
returning the STARTER SWITCH onto OFF.
4
NOTE: if the monitor displays FAIL DRAIN HYD
PRES. this means that the pressure draining DRAIN HYD PRESS
operation has not been performed correctly. In this (L) ON

FEED
case, repeat the operation.
(M)
10:25
PR
S
SM0072
T2-1-47
3.8 MECHATRO CONTROL EQUIPMENT

1. C-1 Mechatro controller
1) Outside view
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
SM0159
2) List of connectors
Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
25 DL EARTH / OPEN(5V
26 GP 0V
27 CANH1 CAN communication
Spare
28 CANL1 CAN communication
29 DO 20 Spare Output EARTH/OPEN
30 DO 21 Safety relay Output EARTH/OPEN
32 DO 23 Extra pressure release Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN
SM0160
T2-1-48
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
22 D1 37 Spare Input GND / OPEN
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
16 Reserved
SM0161
T2-1-49
CN104 1 GA 0V
2 A17 Boom head (Over load) Input 0.5~4.5V
5 A18 Spare Input 0.54.5V
6 GA 0V
7 GA 0V
8 A19 Extra pressure source Input 0.5~4.5V
12 GA 0V
13 A21 Engine coolant
Input Resistor
14 GA temperature
15 A22
Fuel level Input Resistor
16 GP
17 A23 Resistor
Spare Input
18 GA
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
23 A25 Extra pressure source Input 0.5~4.5V
24 GA 0V
25 GA 0V
28 DI 1 Starting point of accel motor Input GND / OPEN
CN105 1 +24V 20~32V
Battery relay output side
2 +24V 20~32V
3 +24V Battery relay output side 20~32V

4 DO 7 Travel 1,2 speed select valve Output 24V/OPEN
5 DO 8 Swing P/B select valve Output 24V/OPEN
6 DO 9 Travel 1,2 speed select valve Output 24V/OPEN
7 DO 11 Attachment boost select valve Output 24V/OPEN
8 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0~800mA
11 D1+ P1 unload Output +0~800mA
12 D1- -0~800mA
13 D2+ P2 unload Output +0~800mA
14 D2- -0~800mA
15 D3+ Travel straight Output +0~800mA
16 D3- -0~800mA
17 D4+ Arm in Output +0~800mA
18 D4- -0~800mA
19 D5+ P1 pump Output +0~800mA
20 D5- -0~800mA
22 D10- OPT changeable relief 1 Output -0~800mA
23 D6+ P2 pump Output +0~800mA
24 D6- -0~800mA
25 D7+ Spare Output +0~800mA
26 D7- -0~800mA
28 D8- -0~800mA
29 D9+ Spare Output -0~800mA
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V
SM0162
T2-1-50
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ Accel motor A phase Output 1.5A
4 F1- Accel motor A phase Output 1.5A
5 F2+ Accel motor B phase Output 1.5A
6 F2- Accel motor B phase Output 1.5A
7 OIL Oil level (spare) 0
8 OILG
9 D11+ OPT changeable relief 2 Output +0~800mA
10 D11- -0~800mA
12 D12- -0~800mA
13 D13+ Bypass valve Output +0~800mA
14 D13- -0~800mA
16 D14- -0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shiled GND
23 CANH2 Proportional vlave expand unit CAN communication
24 CANL2 CAN communication
CN107 1 DI 3 Grid heater feedback Input +24V/OPEN
2 DI 8 Engine coolant temperature Input EARTH / OPEN
3 DI 9 E/G oil pressure Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
5 DI 11 Spare Input EARTH / OPEN
7 DI 13 E/G coolant level Input EARTH / OPEN
10 DI 20 Heater temperature of fuel filter Input EARTH / OPEN
12 DI 32 Hand control nibbler Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
15 DI 40 Heater temperature Input EARTH / OPEN
17 Reserved
SM0163
T2-1-51
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Water separator Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 Spare Input GND / OPEN
6 DI 16 Wiper rise up Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
8 DI 18 ATT boost Input GND / OPEN
10 DI 21 Spare Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation Input GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
24 Reserved
25 H1+ Spare 0~5V
26 H2- 0V
27 H2+ Spare 0~5V
28 H2- 0V
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Spare Output GND / OPEN
6 DO 6 Reserved Output GND / OPEN
7 DO 12 Spare Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Grid heater Output GND / OPEN
15 Reserved
16 GP 0V
17 TXD2 Tranmission RS232C communication
Spare
19 RTS RS232C communication
20 CTS RS232C communication
21 SHG2 Shiled GND
22 DO 10 Spare SV 24V/OPEN
SM0164
T2-1-52
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
Gauge cluster Mechatro
GND source (+24V Battery Yellow /
1 controller (RS232C White 5
direct connection) Black
communication)
Mechatro controller Gauge
2 cluster (RS232C Red 6 GND Black
communication)
Source (+24V starter switch
3 7 White
ON)
GND (RS232C
4 8 Black
communication)
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 120168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3
4 Buzzer Piezo-electricity type
5 Screen change switch
7 Work mode select switch
T2-1-53
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 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17
20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2
11 22 1 3 1 3
13 26 13 26 9 20 CN14 CN15
1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3
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
2) Circuit diagram
SM0167
T2-1-55
SM0168
T2-1-56
SM0169
T2-1-57
4) High pressure sensor : YN52S00048P1
ECONOSEAL SERIES MARK(+)> SPECIFICATION :

3POLES CAP
MATING HOUSING174357-2 PRESSURE RANGE : 0 50 MPa
POWER SOURCE VOLTAGE : 5.0+0.5V DC
COMMON OUTPUT : 1/10Vs-9/10Vs
OUTPUT (+) (Vs=5V DC 0.5 4.5V DC)
POWER SOURCE (+) INSURANCE RESISTANCE : 100M OR MORE
HOUSING (BETWEEN CASING AND ALL IN/OUT
TERMINAL
TERMINALS AT 50V DC MEGGER)
PLASTIC POTTING CONDENSER
COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM
O-RING P14 PIPE

JIS B2401 CLASS1B
THREAD
PF 3/8
Tightening torgue STRUCTURE
73.5N.m (54.2lbf.ft) 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.
Performance Device Function Features Performance Device Function Features
Travel straight Travel straight at combined operation Electric flow controlled variable displacement Pump delivery rate control by a current
pump command to the solenoid proportional valve
of the variable displacement pump
Pump
Travel 2-speed change & Auto 1st (low) 1-2 travel speed change and low speed / high Positive flow rate control Flow control by positive pilot control pressure
speed return torque at heavy duty
Mass handling capability

Travel
Auto parking brake Automatic braking when parking Hydraulics backup control Backup control by hydraulic when the electric
flow controlled variable displacement pump
fails.
Motor overrun protection Prevents overrunning of travel motor on the Boom up conflux circuit Speed up of boom up operation
Travel pilot operation Prevents hunting by the built in travel Arm conflux circuit Speed up of arm operation
Attachment
Reverse rotation protective function Easy positioning to protect it from swinging Bucket conflux circuit For speed-up of bucket operation (digging &
back when stops swinging. dump)
Swing priority circuit Easy operation of stable swing speed, arm Optimum operation by work mode select Efficient operation in all work modes
Swing
(simultaneous operation of arm in and swing slanted leveling, swing press digging (H,S,A,B)
motions)
Automatic swing parking brake Swing parking brake when operating at on a Auto accel Reduce fuel consumption and noise by
consumption
computer
slope lowering engine speed when control lever is
Low fuel
Micro
in neutral position.
Hydraulic pilot control system Light action with operating lever

Easy operability and safety
Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected drop
Attachment
(Natural fall).
Holding valve for boom (Option) Prevention of boom falling when boom head
side piping breaks
Emergency manual valve for lowering For safety, this valve lowers risen attachment
attachment to the ground, if the machine stops with
engine trouble, and the pressure in the
cylinder of attachment can be released.
Pressurized hydraulic oil tank To prevent hydraulic oil from entering dust
and to promote self suction ability of pump
Suction strainer Remove dust on suction side.
Line filter; pilot circuit To prevent pilot operating circuit from

malfunctioning
Return circuit oil filter To prevent hydraulic oil from contamination
Others
Cooling hydraulic oil by oil cooler To prevent hydraulic oil from being deteriorated.
Pressure draining circuit To release the main circuit pressure for piping
repair work.
Main control valve with optional valve Optional piping and additional work are easy
Switching of return line for N&B machine in Switching of return line for N&B machine is
the cab (Option) able to change with a switch in the cab
T2-2-1
E215B-E245B HYDRAULIC SYSTEM
2. HYDRAULIC CIRCUITS AND COMPONENTS
HYDRAULIC DIAGRAM READING KEY
Item Component name
1 Hyd. pump assy
2 Control valve (main)
3 Swing motor unit
4 Travel motor unit
5 Boom cylinder (RH & LH)
6 Arm cylider
7 Bucket cylinder
8 Swivel joint
9 Pilot valve (ATT)
10 Pilot valve (travel)
11 Inline filter
12 Suction strainer
13 Solenoid valve assy
14 Return filter
15 Air breather
16 Restrictor
17 Shuttle valve
18 Short-circuit valve
19 Low pressure sensor block
T2-2-2
HYDRAULIC CIRCUIT (MONOBLOCK VERSION)
SM0077
T2-2-3
3. N&B HYDRAULIC CIRCUIT (OPTION)

N&B HYDRAULIC CIRCUIT READING KEY
Item Component name
50 Selector valve
51 Stop valve
52 Pilot valve
53 Overload relief valve
The hydraulic circuit for N&B is used to add to

standard circuit
Selection condition and proportional valve

command when any of nibbler single & conflux flow
or breaker in service.
Command signal of solenoid proportional valve

SELECTION
(W:O, W/O: -)
Electromagnetic
Conflux/single flow command signal of P1 P2 Travel P1 P2
changeover switch selector valve (50) Pump Pump Straight Unload Unload
(W:O, W/O: -)
Conflux flow of
Conflux ON - O O O O O
nibbler
Single flow of
Conflux OFF - - O - - O
nibbler
Breaker Conflux OFF O - O - - O
When using nibbler, according to specification of

nibbler installed.
Adjust overload relief valve (53) of optional port to

customize specification ordinary set pressure.
T2-2-4
N&B HYDRAULIC CIRCUIT
51
53
52
53
50
SM0078
T2-2-5
4. 4. HOLDING VALVE FOR BOOM & ARM

(OPTION)
HOLDING VALVE FOR BOOM
The holding valve for boom prevents the boom
falling in case of head side cylinder piping breaks.
HOLDING VALVE FOR ARM

The holding valve for arm prevents the arm falling in
case of rod side cylinder piping breaks.
HYDRAULIC CIRCUIT READING KEY

Item Component name
54 Holding valve for boom cylinders
55 Holding valve for arm cylinder
T2-2-6
HOLDING VALVE FOR BOOM & ARM HYDRAULIC CIRCUIT
54 55
SM0079
54
T2-2-7
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
POSITIONING CIRCUIT (TRIPLE ARTICULATION VERSION)
57
R
POSITIONING
CYLINDER
H 58
59
56
SM0080
T2-2-9
6. COLOR CODING STANDARD FOR 7. NEUTRAL CIRCUIT 7.3 PUMP POSITIVE FLOW CONTROL
HYDRAULIC CIRCUITS This section describes the following. (1) Type: The operation is maintained until the
Blue 7.1 Bypass cut valve and unload valve control Electric flow controlled variable displacement opening of spool sleeve is closed.
Feed, drain circuit pump.
7.2 Safety lock lever and pilot circuit
less than 0.44 MPa (64 psi) 7.3 Pump positive flow control (2) Principle:
Green The current command I to the pumps solenoid 7.4 PUMP P-Q CURVE CONTROL OPERATION
7.4 Pump P-Q (Pressure-Quantity) curve control
Return, make up circuit, proportional valve controls the delivery rate of (1) Type:
0.44~0.59 MPa (64~86 psi) the pump. Electrical flow control type variable pump
Purple 7.1 OPERATION OF BY-PASS CUT VALVE AND (3) Operation: (2) Principle:
Secondary pilot pressure, UNLOADING VALVE HOUSED IN CONTROL 1) Flow rate rise operation (Eg. P1 pump) Perform an operation of the value from pump
(including proportional vlave) VALVE By operating any of control levers, the high pressure sensor to P-Q curve control value,
0.59~5 MPa (86~725 psi) operating secondary pressure of pilot valve and send a command to the pump solenoid
(1) By-pass cut valve
Red On starting engine, P1 and P2 unloading rises, and the rising pressure is transformed proportional valve.
Primary pilot pressure, proportional valves (PSV-D, PSV-B) output to the rise of output voltage corresponding (3) Operation:
(including proportional vlave) secondary pressure according to the command to the pressure input by the low pressure The pump high pressure sensor converts the
5 MPa (725 psi) output by mechatro controller, and this pressure sensor. Mechatro controller signal- pressure to the output voltage corresponding to
Orange exerts on PBp1 and PBp2 ports, and processes this change of voltage, resulting the pump delivery pressure.
Main pump drive pressure, consequently the by-pass cut spool is switched in rise of command current value I to the The mechatro controller converts the voltage
5~34.3 MPa (725~4970 psi) to CLOSE side. pump proportional solenoid valve and output by the high pressure sensor to the P-Q
The by-pass cut spool is usually held on CLOSE consequently the pump flow rate rises. This curve control value. On the other hand, select
Blue tone
side after the engine started. And it is switched is called "Positive Control System". the pump positive control command current
At valve operation
to OPEN side only when failure occurred on As the pump command current value rises, value from the low pressure sensor in lower
Red valve the secondary pressure of proportional
pump proportional valve and mechatro order, and the values are output to respective
When solenoid proportional valve (reducing) is solenoid valve also rises. On the regulator
controller. pump proportional valve as a command current.
operating attached on the pump, the spool (652)
(2) Unloading valve With this operation, the pump power is
Red solenoid through piston (643) is pushed leftward, and controlled so as not to be exceed the engine
In active and exciting On starting engine, like by-pass cut valve, the stops at the position where being in
secondary pressures output by P1 and P2 power, therefore engine dose not stall.
proportion to the force of pilot spring (646).
Displaying the flow circuit and standby circuit when unloading proportional valves (PSV-D, PSV-B) The tank port connected to the large bore of
operating. exert on PCb and PCa ports, consequently the servo piston (532) opens, and the piston
Regarding the electrical symbols in this manual, P1 and P2 unloading valves are switched to moves leftward by delivery pressure P1 of
refer to the electric circuit diagram. OPEN side. the small bore resulting in the increase of tilt
angle ( ).
7.2 SAFETY LOCK LEVER AND PILOT CIRCUIT The servo piston (532) and spool (652) are
(1) Purpose: connected to feedback lever (611).
To protect attachment from unexpected Therefore when servo piston moves
movement for safety. leftward, the spool (652) also moves
rightward by means of feedback lever. With
(2) Principle:
this movement, the opening of spool sleeve
Cut pressure source of pilot valve for operation.
closes gradually, and the servo piston stops
(3) Operation: at the position the opening closed
If the safety lock lever (red) is pushed forward completely.
after the engine starts, the limit switch (SW-11) 2) Flow rate reduction operation
is turned on. The timer relay is actuated one As the current value I of mechtro controller
second later which causes the solenoid (SV-4) reduces, the secondary pressure of
of the solenoid valve block (13) to be energized solenoid proportional valve reduces, and
and makes the pilot operating circuit to stand by. spool (652) is moved rightward by the force
of pilot spring (646). With the movement of
spool, the delivery pressure P1 usually flows
into the large bore of piston through the
spool.
The delivery pressure P1 flows in the small
bore of servo piston, but the servo piston
moves rightward due to the difference of
area, resulting in the reduction of tilt angle.
Similarly, when the servo piston moves
rightward, the spool (652) is moved leftward
by the feedback lever.
T2-2-10
NEUTRAL CIRCUIT: Positive control function at safety lock lever down (unloked position)
651 652
611
643 646
532
SM0081
T2-2-11
8. TRAVEL CIRCUIT 8.2 2-SPEED TRAVEL SOLENOID COMMAND

CIRCUIT AND AUTO 1st SPEED RETURN
This section describes the following.
FUNCTION
8.1 Travel forward pilot simultaneous operation
1) Purpose:
circuit
Change travel motor speed with switch.
8.2 2 speed travel solenoid command circuit and
auto 1-speed return function (2) Principle:
If the switch is turned, an electric signal is
8.3 Travel main circuit
issued. It excites the 2-speed travel solenoid
8.4 Travel motor function which in turn converts the primary pilot pressure
and the self pressure to a tilting angle of the
8.1 TRAVEL FORWARD PILOT variable displacement motor.
SIMULTANEOUS OPERATION CIRCUIT (3) Operation:
(1) Purpose: If the rabbit marked switch on the gauge cluster
Light operating force and shockless operation is pressed, the solenoid (SV-3) of the
(2) Mechatronics : proportional valve block (13) is excited and
changes the proportional valve. Then the
1) If the travel lever with damping mechanism
solenoid command pressure is issued from port
is operated for travel right, left and forward
A3, enters the Ps port of the travel motor (4),
motions, the secondary pilot proportional
opens the oil passage to the 2nd speed select
pressure comes out of the 3, 1 ports of P/V
piston, and causes the motor to run in the 2nd
(10). The higher of the pressures is
speed tilting mode by its self pressure.
selected, comes out of the 6, 5 ports and
However, when the main circuit pressure rises
acts upon the low pressure sensors (SE-9)
above 27.3 MPa (3960 psi) (E245B) and 28 MPa
(SE-10).
(4060 psi) (E215B), the motors self pressure
2) The pilot secondary pressure flows to PAr pushes the 2nd speed select piston back to the
and PAL ports of the control valve (2), 1st speed.
moves the travel spool, and switches the
main circuit.
3) The low pressure sensor output voltage is 8.3 TRAVEL MAIN CIRCUIT
input into mechatro controller. The mechatro (1) Operation:
controller performs signal processing and The delivery oil from Pump A1 and A2 ports by
outputs current corresponding to the changing the travel spool with the operation of
increase of flow rate to P1 pump travel pilot flows into P1 port on the left side
proportional valve (PSV-P1) and P2 pump motor (4) and P2 port on the right side motor (4)
proportional valve (PSV-P2), and at the through C,D ports of swivel joint (8) from AL, AR
same time the command current is output to ports of C/V, and rotates the travel motor.
P1 unloading valve (PSV-D) and P2
unloading valve (PSV-B).
4) The secondary pressures output by P1 8.4 TRAVEL MOTOR FUNCTION
pump proportional valve (PSV-P1) and P2 (1) Function:
pump proportional valve (PSV-P2) exert on 1) Prevents the motor from over running on a
pump regulator, actuating the pump on the slope.
delivery flow rate increase side. 2) Check valve that prevents cavitation of the
5) The secondary pressure delivered in P1 hydraulic motor.
unloading valve (PSV-D) and P2 unloading 3) Shockless relief valve and anti cavitation
valve (PSV-B) is fed to PBp1, PCb, PBp2 valve when inertia force stops.
and PCa ports provided in control valve (2).
4) High/Low 2 step speed change mechanism
The secondary pressure from proportional
and auto 1st speed return at high load.
valve which has exerted on PBp1 and PBp2
ports holds the by-pass cut spool on CLOSE 5) Travel parking brake.
side, like the operation in the lever neutral
position.
valve which has exerted on PCb and PCa
ports switches the unloading spool in
CLOSE side.
T2-2-12
TRAVEL CIRCUIT: Travel 2nd speed, RH & LH simultaneous operation.
SM0082
T2-2-13
9. BUCKET CIRCUIT 5) The secondary pressure delivered in travel bucket spool and returns to tank circuit from
priority proportional valve (PSV-C) is led to Bc port of C/V (2).
This section describes the following.
PTb port provided in control valve (2) and References:
9.1 Bucket digging pilot circuit shifts the travel priority valve one stage. In bucket dumping operation, the travel
9.2 Auto accel operation priority valve also switches like digging
9.3 Flow control in the work mode 9.2 AUTO ACCELERATION OPERATION operation, resulting in confluence with travel
9.4 Bucket digging travel priority main circuit straight.
(1) Principle:
9.5 Bucket spool stroke limiter Auto acceleration actuates according to signals When the bucket operation and other
from low pressure sensor. operation are simultaneously performed, the
travel priority valve does not actuate,
(2) Operation:
resulting in single flow of bucket circuit.
9.1 PILOT CIRCUIT FOR BUCKET DIGGING <When lever is set to neutral position>
(1) Mechatronics : In the event where the sensor does not receive
signal for 4 seconds or more even though the 9.5 BUCKET SPOOL STROKE LIMITER
1) When the operation for bucket digging is
acceleration dial is set to MAX position, the (1) Purpose:
performed, the pilot proportional secondary
engine speed should be raised to 1050 rpm. To secure simultaneous operability of boom and
pressure is delivered through port 1 of the
<When lever is operated> arm on boosting up attachment pressure (Pump
right pilot V (9), flows to PAc port, and acts
When the pressure 0.6MPa (87psi) is input to flow rate decreases.) and to prevent cavitations
on the low pressure sensor (SE-1), and at
low pressure sensor in STD specification (travel, at low engine speed
the same time the bucket spool is switched.
bucket, swing, arm), proportional voltage from
2) The voltage output by low pressure sensor (2) Operation:
low pressure sensor inputs in mechatro
(SE-1) inputs in mechatro controller. The On boosting up attachment pressure, pilot
controller, and then the engine speed returns to
mechatro controller performs signal primary pressure exerts on PCc port of C/V(2)
the dial set position corresponding to the lever
processing and outputs current through attachment booster solenoid valve,
operation.
corresponding to the increase of pump flow operates stroke limiter of bucket spool, and
rate to pump proportional valves (PSV-P1) throttle oil path of spool. As a result, P1 pump
and (PSV-P2) on the P1 and P2 pump sides, 9.3 FLOW CONTROL IN THE WORK MODE pressure increases, making the simultaneous
and at the same time the command current operation of boom up and bucket digging
(1) Principle:
is output to P1 unloading valve (PSV-D), P2 possible.
When the engine speed is intermediate speed
unloading valve (PSV-B) and travel priority Even though the engine speed is low, similarly
or lower, command current value to have the
proportional valve (PSV-C). the cavitations can be prevented by actuating
pump delivery rate constant is output.
In the following pages, the relation of the stroke limiter.
operation of low pressure sensor to both the (2) Operation:
increase of pump flow rate and unloading Even if the engine speed specified by
proportional valve is the same. Therefore acceleration potentiometer is low speed, as the
the explanation is omitted. delivery rate corresponds to the intermediate
speed, the actuator moves earlier than the
3) The secondary pressure output by P1 pump
movement equivalent to the control lever angle
proportional valve (PSV-P1) and P2 pump
rate in light load operation.
proportional valve (PSV-P2) exerts on pump
regulator, actuating the pump onto the
delivery flow increase side. 9.4 BUCKET DIGGING AND TRAVEL PRIORITY
4) The secondary pressure delivered in P1 CONFLUENCE (CONFLUX) MAIN CIRCUIT
unloading valve (PSV-D) and P2 unloading (1) Operation:
valve (PSV-B) is led to PBp1, PCb, PBp2
1) The oil delivered through A1 port of P1
and PCa ports provided in control valve (2).
pump goes into P1 port of C/V (2), opens
load check valve LCc through parallel circuit
valve which has exerted on PBp1 and PBp2
and enters in bucket spool.
ports holds the by-pass cut spool on CLOSE
side, like the operation in the lever neutral 2) On the other hand, the oil delivered through
position. A2 port of P2 pump goes into P2 port of C/V
The secondary pressure from proportional (2), confluences with oil from P1 pump
valve which has exerted on PCb and PCa through travel priority valve, and goes into
ports switches the unloading spool in bucket spool. (Confluence of oil from 2
CLOSE side. pumps)
3) 3)With the function of pilot circuit, the oil flow
is switched from bucket spool, and is fed into
bucket cylinder head side through Ac port of
C/V (2). On the other hand, the return oil
from cylinder rod (R) side is throttled by
T2-2-14
BUCKET CIRCUIT: Bucket digging (Travel priority conflux), Auto-accelation and Standby flow rate constant control
SM0083
T2-2-15
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
BOOM CIRCUIT : Boom up operation, Confluence function.
SM0084
T2-2-17
This section describes boom lower operation. 10.5 CONSTANT RECIRCULATION FUNCTION
10.3 Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
10.4 Prevention of natural fall by lock valve and (1) Purpose:
actuation at lowering Prevention of cavitation during boom lowering
10.5 Constant recirculation function of boom down motion.
main circuit (2) Principle:
The oil returning from the boom cylinder head
(H) is recirculated to the rod (R).
10.3 BOOM DOWN PILOT CIRCUIT
(1) Operation: (3) Operation:
When the oil is supplied to the boom cylinder rod
1) If the boom down operation is performed, (R) side during boom down operation, the boom
the secondary pilot proportional pressure moves faster than it should do in some cases by
comes out of port 2 of the right pilot valve (9) the self weight of the attachment.
and acts upon the low pressure sensor (SE- On that occasion, the circuit pressure on the rod
4). (R) side is on the negative side.
At the same time, the pressure acts upon The oil supplied to the boom cylinder rod (R)
the PBb port of C/V (2). flows into the A1 port of the P1 pump and the P1
2) The voltage output of the low pressure port of C/V. The oil then passes through the
sensor (SE-4) enters the mechatro boom spool and goes out of the Bb port.
controller and processed in it. On that occasion, the oil returning from the head
3) Then, the proportionl secondary pressure (H) goes through the recirculation path in the
fed into C/V (2) PBb port and branches off in boom spool, pushes the check valve in the spool
two lines and switches boom spool and open, is recirculated to the Bb port and is
releases boom lock valve. supplied to the rod (R). When the (R) pressure
is larger than the head (H) pressure, the check
valve in spool closes.
10.4 PREVENTION OF NATURAL FALL BY LOCK
Thereupon, the recirculation is stopped.
VALVE AND ACTUATION AT LOWERING
(1) Purpose:
Prevention of natural fall when the lever is
neutral
(2) Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation:
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line
on the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from
making a natural fall.
T2-2-18
BOOM CIRCUIT: Boom down operation & Prevention of natural boom falling.
SM0085
T2-2-19
11. SWING CIRCUIT as the swing spool is shifted, the oil pushes the
load check valve LCs open through the parallel
This section describes the following operations.
circuit, enters the B port of the swing motor via
11.1 Swing left pilot circuit the Bs port of C/V (2), and rotates the swing
11.2 Swing auto parking brake motor counterclockwise.
11.3 Swing main circuit
11.4 Swing motor circuit
11.4 SWING MOTOR CIRCUIT
(1) Anti cavitation circuit at swing deceleration
11.1 PILOT CIRCUIT FOR LEFT SWING
(2) Shockless relief valve that prevents the swing
(1) Operation: motor from being reversed.
1) When the left swing operation is performed,
the pilot proportional secondary pressure is
delivered through port (1) of left pilot V (9),
and the secondary pressure acts on PBs
port of C/V (2), and simultaneously flows out
from Pss port of C/V and acts on low
pressure sensor (SE-5).
2) The voltage output by the low pressure
sensor is input in the mechatro controller,
and is signal-processed.
3) Then, the secondary pressure led into PBs
port of C/V (2) switches the swing spool.
11.2 SWING AUTO PARKING BRAKE

(1) Purpose:
Swing lock in neutral position and parking
(2) Principle:
Release mechanical brake only when required
to operate swing and arm in.
(3) Operation:
1) The swing parking system excites the swing
parking SOL (SV-1) usually if the key switch
is turned on and works by the action of the
mechanical brake.
2) The mechanical brake is released if the
swing parking solenoid is de-excited only
when the secondary operating pressure in
the swing and arm in actions acts upon any
of the low pressure sensors (SE-5, 7).
3) The swing parking solenoid (SV-1) is excited
five seconds after the pressure of the swing
low pressure sensors (SE-5) is reduced to
zero.
In the case of arm in operation, the swing
parking solenoid (SV-1) is excited the
moment the pressure of the arm in low
pressure sensor (SE-7) is reduced to zero.
This causes the mechanical brake to
operate.
11.3 SWING MAIN CIRCUIT

(1) Operation:
The oil delivered from the A2 port of the P2
pump enters the P2 port of C/V (2) and is
branched off into the bypass line and the parallel
circuit. However, since the bypass line is closed
T2-2-20
SWING CIRCUIT: Swing operation (LH)
SM0086
T2-2-21
12. ARM CIRCUIT 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
12.1 Arm in, light-load operating pilot circuit valve CRar is open, and is flowed into arm 2
12.2 Arm in, light-load variable normal recirculation spool through arm 1 spool.
main circuit / internal conflux main circuit 4) Because arm 2 spool is switched to normal
recirculation position, causing restriction of
12.1 ARM IN, LIGHT-LOAD OPERATING PILOT passage to tank, the return oil from arm
CIRCUIT cylinder (R) side flows into arm cylinder (H)
side.
(1) Purpose:
Speed-up and Anticavitation when the arm is at Because, at light load, the pressure in
light loaded. cylinder rod (R) side is higher than that in
the head (H) side, it opens the check valve
(2) Principle:
housed-in arm 2 spool and is recirculated
The oil returning from the arm cylinder rod (R) is
in the head (H) side, resulting in the speed
recirculated variably to the head (H) at arm 2
up of arm-in operation at light load.
spool in C/V.
5) Cavitations prevention control in arm-in
(3) Operation: operation.
1) When the arm in operation is performed, the Command current is output to arm 2
secondary pilot proportional pressure gets solenoid proportional valve by signal
out of port 4 of the left pilot valve (9) and acts processing of E/G speed and arm-in pilot
upon the low pressure sensor (SE-7). pressure, accordingly the arm 2 spool is
At the same time, the pressure is branched switched to neutral (cavitations prevention)
off in two flows, acts upon the PAa1 port and position, resulting in cavitations prevention.
the PLc2 port, changes over the arm spool
and the arm lock valve CRar releases. Position of arm 2 spool
2) The output voltage by the low pressure
Neutral position
sensor is input into mechatro controller, and (Anticavitation position)
is pilot signal-processed, and is output to Normal recirculation position
P1, P2 pump proportional valve (PSV-P1), Recirculation
(PSV-P2) and arm 2 inverse proportional
valve (PSV-A).
3) The secondary pressure from pilot From arm out
proportional valve, which is reduced by arm P/V
2 inverse proportional valve (PSV-A) From arm 2 inverse
proportional valve
switches arm 2 spool.
SM0195
12.2 ARM-IN, LIGHT-LOAD VARIABLE NORMAL Reference:

RECIRCULATION, INTERNAL CONFLUX In light-load arm-in operation (normal
MAIN CIRCUIT recirculation, conflux), when the attachment
(1) Operation: to which the circuit in P1 pump side is
applied is operated, the meter-in path of arm
1) The P2 pump delivery oil flows in travel left
2 spool is closed, resulting in single flow
section through P2 port of C/V (2) and is
operation.
branched off in by-pass circuit and parallel
circuit, but because arm 1 spool is switched,
Spool position at arm in,
the delivery oil which goes through parallel light load and combined operation
circuit opens load check valve LCa and is (This position is not shown in hydraulic diagram)
flowed into arm 1 spool. Meter-in passage
Neutral position
2) On the other hand, P1 pump delivery oil (Close)
flows in P1 port of C/V (2), and the flows in
travel straight section and travel right
tandem path. Then because arm 2 spool
was switched, the delivery oil opens load Normal recirculation opsition
check valve LCAT2, goes through arm 2 Arm 2 spool
SM0196
spool, and confluences with P2 pump
delivery oil in the valve section, and then is
flowed into arm cylinder head (H) side
through Aa port of C/V (2).
T2-2-22
ARM CIRCUIT: Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function
SM0087
T2-2-23
This section describes the following operations. 4) The return oil returns directly into tank circuit
12.3 Arm in, heavy load operating pilot circuit because arm 2 spool is switched to
(recirculation cut) recirculation cut position.
12.4 Arm in, heavy load operating sequence
confluxed main circuit Position of arm 2 spool
Neutral position Recirculation cut position
12.3 ARM IN, HEAVY LOAD OPERATING PILOT

From
CIRCUIT
arm out
(1) Operation: P/V
From arm 2 inverse
1) 1)In arm-in operation, when the heavy proportional valve
loading is applied to arm and the P2 pump
pressure increases to the set pressure, the SM0197
voltage output by P2 pump pressure sensor

(SE-23) is converted to signal (signal
processing) by mechatro controller,
consequently the current of arm 2 solenoid
proportional valve is controlled according to
the load pressure and the arm variable
recirculation is cut.
When the recirculation is cut, internal
confluence is held similarly to that in light
load operation.
2) Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.
12.4 ARM IN, HEAVY LOAD OPERATING

RECIRCULATION CUT MAIN CIRCUIT
(1) Purpose:
Speed up for arm in operation
(2) Principle:
Cut the recirculation and reduce rod pressure.
(3) Operation:
1) P2 pump delivery oil flows in the travel left
section through P2 port of C/V (2) and
branched off in by-pass circuit and parallel
circuit. Consequently the arm spool is
switched and pushes and opens load check
valve LCa through parallel circuit, and flows
in the arm spool.
2) On the other hand, P1 pump delivery oil
flows in P1 port of C/V (2), and flow in travel
right tandem passage through travel straight
section. Then because arm 2 spool was
switched, the delivery oil opens load check
valve LCAT2, and confluences with P2
pump delivery oil in the valve section, and is
flowed into arm cylinder head (H) side
through Aa port of C/V(2).
3) The return oil from arm cylinder (R) side
flows in Ba port of C/V(2) and is flowed to
arm lock valve CRar, but because the arm
lock valve CRar is open, the return oil goes
through arm lock valve CRar and flows in
arm 2 spool.
T2-2-24
ARM CIRCUIT: Arm in (Heavy load) operation, Arm confluence & recirculation cut function
SM0088
T2-2-25
This section describes the following operations. 12.7 NATURAL FALL PROTECTION WITH ARM
12.5 Arm out pilot circuit LOCK VALVE
12.6 Arm out 2 pumps conflux main circuit (1) Purpose:
12.7 Natural fall protection with arm lock valve To prevent the arm from falling naturally by the
weight of the arm and bucket.
(2) Principle:
12.5 ARM OUT PILOT CIRCUIT
Complete seat of the return circuit against the
(1) Operation: arm spool of the arm cylinder (R) side circuit.
1) When the arm out operation is performed, (3) Operation:
the secondary pilot proportional pressure
gets out of port 8 of the left pilot valve (9), 1) When the secondary pressure for arm
and acts upon the low pressure sensor (SE- operation disappears and the arm cylinder
8). At the same time, the oil is branched off stops, the pressure on the rod (R) side
in two flows and act upon the PBa1 and passes through the selector of the lock valve
PBa2 ports of C/V (2). from the Ba port of C/V, acts the back
pressure on the lock valve CRar and seats
2) The operating proportional secondary
the lock valve.
pressure flowed in PBa1 port of C/V (2)
switches the arm 1 spool. 2) Since the oil flow into the arm spool from the
lock valve is shut off completely, natural fall
3) Then, the operating secondary pressure
of the arm due to oil leaks through the arm
flowed in PBa2 port of C/V (2) switches the
spool is prevented.
arm 2 spool valve.
12.6 ARM OUT 2 PUMPS CONFLUX MAIN

CIRCUIT
(1) Purpose:
Arm out operation speed up.
(2) Principle:
The oil delivered by the P1 pump is confluxed
with that delivered by the P2 pump in C/V (2).
(3) Operation:
1) P1 pump delivery oil opens load check valve
(LCAT2) by switching arm 2 spool and
confluxes with P2 pump delivery oil just
short of the arm lock valve.
2) And, P2 pump delivery oil flows through arm
1 spool and confluences with P1 delivery oil,
opens lock valve of arm lock valve CRar with
free flow and is flowed into arm cylinder rod
(R) side through Ba port of C/V(2).
3) On the other hand, the return oil from arm
cylinder (H) side flows in Aa port, and
returns into tank circuit through arm 1 spool
and arm 2 spool.
The return line which does not pass through
boost check valve is used for this return
circuit to reduce the pressure loss.
T2-2-26
ARM CIRCUIT: Arm out operation, Confluence function
SM0089
T2-2-27
13. COMBINED CIRCUIT because the travel straight spool is shifted

and exerts on the right travel operation.
This section describes only the difference in
(In travel straight operation, P2 pump
combined operation.
delivery oil exerts on travel operation.)
13.1 Boom up / travel, pilot circuit
4) However, a portion of the flow is led to the
13.2 Boom up / travel, main circit spool of short-circuit valve notch restriction.
The speed of attachments like travel, boom,
13.1 BOOM UP / TRAVEL, PILOT CIRCUIT etc. is adjusted by the circuit of restriction.
(1) Operation:
<Operation: Different point of pilot circuit from
independent operation >
1) The mechatro controller outputs command
current to travel priority solenoid
proportional valve (PSV-C) and to short-
circuit solenoid proportional valve (PSV-R)
after signal processing.
And the solenoid proportional valve outputs
secondary pressure and acts on PTb port
and short-circuit valve.
2) Then the pressure of PTb port switches the
travel priority valve. And the secondary
pressure of solenoid valve in short-circuit
valve switches spool of short-circuit valve 1
step.
13.2 BOOM UP / TRAVEL, MAIN CIRCUIT

(1) Purpose:
To insure straight travel movement during travel
operation even if the attachment is operated.
(2) Principle:
The travel action and the attachment action are
actuated by separate pumps.
(3) Operation:
1) P1 pump delivery oil flows through P1 port of
C/V(2) and branches off in P1 parallel circuit
and spool of short-circuit valve.
P2 pump delivery oil flows through P2 port of
C/V(2) and branches off in P2 tandem circuit
and spool of short-circuit valve.
2) The delivery oil flowed into P1 parallel circuit
of P1 pump opens check valve CT1 and
LCb and flows in boom spool, which exerts
on boom up operation.
The delivery oil flowed into travel priority
spool of P1 pump opens check valve CT2
because the travel priority spool is shifted,
and flows in boom conflux spool and exerts
on boom up operation with the internal oil
conflux.
(In travel straight operation, P1 pump
delivery oil exerts on operation of
attachment.)
3) The delivery oil flowed into P2 tandem circuit
of P2 pump flows in left travel spool to travel
leftward.
The delivery oil flowed into travel priority
spool of P2 pump flows in right travel spool
T2-2-28
COMBINED CIRCUIT: Boom up & Travel forward 1st speed operation, Travel priority function.
SM0090
T2-2-29
In this section, the independent operation is omitted Position of arm 2 spool

and describes difference in combined operation.
13.3 Swing / Arm in light load, pilot circuit
13.4 Swing / Arm in, swing priority main circuit Position of forced recirculation
Neutral position Meter-in passage

13.3 SWING / ARM IN LIGHT LOAD, PILOT (Close)
CIRCUIT
From From arm 2
(1) Operation: arm out inverse
P/V proportional valve
1) On operating swing (left) and arm in motions
Normal recirculation position
simultaneously, mechatro controller outputs Arm 2 spool SM0198
command current to travel priority solenoid
proportional valve (PSV-C) and arm 2
solenoid inverse proportional valve
according to signal processing, and this
proportional valve outputs secondary
pressure, which acts on PTb port and PAa2
port of C/V(2).
2) PTb port pressure switches the travel
priority spool, and the PAa2 port pressure
switches the arm 2 spool to the forced
recirculation position.
13.4 SWING / ARM IN, SWING PRIORITY MAIN

CIRCUIT
(1) Purpose:
Stable swing speed.
(2) Principle:
Raise the oil pressure flowing to arm cylinder,
and give a priority of the delivery of P2 pump to
swing operation.
(3) Operation:
1) The swing main circuit operates with P2
pump flow. But on P2 pump circuit side, the
flow goes to the swing circuit and arm circuit
simultaneously because the swing circuit
and arm circuit are parallel. Then since the
return oil from arm cylinder rod (R) side is
restricted in the arm 2 spool because the
arm 2 spool is switched to forced
recirculation position, the pressure of return
oil is raised, causing the rise of circuit
pressure on the arm cylinder head (H) side.
2) At the same time meter-in of arm 2 spool
closes and arm in conflux is therefore
cancelled, and delivery oil from P2 pump
and P1 pump are combined in the parallel
circuit on P2 pump side because the travel
straight spool was switched.
The conflux oil of P1 and P2 delivery oil in
high pressure flows in swing side taking
priority over all others.
This operation is called "Swing Priority
Circuit".
T2-2-30
COMBINED CIRCUIT: Swing / Arm in operation, swing priority function
SM0091
T2-2-31
14. PRESSURE DRAINING (RELEASING) 14.2 PRESSURE RELEASING MAIN CIRCUIT

CIRCUIT (1) Operation:
14.1 Pressure releasing pilot circuit CAUTION:
14.2 Pressure releasing main circuit before to perform the hydraulic pressure releasing,
make sure to place bucket on the ground.
14.1 PRESSURE RELEASING PILOT CIRCUIT
When the operating lever is shifted to neutral
(1) Purpose:
during engine running, "DRAINING HYD.
To release the pressure in main circuit for piping
PRESS." is displayed on the gauge cluster
repair works.
while the mode switch is changed to pressure
(2) Principle: relieving mode.
After the mode is switched to "Pressure Relief In this time the intermittent buzzer sounds
Mode" with switch on gauge cluster, mechatro continuously. When right and left operating
controller outputs the following commands. levers are operated 4 or 5 times to their full
1) Minimum tilting command value to pump stroke, pressure is relieved.
proportional valve (PSV-P1, PSV-P2). After draining pressure is completed, turn off the
2) Output "Pressure relief control speed starter key and buzzer sound stops. If the pump
command value" at engine governor motor pressure is determined to be more than 1 MPa
(M2). (145 psi) by the output value of the high
3) Stand-by command value to P1, P2 pressure sensor (SE 22, SE 23) (or the high
unloading proportional valves. pressure sensors are broken) "FAIL DRAIN
How to switch to "Pressure release HYD. PRESS" is displayed and the buzzer
mode" sounds continuously. In that case, also the
1) Select the service diagnosis mode 1. buzzer is not stopped unless the engine key is
(Keeping pressing of the "BUZZER STOP turned to OFF. Repeat the pressure releasing
SWITCH" [ ] on gauge cluster, turn procedure once again.
the starter key ON.)
2) Select the service Adjustment Mode 1. (2) Hydraulics:
(Under the condition that "Screen No.1" If the Unloading valves are turned to the
of "Service diagnosis mode 1" is pressure release position, the oil delivered by
indicated, keeping pressing of the each pump is unloaded to the tank passage. If
"BUZZER STOP SWITCH", press the the spools are switched by pilot operation, the
SELECT switch [ ] 3 times. remaining pressure from the actuators may be
When "LANGUAGE/LOGO", relieved to the tank circuit, i.e. the main circuit
"ADJUSTING MODE 1" and "PRESET pressure may be released.
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
PRESSURE DRAINING (RELEASING) CIRCUIT: at pressure release mode
651 652
611
643 646
532
SM0092
T2-2-33
T2-2-34
ELECTRICAL SYSTEM E215B-E245B
ELECTRICAL SYSTEM MAIN COMPONENTS

ELECTRICAL SYSTEM (Overall system)
SM0004
A - Cab Control D - Hydraulic System Electrical Components

B - Mechatro Controller and Fuse&Relay box E - Engine Electrical Components
C - Batteries, Batteries Relay, Fuse link F - Light, Horn, ect
T2-3-1
E215B-E245B ELECTRICAL SYSTEM
A - CAB CONTROL
Electrical components
10 1
2
16
4
14
5
13
12 6
11 7
8
15
1 - Cluster gauge 9 - Cigarette lighter

2 - Power Boost switch 10 - Hour meter
3 - Starter switch 11 - Climate controls panel
4 - Engine speed throttle 12 - Quick coupling switch (opt.)
5 - Work lights switch 13 - Tuner
6 - Single/Double flow switch 14 - Cab work lights switch (opt.)
7 - Heavy Lift switch (opt.) 15 - Parking brake release switch
8 - Load momentum switch (opt.) 16 - Horn switch
T2-3-2
Cluster Gauge
SM0003
1 - Coolant temperature indicator 7 - Windshield washer button

2 - Fuel level indicator 8 - Wiper button
3 - Screen change button 9 - Buzzer cut-off button
4 - Select button 10 - Travel speed button
5 - Auto-Idle button 11 - Display
6 - Work Mode button
T2-3-3
Cluster gauge wiring harness
10
12
13
14
VIEW I
15
6 7 8 16
4 17
3 19
10
1 a-a
2 20
9
b-b
DETAIL a-a
c-c
11
I 2 3 4 5 6 7
1 E
8
8
W Br
18
VIEW E
DETAIL c-c
DETAIL b-b SM0098
1 - Starter switch (SW-1) 11 - Wiper motor (M-3)

2 - Engine speed throttle (SE-16) 12 - 12 V socket (E-23)
3 - Work light switch (SW-55) 13 - Speaker right (E-9)
4 - Single/Double flow switch (SW-15) 14 - Connector for cab work light (SW-26)
5 - Heavy Lift switch (SW-35) (opt.) 15 - Connector for room light (L-5)
6 - Over load alarm select switch (SW-12) (opt.) 16 - Connector for wiper interlock switch (SW-19)
7 - (opt.) 17 - Speaker left (E-8)
8 - Cigarette lighter (E-14) 18 - Hour meter (E-3)
9 - Cluster gauge (C-2) 19 - Connector with A label (CN-5F)
10 - Starter switch (GND) (SW-1) 20 - Connector with B label (CN-6F)
T2-3-4
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
Fuse & Relay box

FUSES
SM0008
FUSES BOX FUSES BOX
FUSE No. PROTECTED CIRCUIT Rating FUSE No. PROTECTED CIRCUIT Rating
(A) (A)
FUSE 1 Cab Work Light 20 FUSE 19 Air Conditioner 5
FUSE 2 Cab Work Light 20 FUSE 20 Work Light 20
FUSE 3 Monitor 5 FUSE 21 DC-DC Converter 10
FUSE 4 Wiper , Washer 20 FUSE 22 Opt.8 (Bucket Control) 5
FUSE 5 Option 1 20 FUSE 23 Opt.8 (Roof Wiper) 15
FUSE 6 Option 3 20 FUSE 24 Option 20
FUSE 7 Air Conditioner 15 FUSE 25 Safety Look Lever 10
FUSE 8 Air Conditioner 5 FUSE 26 Mechatro Controller 5
FUSE 9 Opt. (Hand Control) 5 FUSE 27 Mechatro Controller 20
FUSE 10 Relay, Hour Meter 5 FUSE 28 Engine Controller (ECU) 15
FUSE 11 Cigarette Lighter 10 FUSE 29 Engine Controller (ECU) 15
FUSE 12 Horn, Horn Relay 10 FUSE 30 Monitor (Back Up) 5
FUSE 13 Radio 10 FUSE 31 Fuel Supply Pump 15
FUSE 14 Starter Key Switch 20 FUSE 32 Mechatro Contr. (Back Up) 5
FUSE 15 Room Lamp, Tuner 5 FUSE 33 Spare 5
FUSE 16 Opt.2 (Auto Grease) 10 FUSE 34 Spare 10
FUSE 17 Option 4 10 FUSE 35 Spare 15
FUSE 18 Solenoid Valve 10 FUSE 36 Spare 20
T2-3-6
RELAYS
SM0009
1 - Window washer motor relay (RLY 32) 16 - Wiper motor relay (RLY 29)
2 - Wiper motor reversing relay (RLY 30) 17 - Discharge pressure relay (RLY 17)
3 - Cab working light relay (RLY 9) 18 - Grease (forward) relay (RLY 27)
4 - Cab working light relay (RLY 11) 19 - Grease (reverse) relay (RLY 35)
5 - Working light relay (RLY 6) 20 - Safety relay (RLY 4)
6 - Alternator relay (RLY 28) 21 - Bucket control relay (RLY 10)
7 - Auto-Idle stop relay (RLY 24) 22 - Travel alarm relay (RLY 8)
8 - Lever look relay (RLY 26) 23 - Revolution right relay (RLY 12)
9 - Auto-Idle stop relay (RLY 23) 24 - Nibbler open relay (RLY 15)
10 - Engine emergency stop relay (RLY 25) 25 - Revolution left relay (RLY 13)
11 - Horn relay (RLY 5) 26 - Reserve relay (RE-RLY 5)
12 - Nibbler close relay (RLY 16) 27 - Reserve relay (RE-RLY 6)
13 - Reserve relay (RE-RLY 1) 28 - Reserve relay (RE-RLY 4)
14 - Reserve relay (RE-RLY 2) 29 - Reserve relay (RE-RLY 3)
15 - Wiper motor relay (RLY 31)
T2-3-7
C - BATTERIES, BATTERIES RELAY, FUSES LINK
7 2
SM0005
1 - Batterie relay (R-1) 5 - Batteries (E-12)

2 - Fuse Link 1, 2, 3, 4 (E-25) 6 - Pre-Heater relay (R-3)
3 - Starter motor relay (R-2) 7 - Fuse Link 5 (E-26)
4 - Fuel filter heater relay (R-40)
Fuses located into radiators compartment

Fuse No. Protected circuit Value (A)
FUSE 1 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
D HYDRAULIC SYSTEM ELECTRICAL COMPONENTS
14 3
4 2
28
15
13
1
30
29
26 27
16
17
18
19
12 11 6 7 8 9
5 10
25 24 23 22 21 20
SM0006
1 - Extra valve selector press sensor (SE-29) (opt.) 16 - P1 opt. sensor valve (SE-20)
2 - Pomp P2 proportional solenoid valve (PSV-P2) 17 - Travel right sensor (SE-9)
3 - Pump P1 proportional solenoid valve (PSV-P1) 18 - Travel left sensor (SE-10)
4 - Swing sensor (SE-5) 19 - P2 Opt. sensor valve (SE-11)
5 - Lever lock solenoid valve (SV-4) 20 - Bucket digging sensor (SE-1)
6 - Power boost solenoid valve (SV-2) 21 - Bucket dump sensor (SE-2)
7 - P2 Unload proportional solenoid valve (PSV-B) 22 - Boom raising sensor (SE-3)
8 - Travel priority prop. solenoid valve (PSV-C) 23 - Boom lowering sensor (SE-4)
9 - P1 Unload proportional solenoid valve (PSV-D) 24 - Arm in sensor (SE-7)
10 - Arm 2 inverse prop. solenoid valve (PSV-A) 25 - Arm out sensor (SE-8)
11 - Two speed select solenoid valve (SV-3) 26 - Pump P1 sensor (SE-22)
12 - Swing parking brake solenoid valve (SV-1) 27 - Pump P2 sensor (SE-23)
13 - Short-circuit proportional solenoid valve (PSV-R) 28 - Relief adjustment prop. solenoid valve 1 (PSV-E)
14 - Extra dis-press solenoid valve (SV-11) (opt) 29 - Relief adjustment prop. solenoid valve 2 (PSV-I)
15 - Extra dis-press sensor (SE-28) (opt) 30 - Selector E&N solenoid valve (SV-13)
T2-3-9
E ENGINE ELECTRICAL COMPONENTS
15
18
1
17
19
13
4
14
16
12
10 9 3 8 5 6-7 11
SM0007
1 - Air filter restriction switch (SW-8) 11 - Air compressor (E-21)

2 - Engine coolant level switch (SW-24) 12 - Cold start air heater (E-12)
3 - Stepping Motor (M-2) 13 - Fuel filter heater (E-20)
4 - Starter motor assembly (M-1) 14 - Engine stop solenoid (SV-15)
5 - Thermo-switch for heater (SW-52) 15 - Fuel sensor (SE-15)
6 - Coolant thermo sensor (SE-14) 16 - Engine oil level sensor (SE-12)
7 - Engine coolant temperature switch (SW-6) 17 - Water separator restriction switch (SW-36)
8 - Alternator assembly (E-2) 18 - Water separator heater (E19)
9 - Engine revolution sensor (SE-13) 19 - Fuel filter heater switch (E-20)
10 - Engine oil pressure switch (SW-7)
T2-3-10
F ELECTRICAL COMPONENTS (Lights, Horns)
4 5
6 SM0011
1 - Frame Working light (L-2 4 - Horn high (E5)

2 - Boom Working light left (L-1) 5 - Horn low (E6)
3 - Boom Working light right (L-6) 6 - Engine room light (L-11)
T2-3-11
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 DIAGRAM (No. 1)
19
17
1
20
31
26
16 18
21
10
25
14
3
9 15 22 35
4
11 23
34
29
30
2 24
12
13
6
7
32
33
28
27 8
SM0093
T2-3-13

36 Cluster gauge C-2
37 Water separator restriction switch SW - 36
38 Accel potentio pressure sensor SE -16
39 Bucket digging sensor SE - 1
40 Bucket dump sensor SE - 2
41 Boom raising sensor SE - 3
42 Boom lowering sensor SE - 4
43 Arm in sensor SE - 7
44 Arm out sensor SE - 8
45 Swing sensor SE - 5
46 Travel right sensor SE - 9
47 Travel left sensor SE - 10
48 Pump P1 sensor SE - 22
49 Pump P2 sensor SE - 23
50 P1 option sensor (2PB) SE - 20
51 P2 option sensor (Hammer) SE - 11
52 Engine coolant temperature switch SW - 6
53 Engine coolant thermo sensor SE - 14
54 Fuel level sensor SE - 15
55 Engine speed sensor SE - 55
56 Power boost switch right SW - 22
57 Power boost switch left (opt.) SW - 23
58 Swing parking release switch SW - 4
59 Swing parking brake solenoid valve SV - 1
60 Two-speed select solenoid valve SV - 3
61 Power boost solenoid valve SV - 2
62 P2 Unload proportional solenoid valve PSV - B
63 Travel priority proportional solenoid valve PSV - C
64 P1 Unload proportional solenoid valve PSV - D
65 Arm two-speed inverse proportional solenoid valve PSV - A
66 Pump P1 proportional solenoid valve PSV - P1
67 Pump P2 proportional solenoid valve PSV - P2
68 OPT. Relief adjustment proportional solenoid valve 1 PSV - E
69 OPT. Relief adjustment proportional solenoid valve 2 PSV - I
70 Short-circuit proportional solenoid valve PSV - R
71 Short-circuit proportional solenoid valve M-2
T2-3-14
37 35 58
59
60
61
38 62
39
63
40
64
41
65
42
66
43
44 67
45
46
47
48
49
50
51
52
36 53
54 68
55 69
70
71
56
SM0094
57
T2-3-15

72 Engine oil pressure switch SW - 7
73 Air filter restriction switch SW - 8
74 Engine oil level sensor SE -12
75 Engine coolant level switch SW - 24
76 Conflux/single select switch SW - 15
77 Lever lock switch SW - 11
78 Lever lock relay R- 26
79 Operating lever lock solenoid valve SV - 4
80 Heavy lift switch SW - 35
81 Extra dis. Pressure relay opt. R - 17
82 Extra dis. Pressure solenoid valve opt. SV - 11
83 Extra dis. Pressure sensor opt. SE - 28
84 Prevent spark relay R - 31
85 Wiper motor relay R - 29
86 Wiper motor reversing relay R - 30
87 Window washer motor relay R - 32
88 Wiper motor M-3
89 Washer motor M-4
90 Wiper interlock switch SW - 19
91 Selector detect sensor opt. SE - 29
92 Selector solenoid opt. SV - 13
93 Air conditioner ampl. C-4
94 Receiver drier E - 10
95 Air compressor clutch E - 11
96 Cigarette lighter E - 14
97 Room light L-5
98 Horn relay R-5
99 Horn high E-5
100 Horn low E-6
101 Horn switch right opt. SW - 5
102 Horn switch left opt. SW - 10
T2-3-16
35
93
94 95
72
73
82
74 81
83
75
96
76 88
84 85
97
86
78 79
77
89
87
80 90
98
99
100
91 101
102
92
SM0095
T2-3-17

103 Revolution left nibbler relay R - 13
104 Revolution right nibbler relay R - 12
105 Diode D - 16
106 Diode D - 17
107 Revolution right nibbler switch SW - 33
108 Revolution left nibbler switch SW - 34
109 Revolution right nibbler solenoid valve SV - 6
110 Revolution left nibbler solenoid valve SV - 7
111 Pressure sensor boom head (for overload alarm) SE - 26
112 Overload alarm select switch SW - 12
113 Working light relay R-6
114 Working light switch SW - 55
115 Boom working light right L-6
116 Boom working light left L-1
117 Frame working light L-2
118 Engine room light switch SW - 16
119 Engine room light L - 11
120 Fuel supply pump (automatic fuel stop) M - 11
121 Auto grease motor opt. M-8
122 Fleet link opt. -
123 Antenna GPS -
124 Antenna GSM -
T2-3-18

35 115
113
116
112 117
114
111
118 119
109
104 107
120
105
106
121
110
108
103
123 124
122 SM0096
T2-3-19

125 12 V Socket E - 23
126 DC DC converter E - 22
127 Tuner E-7
128 Antenna -
129 Speaker left E-8
130 Speaker right E-9
131 Quick coupler operation solenoid valve SV - 14
132 Quick coupler operation switch SW - 64
133 Diode D - 22
134 Thermo switch for heater SW - 52
135 Seat heater opt. E - 26
136 Cab working light relay 1 R-9
137 Cab working light relay 2 R - 11
138 Cab working light switch SW - 26
139 Cab working light front 1 L-7
140 Cab working light front 2 L-8
141 Cab working light front 3 L - 15
142 Cab working light front 4 L - 16
143 Cab working light back 1 L - 18
144 Cab working light back 2 L - 17
145 6P Connector -
T2-3-20
135
134
136
139
131
138 140
132 141
133
142
137 143
144
127
128
129
126
130
145
125
SM0097
(1)
T2-3-21
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
CLUSTER GAUGE WIRING HARNESS ASSEMBLY
SM0099
T2-3-23
PLATFORM WIRING HARNESS ASSEMBLY READING KEY

are from X side
SM0253 SM0199
T2-3-24
PLATFORM WIRING HARNESS ASSEMBLY
SM0252
T2-3-25
UPPER FRAME WIRING HARNESS ASSEMBLY READING KEY

are from X side
SM0199
SM0255
T2-3-26
UPPER FRAME WIRING HARNESS ASSEMBLY
SM0254
T2-3-27
ENGINE WIRING HARNESS (KSB & STOP) READING KEY
SM0257
WIRING DIAGRAM
1 2
SM0258
1 To engine coolant temperature sensor (SE-14)
2 To operators compartment wiring assembly, connector [CN-2M]
3 To KSB solenoid - The connector view on the cable

are from X side
4 To engine stop solenoid (SV-15)
SM0199
T2-3-28
ENGINE WIRING HARNESS (KSB & STOP)
SM0256
T2-3-29
T2-3-30
COMPONENT OPERATION
M0103
COMPONENT OPERATION E215B-E245B

Group 1 Hydraulic Pump Assy
Group 2 Pilot Valve
Group 3 Control Valve
Group 4 Swing Device
Group 5 Travel Device
Group 6 Swivel Joint
Group 7 Cylinders
Group 8 Air Conditioner system
COMPONENT OPERATION
CONTENTS
Group 1 - Hydraylic pump assy Boost check valve (517)..................... T3-3-18

Hydraulic circuit diagram......................... T3-3-19
Outline .................................................... T3-1-1
Operation ................................................ T3-3-20
General view and hydraulic ports ...... T3-1-1
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 Valve casing section ............................... T3-4-8
regulator ........................................ T3-1-18
Operation of relief valve ..................... T3-4-8
Control curve of pump............................. T3-1-19
Brake section .......................................... T3-4-11
Swing reduction unit................................ T3-4-12
Group 2 - Pilot valve
Pilot valve (ATT) ..................................... T3-2-1 Group 5 - Travel device
Outline ............................................... T3-2-1
Outline..................................................... T3-5-1
Construction....................................... T3-2-2
Specifications..................................... T3-5-1
Operation ........................................... T3-2-3
Hydraulic motor.................................. T3-5-2
Pilot valve (travel) ................................... T3-2-5
Planetary gearbox.............................. T3-5-2
Outline ............................................... T3-2-5
Ports E215B....................................... T3-5-2
Construction and operation................ T3-2-6
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
Hydraulic motor E245B ...................... T3-5-8
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
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 A2
PH1
PH2 a4
PSV1 PSV2
2 a3 4 a4
PH1 PH2
a1 a2
Dr3 B3
a5
A3
1 Dr B1
SM0745
1- Main pump assy PH1 - Pressure sensor port G 3/8-17

2- Regulator assy (Q.ty 2) PH2 - Pressure sensor port G 3/8-17
3- Gear pump assy (for pilot) a1 - Gauge port G 1/4-15
4- Solenoid proportional reducing valve (Q.ty 2) a2 - Gauge port G 1/4-15
5- PTO unit a3 - Gauge port G 1/4-15
A1 - Delivery port SAE 6000 psi 1'' a4 - Gauge port G 1/4-15
A2 - Delivery port SAE 6000 psi 1'' a5 - Gauge port G 1/4-14
B1 - Suction port SAE 2500 psi 2 1/2'' A3 - Delivery port of gear pump G 1/2-19
Dr - Drain port G 3/4-20 B3 - Suction port of gear pump G 3/4-20.5
PSV1 - Servo assist port G 1/4-13 Dr3 - Drain port of gear pump G 3/8-15
PSV2 - Servo assist port G 1/4-13
T3-1-1
E215B-E245B HYDRAULIC PUMP ASSY
Hydraulic circuit diagram
4 4
2 2
SM0746
1- Main pump assy

2- Regulator assy (Q.ty 2)
3- Gear pump assy (for pilot)
4- Solenoid proportional reducing valve (Q.ty 2)
T3-1-2
Specifications
Item Main pump Gear pump for pilot

Pump K3V112DTP1KMR-YTOK-HV ZX10LPRZ7-07G
Variable displacement plunger Fixed displacement type gear
Type
pump: regulator attached type pump
Max. displacement capacity cm3 110 x 2 10
rpm
(Clockwise
Revolution Rated
seen from
2000
shaft end)
Rated 34.3
Pressure MPa 5.0
ATT boost 37.8
Max. flow L/min 220 x 2 at 7.8 MPa 20
Max. input Power
kW 118 3.4
(at 2000 rpm)
Max. input torque
Nm 665 14.7
(at 1200 rpm)
Model KR3G-YTOK-HV
Control Electric flow control, positive flow control, total power control at
Regulator function emergency mode and power shift control
With solenoid proportional reducing valve
Others
(KDRDE5K-31/30C50)
Mass 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
HYDRAULIC PUMP
MAIN PUMP
953 806 789 532 (Three Bond N 1305N) 724 901 808 954 717 151 152
886 214 548 531 702 792 534 A
535 732
717 211
261
406
824
774
111
B B
127
123
710
212
401 251 490 271 153 156 157 468 313 124 710 116 467 466 312 885 314 141 271 113
728 727 725
05
04
Nm
401 M20 430 546
406 M8 29
407 M6 12 725
414 M10 57 727
466 PF 1/4 36
467 PF 3/8 74
468 PF 3/4 170
490 NPTF1/16 8.8
531,532 M24X2 240
806 M16 130
808 M20 240 A B-B
407 325
SM0747
111 Drive shaft (F) 313 Valve plate (R) 717 O-ring; 1B G145 (Q.ty 4)
113 Drive shaft (G) 314 Valve plate (L) 724 O-ring; 1B P8 (Q.ty 16)
116 Gear #1 325 Sensor block 725 O-ring; 1B P11 (Q.ty 9)
123 Roller bearing (Q.ty 2) 326 Cover 727 O-ring; 1B P14 (Q.ty 3)
124 Needle bearing (Q.ty 2) 401 Socket bolt; M20X210 (Q.ty 8) 728 O-ring; 1B P24 (Q.ty 4)
127 Bearing spacer (Q.ty 3) 406 Socket bolt; M8X20 (Q.ty 4) 732 O-ring; 1B P18 (Q.ty 2)
141 Cylinder block (Q.ty 2) 407 Socket bolt; M6X55 (Q.ty 3) 774 Oil seal
151 Piston (Q.ty 18) 466 VP plug; PF1/4 (Q.ty 2) 789 Back up ring; P18 (Q.ty 2)
152 Shoe (Q.ty 18) 467 VP plug; PF3/8 (Q.ty 2) 792 Back up ring; G35 (Q.ty 2)
153 Retainer plate (Q.ty 2) 468 VP plug; PF3/4 (Q.ty 4) 806 Nut; M16 (Q.ty 2)
156 Spherical bushing (Q.ty 2) 490 VP plug; NPTF1/16 (Q.ty 4) 808 Nut; M20 (Q.ty 2)
157 Cylinder spring (Q.ty 18) 531 Tilting pin; M24X2 (Q.ty 32) 824 Snap ring (Q.ty 2)
211 Shoe plate (Q.ty 2) 532 Servo piston M242 (Q.ty 2) 885 Valve plate pin (Q.ty 2)
212 Swash plate (Q.ty 2) 534 Stopper (L) (Q.ty 2) 886 Spring pin (Q.ty 4)
214 Tilting bushing (Q.ty 2) 535 Stopper (S) (Q.ty 2) 901 Eye bolt M10 (Q.ty 2)
251 Swash plate support (Q.ty 2) 546 Spacer (Q.ty 2) 953 Socket screw; M16X35 (Q.ty 2)
261 Seal cover (F) 548 Feed back pin (Q.ty 2) 954 Set screw; M20 (Q.ty 2)
271 Pump casing (Q.ty 2) 702 O-ring; 1B G35 (Q.ty 2) 04 Gear pump
312 Valve block 710 O-ring; 1B G95 (Q.ty 2) 05 PTO unit
T3-1-4
GEAR PUMP (FOR PILOT)
361 700 433
354
434
351
B3
353 435
312
311
Dr4 a3 A3
728
710 308 850
732 310 309
355
307 434
466
725
Nm
312 M14 x 1.5 29
433 M8 17
434 M8 17
435 M10 33
466 G 1/4 16
SM0748
307 - Poppet 435 - Flange socket; M1035 (Q.ty 2)

308 - Seat 466 - Vp plug; G1/4 (Q.ty 2)
309 - Ring 700 - Ring
310 - Spring 710 - O-Ring
311 - Adjust screw 725 - O-Ring
312 - Lock nut; M141.5 728 - O-Ring
351 - Gear case 732 - O-Ring
353 - Drive gear 850 - Locking ring
354 - Driven gear a3 - Gauge port; G1/4 16 Nm
355 - Filter A3 - Delivery port; G3/8 34 Nm
361 - Front case B3 - Suction port; G3/4 74 Nm
433 - Flange socket; M840 (Q.ty 2) Dr4 - Drain port; G3/8 34 Nm
434 - Flange socket; M855 (Q.ty 2)
T3-1-5
PTO GEAR CASE
125 468
711
118
11 262
728
117
414
126 825
128
710
10 435
12 886
826
SM0749
10 - Idle shaft 414 - Socket bolt; M10x20 (Q.ty 4)

11 - Gear case 435 - Flange socket; M1020 (Q.ty 4)
12 - Pin 468 - Vp plug: G3/4
117 - 2nd gear 710 - O-Ring
118 - 3rd gear 711 - O-Ring
125 - Ball bearing (Q.ty 2) 728 - O-Ring
126 - Roller bearing 825 - Snap ring
128 - Bearing spacer (Q.ty 2) 826 - Snap ring
262 - Cover 886 - Pin (Q.ty 2)
T3-1-6
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 111
the two pumps and, at the same time, drives the
pilot gear pump arranged on another shaft.
The pump assy consists largely of: 116
- the rotary group, the main part of the pump that
makes rotary on;
- 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) The sub group of the piston-shoe is pressed against
at its both ends. The shoe, which is caulked to the the shoe plate by the cylinder spring, via the retainer
piston, forms a spherical joint and relieves it of thrust plate and the spherical bushing, so that it moves
force that is generated by load pressure. smoothly over the shoe plate. The cylinder blocks
Further, the piston is provided with a pocket so it (141) are also pressed against valve plates (313) or
moves lightly on shoe plate (211), taking hydraulic (314) by the action of cylinder spring (157).
balance.
111
312 313
124
116
124
314
141
157
156
153
151
211
152
SM0245
T3-1-7
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 532
that is formed on the opposite side of the shoe
sliding surface and is supported by the swash plate
support. 531
214
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 211
the spherical part of the tilting pin and changes the 212
tilting angle (a).
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
313
are installed to valve block (312) to feed oil and
recycle it from cylinder block (141). The oil switched
312
over by the valve plate is connected with the
external pipe by way of the valve block.
111
885
116
314
141
PTO GROUP
SM0247
The PTO group is composed of 1st gear (116), 2nd
gear (117) and 3rd gear (118). The 2nd and the 3rd
gear are supported by bearings (125) and (126)
117
respectively and installed to the valve block.
Now, if the shaft is driven by the engine, the cylinder
block rotates together by the spline linkage. If the
swash plate is inclined, the pistons arranged in the
cylinder block make reciprocating motion with
respect to the cylinder while rotating with the 126
cylinder block. If we keep an eye on a single piston,
it makes a motion away from the valve plate (oil
suction process) in the first 180 and a motion
toward the valve plate (oil delivery process) in the
remaining 180. If the swash plate is not inclined 118
125
(zero tilting angle), the piston does not stroke i.e.
delivers no oil.
The shaft rotation is taken up by the 1st gear (116) 125
and transmitted to the 2nd gear (117) and the 3rd
gear (118), in that order, to drive the gear pump that
is linked to the 3rd gear. SM0248
T3-1-8
REGULATOR
Construction
B B- B 418 079
757 413 D 646 438

438
656
D
541 B
722 543 755 545 439 730 643 924
725 466 755
724 644 645 728 801
708
A -A
734
653 654
897 876 874 755 655 836 651 652 601 624 629 630
A
412 612 858 641 628
814
615 627
802
614
613 753
A
611 756
631
875
898
732 763
733 887
622 621 623 625 626
662 642
466
545 541
543 755
E
755
E- E D- D
496
SM0249
T3-1-9
412 - Socket bolt; M850 (Q.ty 2) 29 Nm 652 - Spool

413 - Socket bolt; M870 (Q.y 2) 29 Nm 653 - Spring seat
418 - Socket bolt; M512 (Q.ty 2) 6.9 Nm 654 - Return spring
438 - Socket bolt; M620 (Q.ty 10) 12 Nm 655 - Set spring
439 - Socket bolt; M635 (Q.ty 3) 12 Nm 656 - Block cover
466 - Vp plug; G1/4 36 Nm 662 - Spring
496 - Plug; NPTF1/16 (Q.ty 15) 8.8 Nm 708 - O-Ring
541 - Seat 722 - O-Ring (Q.ty 3)
543 - Stopper 1 (Q.ty 2) 724 - O-Ring (Q.ty 8)
545 - Ball (Q.ty 2) 725 - O-Ring
601 - Casing 728 - O-Ring
611 - Feed back lever 730 - O-Ring
612 - Lever 1 732 - O-Ring
613 - Lever 2 733 - O-Ring
614 - Fulcrum plug 734 - O-Ring
615 - Adjusting plug 753 - O-Ring
621 - Compensating piston 755 - O-Ring (Q.ty 7)
622 - Piston case 756 - O-Ring
623 - Compensating rod 757 - O-Ring
624 - (C) Spring seat 763 - O-Ring
625 - Outer spring 801 - Nut; M8 (Q.ty 3) 16 Nm
626 - Inner spring 802 - Nut; M10 19 Nm
627 - (C) Adjusting stem 814 - Snap ring
628 - (C) Adjusting screw 836 - Snap ring
629 - (C) Cover 858 - Snap ring (Q.ty 2)
630 - Lock nut; M301.5 160 Nm 874 - Pin; 411.7L
631 - Sleeve 875 - Pin; 48L (Q.ty 4)
641 - Pilot cover 876 - Pin; 58L (Q.ty 2)
642 - Spool 887 - Pin
643 - Pilot piston 897 - Pin; 419L
644 - (Q) Spring seat 898 - Pin; 8.510L
645 - (Q) Adjusting stem 924 - Socket screw; M820
646 - Pilot spring 079 - Solenoid proportional reducing valve
651 - Sleeve
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
T3-1-10
Operation condition, because the power shift pressure is 0

MPa, the power control is not worked.
CONTROL FUNCTION With this mechanism, it is possible to obtain proper
Electric flow control power for the working condition. This regulator is
Positive flow control made up of the above two kinds of control system,
Total horsepower control but when both controls are actuated together, the
Emergency mode control low tilt angle (low delivery rate) command precede
Hydraulic positive control on mechanical operation described later.
Hydraulic total horsepower control
POSITIVE FLOW CONTROL
SUMMARY As shown beside, the delivery rate Q of the pumps
The regulator KR3G-YTOK for the in-line type axial is controlled by the input current I (pilot pressure Pi).
piston pump K3V series is composed of the control
mechanism as mentioned below:
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 I SM0250
delivers only the necessary oil flow, the machine

does not consume excessive power.
Constant power control at emergency mode

When the electromagnetic proportional pressure-
reducing 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
Flow rate increase
As the command current value I rises, the

secondary pressure P2 of electromagnetic
proportional pressure-reducing valve rises, and by
CL
pressing pilot piston (643) in (A) direction it stops at
652
the position the secondary pressure P2 balances
the pilot spring force (646). The movement of pilot 646
piston is transferred to lever 2 (613) through pin B 613
(875), and rotates at (B) fulcrum in arrow direction. D 876 F 897
Furthermore the lever 2 movement is transferred to 875
feedback lever (611) through pin (897) and rotates A 611
at (C) fulcrum in the same arrow direction as (B). 643
Consequently the spool (652) connected to C
feedback lever moves towards (D). When the spool
moves towards (D), the port CL connected to tank E 532
port is open and the pressure in servo piston large Psv A
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.
Pd1
With this movement, the opening of spool sleeve CL
gradually closes, and the servo piston stops at the a3
position the opening closes completely.
B SM0895
T3-1-12
Flow rate decrease
As the command current value I is reduced, the

secondary pressure P2 of electromagnetic 613
proportional pressure-reducing valve is reduced, CL
and by pressing pilot piston (643) in (G) direction it
652 G
stops at the position the pilot spring force (646)
balances the secondary pressure P2. The 646
movement of pilot piston is transferred to lever 2 H
(613) through pin (875), and rotates at (H) fulcrum in J 876 L 897
arrow direction. Furthermore the lever 2 movement 875
is transferred to feedback lever (611) through pin 611
(897) and rotates at (I) fulcrum in the same arrow 643
direction as (H). Consequently the spool (652) I
connected to the feedback lever moves towards (J). K
532
When the spool moves towards (J), the delivery
pressure Pd1 is led in servo piston large bore Psv A
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 Pd1
towards (K), consequently the spool is returned to CL
the original position. a3
With this movement, the opening of spool sleeve
gradually closes, and the servo piston stops at the
B SM0896
position the opening closes completely.
T3-1-13
POWER CONTROL (IN EMERGENCY MODE)
When the load pressure rises, the pump tilt angle is

reduced preventing the overloading of engine. The Q
operation of power control is the same as the flow
rate control, and is explained below.
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 Pd1 SM0897
(626). The movement of compensating rod is
transferred to lever 1 (612) through pin (875), and
rotates at (N) fulcrum in arrow direction. 897 896 625
Furthermore the lever 1 (612) movement is R N 612 626
transferred to feedback lever (611) through pin
(897) and rotates at (O) fulcrum in the same arrow CL G
direction as (N). Consequently the spool (652) 652
connected with feedback lever moves towards (P).
H
When the spool moves towards (P), the delivery 646
pressure Pd1 is led in servo piston large bore P 875
M
diameter chamber through spool and CL port. Since 623
the delivery pressure Pd1 is constantly led to servo 621
611
piston large bore diameter chamber, the servo
piston moves towards (Q) according to the O
difference of area, resulting in the reduction of tilt Q
angle, consequently the flow rate is also reduced. 532
Psv A
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
CL
a3
B SM0898
T3-1-14
Flow rate recovery operation
Because the compensating rod (623) is pushed

towards (S) with the force of outer spring (625) and 897 876 625
inner spring (626) with reduction of self pump X T 612 626
S
delivery pressure Pd1, and moves to the position
CL
the spring force of outer spring (625) and inner G
spring (626) balances the delivery pressure Pd1. 652
The movement of compensating rod is transferred H
to lever 1 (612) through pin (875), and rotates at (T)
fulcrum in arrow direction. V J 875
Furthermore the lever 1 (612) movement is 623
621
transferred to feedback lever (611) through pin 611
(897) and rotates at (T) fulcrum in the same arrow
direction as (N). Consequently the spool (652) U
W
connected to feedback lever moves towards (V). As
532
the spool moves towards (V), CL port is open and Psv A
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
Pd1
position. With this movement, the opening of spool CL
sleeve gradually closes, and the servo piston stops
a3
at the position the opening closes completely.
B SM0899
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
Power shift control

The pump set power is controlled according to the
movement of control by power shift pressure Pf. As Q
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.
Pd1 SM0900
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 Q
using the adjust screw.
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
I (Pi)
No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change
Q
Min. increase in delivery flow L/min 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 I (Pi)
SM0996
increase a required power at the maximum delivery
pressure (at relieving action).
Adjust screw No 953
Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min 4.6
T3-1-16
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 Q
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.
Adjusting the Outer Spring (See REGULATOR-

Construction) (At emergency mode)
Adjust it by loosening lock nut (630) and by
tightening adjust screw (628) (or loosening it).
Pd1
Tightening the adjust screw shifts the control chart Q
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. 628
Increase in delivery pressure MPa 2.06
Increase in input torque 50
Adjusting the Inner Spring (See REGULATOR-

Pd1
SM0997
Construction) (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
Increase in flow L/min 12
Increase in input torque Nm 58.7
T3-1-17
ADJUSTING THE FLOW CONTROL

CHARACTERISTICS (See REGULATOR-
Construction)
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
Increase Pilot pressure Pi MPa 0.13
Decrease in delivery flow L/min 18.5
Causes of fault resulting from regulator I (Pi)

SM0998
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 reducing
valve.
3. Stick of compensating piston and
compensating rod
Disassemble and clean it.
4. Stick of pin
THE MAX. FLOW RATE IS NOT DELIVERED

1. Check that pilot differential pressure Pi is
normal.
2. Stick of pilot piston
3. Stick of spool
NOTE: when the damage of part is severe, replace

the part with new one.
T3-1-18
CONTROL CURVE OF PUMP
250
Q 2000min-1:
(H mode)
200 1800min-1:
(S mode) [2] [1]
150
[3]
Q [ L/min ]
100
50
Q (2000min-1)
0 5 10 15 20 25 30 35 40
Pd [MPa]
250
[4] 91kW : At emergency mode
718mA Input revolution ;2000 min-1
220L Input horse power ;114 kW
Input torque ;544 N.m SM0999
[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
NOTE:
T3-1-20
PILOT VALVE E215B-E245B
PILOT VALVE (ATT)
OUTLINE
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
The adjust nut

(opposing flats : 22) :
Fix adjust nut
(opposing flats : 22)
when the lever is installed by PF1/4
means of spanner or the like. T=29.4 (21.7)
Then tighten the mating lock
nut to 41 + 3 N.m (302.2 lbf.ft). T=Tightening torque
: N.m (lbf.ft)
VIEW A
Model PV48K2004
Operating torque Refer to the curve below
Max. primary pressure 6.9 MPa (1000 psi)
Primary pressure 5.0 MPa (725 psi)
Rated flow 20 L/min (5.3gal/min)
Weight Approx. 1.9 kg (4.2 lbs)
A
PORT 1, 3 PORT 2, 4
(580)4.0 4.0(3.0) (580)4.0 4.0(3.0)

Secondary pressure [MPa (psi)]
Secondary pressure [MPa (psi)]

Operation torque [N.m (lbf.ft)]
Operation torque [N.m (lbf.ft)]

(464)3.2 (464)3.2
(435)3.0 3.0(2.2) (435)3.0 3.0(2.2)
SINGLE OPERATING TORQUE SINGLE OPERATING TORQUE
2.21(1.63) 2.29(1.69)
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
SECONDARY PRESSURE SECONDARY PRESSURE
(145)1.0 1.0(0.74) (145)1.0 1.0(0.74)

0.94(0.69) 0.94(0.69)
(87)0.6 (87)0.6
1.17 (0.86) 1.17 (0.86)
0.98 (0.72) 0.98 (0.72)
0 0 0 0
0 1.1 2 4 6 7 0 1.12 4 6 8 9.4
PUSH ROD STROKE (mm) PUSH ROD STROKE (mm)
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
P T
1 3 2 4
HYDRAULIC SYMBOL
SM0591
T3-2-1
E215B-E245B PILOT VALVE
CONSTRUCTION
****312
302
501
***301
*212
213
151
211
214
216- 2 216- 1
241- 2 241- 1
201- 2
201- 1
**217
101 221
PORT 2,4 PORT 1,3

SM0592
Tightening Tightening
No. Parts Q.ty torque No. Parts Q.ty torque
Nm (lbfft) Nm (lbfft)
101 Casing 1 216-2 Spring seat 2
151 Plate 1 **217 Washer 2 (Shim) 4
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
*212 Push rod 4 ***301 Joint: M14 1 47.1 (34.7)
213 Seal 4 302 Circular plate 1
214 O-ring: 1B P20 4 ****312 Adjust nut: M14 1 68.6 (50.6)
216-1 Spring seat 2 501 Boots 1
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
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) PORT (1,3) SM0593
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 511
a pressure.
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 509
ports (2, 4) and the T port close. Thus the
secondary pressure is kept constant.
T PORT
P PORT
PORT (2,4) PORT (1,3) SM0595
T3-2-3
4. 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 (TRAVEL)

OUTLINE
Outside view
Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port

2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port
SM0596
Specifications
P T
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol SM0597
Performance characteristics
Secondary pressure
[MPa (psi)] Secondary pressure
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram SM0598
T3-2-5
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)
5
3
8 10
3
11 12
4
10
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
PBp1 PBp2
PBp1 PBp2 PAa2
Arm 2 Option
PBo
PBo
PAc PAa1
Bucket Arm 1
PAa
PAb
(P4)
Boom Swing
(P3)
PBr PCa
Travel right P2 unload
(T3)
PTb
Travel priority PBL Travel left
PAa2 PBo
A VIEW A
CT1
T2
P1 unload
PCb PAL PTb
Travel PL
PCb
priority Ar
CMR1 CMR2
USE FOR YN30V00101
PAr Br
PB1 Travel
F1
PBr PAr
1
Ab right
XAb PAb CP1 (HEAD)
PBs Bb Boom
PBb
PBb (ROD)
LCb CRb PC
PCc PBa1 Pss PAc PBc
Ac Bc
(HEAD) (ROD)
LCc Bucket
MU PBa2 PAo PCAP2 LCAT2
PAa2
Arm 2 PBa2
PBp1 PBp2
(P2) (P3) SM0824
T3-3-1
E215B-E245B CONTROL VALVE
CONTROL VALVE OUTSIDE VIEW (2/2)
PTb
PBL
CT2
P2
CP2
CT1
P1
Pcb PAL
T1
T2
CT2 PCb PAL
Travel left PBL
PAL AL BL
CP2 P2 unload
USE FOR YN30V00101
PCa PAr
Boom PB1
F1
PB1 PCa
conflux CCb Bs
PBs As PBs
Swing PAs
Pss Aa PBb
LCs
PCc PBa1 Pss
Arm 1 PLc2 CRa (HEAD)
PBa1 PAa1
Ba
LCa
(ROD) MU PBa2 PAo
PAo Option PBo
Ao Bo
LCo
PBp1 PBp2
(P2)
SM0825
T3-3-2
CONTROL VALVE PORTS

Port size Tightening torque Ports Description
PF3/4 150~180 Nm (111~133 lbfft) MU
(T3) Pluged
PF1/2 98~120 Nm (72~89 lbfft) (P3) Pluged
(P4) Pluged
PF3/8 69~78 Nm (51~58 lbfft) 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
PF1/4 34~39 Nm (25~29 lbfft) 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 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
M12 83~110Nm (61~81 lbfft) P1 Pump port (P1 side)
P2 Pump port (P2 side)
T1 Tank port 1
T2 Tank port 2
T3-3-3
Port size Tightening torque Ports Description

M12 83~110Nm (61~81 lbfft) P1 Pump port (P1 side)
P2 Pump port (P2 side)
T1 Tank port 1
T2 Tank port 2
M10 49~65 Nm (36~48 lbfft) Ar Right travel motor port (forward)
Br Right travel motor port (reverse)
AL Left travel motor port (forward)
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 Specifications
Model KMX15YD/B44041
Maximum flow rate [L/min (gal/min)] 220 (58)2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 702L/min (18.52gal/min)]
When power boost pressure 37.8 (5480) [at 602L/min (15.92gal/min)]
Overload relief valve set pressure
39.7 (5760) [at 30L/min (8gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
Overload relief valve set pressure
37.8 (5480) [at 30L/min (8gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
T3-3-4
CONSTRUCTION AND OPERATION

Construction
Control valve (1/6)
PBa2 PAo
PBp1 PBp2
PBp1 PBp2
(P3)
(P3) (P4)
(P4)
PAa2 PBo
A
B
273x10 T2
273x10 H
H P1 unload PCb PAL
(Travel priotity) Travel left
C C
USE FOR YN30V00101F1
PAr
PB1 Boom conflux
Travel right (P2 unload)
D D
PBs
Boom Swing
E PCc
PBb
Pss
E
PBa1
Bucket Arm 1
F F
PBa2 PAo
PA
Arm 2 MU Option
G G
K PBp1 PBp2 K
(P3)
B A SM0826
T3-3-5
Control valve (2/6)
J
154 164 101
P2
T2 T1
PAL JJ PBL
YT1
PB1 PCa
YBG1
P2-20
PBs PAs
YS1
Pss
PBa1 PAa1
YA1
PAo PBo
YP1
SECTION A-A
(P4)
163 162 163 169 155 162
154 164
P1
102
973 973
PTb PCb
P1-20
973 973
PBr PAr
YT1
973
PAb PBb
YB1
973 973
PBc PCc
PAc
YK1
974
973
PAa2 PBa2
YAG
1
974
(P3)
SM0532 162 162 169 155 163 162 SECTION B-B
T3-3-6
Control valve (3/6)
202 P1 unload Travel left 201

333 PCb PAL
331 333
336 331
329
327 336
601 MR 324
331
261 323
309
PL 331
261
306
159 AL 163
162
512
511
522 521
CP2
552
CMR2 551
562 164
562 162
CMR1
BL
552
163
522
512
307
261
331 264
PBL
327 205
329 SECTION C-C
336
331
333 Travel priority
202 PTb
201 Travel right Boom conflux
333 202
331 PAr PB1
333
336 331
324
323 339
326
331 325
261
331
306 261
511
161 521
CCb
163 Ar 551
164
511
305
521
CP1
551 551
164 164
163
Br
161 310
164
154
(T3)
261
264 331
PBr
327
205
329
SECTION D-D 336
331
333
PCa
SM0533 P2 unload 202
T3-3-7
Control valve (4/6)
Swing 204
203 PBs
Boom 333
333
336 Pss 331
331
336
603 322
211 321 322
AbR
279 x 3 266 321
331
331
215 XAb 261 261
160 303
514 161
524
As 162
CRb
556 Ab
163
164 511
511 523
521 LCs
LCb 556
164
551
Bb 162
164 Bs
161
301
266
264
264
602 PAb
160 PAs
206
205 BbR
SECTION E-E
551 Bucket
164 201
209 333
216 PCc Arm 1 331
333 PBa1 336
331 322
PBc
336
322 321
321 BaR 603
602 BcR 171
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc
LCa
551 551
164 164
Ac
162 Aa
302
161
264 264
603 PAc PAa1 205
205 SECTION F-F 605
AcR AaR SM0534
T3-3-8
Control valve (5/6)
201 Arm 2 Option 201

333 PBa2 PAo
333
331
340 331
328
321 336
331 324
261 AoR
323
604
308 MU 331
162
261
162
162 311
511
521 Ao
LCAT2 511
551
164 521
515
LCo
521 551
LCAP2
551 164
164
Bo
162
161
604
BoR
264 264
PAa2 PBo
205 205
SECTION G-G
T2
161
P1
511
T1
521 163
CT1 163
551
162
511
164 P2
521
CT2
551
164
SECTION H-H SM0535
T3-3-9
Control valve (6/6)
207 266
160
278 x 5 264
264
528
527
T2 518
T1
517
SECTION J-J
PBp1 PBp2
606
606
163
SM0536
SECTION K-K
T3-3-10
Tightening torque Tightening torque

No. Parts Name Q.ty No. Parts Name Q.ty
101 Casing A 1 321 Spring 5
102 Casing B 1 322 Spring 4
220~250 (162~184) 154 Plug PF3/4 3 323 Spring 3
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
164 O-ring 19 331 Spring seat 24
16~18
169 O-ring 2 333 Spacer bolt 12
Loctite #262
9.8~14 (7.2~13) 171 Socket bolt 336 Stopper 10
201 Cover 5 339 Stopper 1
203 Cover 1 511 Poppet 11
204 Cover 1
Back pressure check
207 1 515 Poppet 1
valve cover
209 Cover 1 517 Boost check valve 1
9.8~14 (7.2~13) 211 Lock valve selector sub 2 518 Poppet 1
212 Plate 1 521 Spring 11
215 Boom dowering valve 1 523 Spring 1
216 Piston 1 524 Spring 2
264 O-ring 10
25~34 (18~25) 273 Socket bolt 40 230~260 (170~192) 551 Plug 13
98~120 (72~89) 274 Socket bolt 4 130~150 (96~111) 552 Plug 2
98~120 (72~89 275 Socket bolt 4 230~260 (170~192) 556 Plug 3
25~34 (18~25) 278 Socket bolt 5 562 O-ring 2
9.8~14 (7.2~13) 279 Socket bolt 3
301 Boom spool sub 1 69~78 (51~58) 601 Main relief valve 1
302 Arm 1 spool 1 69~78 (51~58) 602 Over load relief valve 2
303 Swing spool 1 69~78 (51~58) 603 Over load relief valve 3
Plug assy for relief valve
304 Bucket spool 1 69~78 (51~58) 604 2
hole
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
311 Option spool 1
T3-3-11
Main relief valve (601)
123 125 562 663 163 661

124 561 611 621 614 613
521 121 103 664 652

512 541 122 104 673 671
SM0827
Main relief valve (Two step relief)

torque No. Parts Qty torque No. Parts Qty
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 1
T3-3-12
Over load relief valve (602, 603, 605)
564 521 124 561 611 661

301 563 123 125 562 621 612
511 522 101 102 671

161 541 162 651
SM0828
Over load relief valve

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
511 Plunger 1 651 Adjust screw 1
521 Spring 1 661 O-ring 1
522 Spring 1 28~31 (21~23) 671 Lock nut; M14 1
T3-3-13
Arm 2 spool (308)
351 371 361 340 319 308 317 340 361 371 350
SM0829
Arm 2 spool
16~18 (33~35)
308 Spool 1 350 Plug 1
Loctite #638
16~18 (33~35)
317 Plunger 1 351 Plug 1
Loctite #638
340 Spring 2 371 Backup ring 2
Boom spool (301)
301 317 340 361 371 350
SM0830
Boom spool
16~18 (12~13)
301 Spool 1 350 Plug 1
Loctite #638
340 Spring 1 371 Buckup ring 1
T3-3-14
Lock valve selector (211)
101
171 164
201
321
PLc A B Dr
166 541 167 511 161
SM0831
Lock valve selector

10~14
101 Casing 1 171 Socket bolt 3
(7.4~10.3)
161 O-ring 4 49~59 (36~44) 201 Plug 1
166 O-ring 1 511 Spool 1
167 O-ring 1 541 Sleeve 1
T3-3-15
Bypass cut valve (606)
302 301 402 401
P Pi
T Dr
201 202 102 101

SM0832
Bypass cut valve

98~120 (72~89) 101 Plug 1 301 Plunger 1
201 Poppet 1 69~78 (51~58) 401 Plug 1
202 Spring 1 402 O-ring 1
T3-3-16
Swing shuttle valve cover (204)
PBs
555
A
Pss
G1/4
A SECTION B-B
166 542 541 PBs G3/8
B B
Pss
554
202
PAs
SECTION A-A
SM0833
Swing shuttle valve cover

166 O-ring 1 542 Seat 1
202 Cover 1 25~29 (18~21) 554 Plug 1
7.9~9.8
541 Steel ball 1 555 Plug 1
(5.9~7.2)
T3-3-17
Boost check valve (517)
104
107
102
101
SM0834
Boost check valve

20~29 (15~21)
101 Poppet 1 104 Plug 1
Loctite #262
102 Poppet 1 107 Spring 1
T3-3-18
HYDRAULIC CIRCUIT DIAGRAM
2 12
3 11
10
9
6
7
SM0835
1- Travel priority 7- Option

2- P1 Unload 8- Arm 1
3- Travel right 9- Swing
4- Boom 10- P2 Unload
5- Bucket 11- Boom conflux
6- Arm 2 12- Travel left
T3-3-19
OPERATION
1. In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through
unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic
tank through tank port T1. And when the operation of unloading valve is impossible due to failure of electric
control system, because the by-pass cut valve (606) located on the downstream of center by-pass
passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through travel priority spool
(306), and then flows though the center by-pass passage (52) which passes through travel right, boom,
bucket and arm 2 and the by-pass cut valve (606) on P1 side, and flows into low pressure circuit (D) and
boost check valve (517), and then returns to the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure
circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to
the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is impossible,
because the by-pass cut valve (606) located on the downstream of center by-pass passage (55) opens,
the hydraulic oil through hydraulic pump P2 port passes through main passage, and then flows though the
center by-pass passage (55) which passes through travel left, swing, arm 1 and option and the by-pass
cut valve (606) on P2 side, and flows into low pressure circuit (D) and boost check valve (517), and then
returns to the hydraulic tank through tank port T1.
(D)
606
Pss
517 52
306
YP1 YS1 YT1
YA1 YBG1
T1
P2
P1
YAG1 YK1 YB1 YT1

P2-20 P1-20
309
310 606
55
(*)
(D)
SM0836
In neutral position
(*) Connected to low pressure circuit of P2 side casing
T3-3-20
2. 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 BL
CP2
324 323 306
PBL
PAL
SM0837
In left reverse travel (at PBL is pressurized)
T3-3-21
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 CMR2
P2 P2
B B
CMR1 CMR1
P1 P1
A A
307 307
327 327
329 329
PTb PTb
P2 P1 P2 P1
PTb PTb
Dr Dr Dr Dr
A
B A
B
SM0838
Circuit (I) Circuit (II)
A - to each actuator
B - to travel right
Movement of travel priority spool
T3-3-22
3. 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
PBc
PCc
Bc Ac
LCc
322 321 304 (D) 511
(R) (H) SM0839
In bucket digging operation (Stroke limiter ON)
T3-3-23
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 Ac
LCc
322 321 304 511
(R) (H)
SM0840
(D*) Downstream of boost check valve

In bucket dumping operation
T3-3-24
4. Boom
a) In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves
rightward against the force of springs (321) (322), and simultaneously the secondary pressure of
solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309).
And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of
springs (325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa
and switches unloading spools (310).
load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing
through U-shaped passage, and supplied to the both boom cylinders head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter
of boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517),
and returns to the hydraulic tank through tank port T1.
(R) (R)
(H) (H)
301 (D) 53 511 514 (A) 321 322
Bb LCb CRb
Ab
PAb PBb
SM0841
(A): BH chamber
In boom up operation (Boom spool)
T3-3-25
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)
305 56 SM0842
(B): Conflux passage to Ab port of P1 casing

In boom up conflux operation (Boom conflux spool)
T3-3-26
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)
(R) (R)
(H) (H)
301 317 53 511 514 (A) 321 322
LCb CRb
Bb Ab
PAb PBb
(D) SM0843
(A): BH Chamber
In boom down operation
T3-3-27
5. Arm operation
a) In arm out operation
On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302)
moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure
of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs
(321) (328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and
switches unloading spools (309).
load check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool
(302) and casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass
passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage,
and pushes and opens load check valve LCAP2 (515) provided with orifice, and flows into U-shaped
passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and
casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil
from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side
(R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of
arm 1 spool (302) and casing and passes though low pressure circuit (D) and casing inside passage
(HH) and then flows into low pressure circuit (D) through between the perimeter of arm 2 spool (308)
and casing.
The return oil in low pressure circuit (D) returns to hydraulic tank through tank port T1 without passing
through boost check valve (517).
(R) (H)
322 321 211 (AR) 514 302
511
CRar Ba LCa Aa
56
PBa1 PAa1 P1 LCAT2
(D')
LCAP2
Arm 1 (D)
RH (D') P1
RR HH PAa2
52 PBa2
(D') Dr Dr
Arm 2
(F)
PBa2 PAa2 Ba
(ROD) Aa (HEAD)
53 (G)
MU
AP2
LCAT2 LCAP2
328 321 308 511 515 SM0844
(F): To arm 1 spool

(G): To pilot cut valve
In arm out operation
T3-3-28
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).
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
(R) (H)
322 321 211 (AR) 514 302

CRar 511
Ba LCa Aa
56
PBa1 PAa1
Arm 1
(D')
RR RH HH
(D) 52
Arm 2 (a)
PBa2 PAa2
[XR]
53
MU
LCAT2 LCAP2
328 321 308 319 (D) 511 515 317
P1
(D') LCAT2
LCAP2
(D)
P1
PAa2 PBa2
Dr Dr
(F)
Aa (Head)
Ba
Circuit (I) (Rod)
(G) SM0845
(F): To arm 1 spool

In arm in operation (At light load: arm recirculation function)
T3-3-30
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.
(R) (H)
322 321 211 (AR) 514 302
CRar 511 LCa
Ba Aa
Circuit (II)
56
PBa1 PAa1 P1 LCAT2
(D') LCAP2
Arm 1 (D') (D)
P1
(D) RR 52 RH HH PAa2 PBa2
Dr Dr
Arm 2 (a) (F)
PBa2 PAa2 Aa(Head)
Ba
[XR] (Rod)
MU 53
(G)
LCAT2 LCAP2
328 321 308 319 (D) 511 515 317 SM0846
(F): To arm 1 spool

In arm in operation (In heavy load operation)
T3-3-31
6. Swing operation
On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves
leftward or rightward against the force of springs (321) (322), and simultaneously the secondary pressure
of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through
shuttle valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot
pressure acts on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and
then is led to port Pss.
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load
check valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through
U-shaped passage and is supplied to swing motor A side or B side through port (As) or (Bs).
In the meantime, the return oil from swing motor A side or B side passes through between the perimeter
of swing spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and
boost check valve (517), and then returns to the hydraulic tank through tank port T1.
204
PAs
PBs
Pss
Bs As
LCs
(D) 56 511 (D) 303 321 322
B A
Swing motor
SM0847
Swing operation
T3-3-32
7. 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.
324 323 604 311 511
Ao LCo Bo
(O)
AoR
BoR
56
PAo PBo
(D) SM0848
Spool actuation for operation in option
T3-3-33
8. 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.
1 RH 514 BH Sb PLc Dr 2 541 511
CRb
Ab
(a) (b)
321
PLc Sa Sb Dr
A A
SECTION A-A
Sa
321 322
PBb
Dr 301 (D) SM0849
1. Return oil from boom cylinder head

2. Lock valve selector
Lock valve operation (At boom spool neutral position)
T3-3-34
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 514 BH Sb PLc Dr 2 541 511

1
CRb
(a) (b)
Ab
321
PLc Sa Sb Dr
A A SECTION A-A
Sa
321 322
PBb
Dr 301 (D) SM0850
1. Return oil from boom cylinder head

2. Lock valve selector
Lock valve selector operation (At boom down operation)
T3-3-35
9. 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
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
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
518
T1
102
1
517 (D) 528
527
T2 518
102
T1
517
(D) 2
SM0971
1. In normal operation
2. In make up operation
Boost check valve operation
T3-3-38
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
517 (D)
SM0992
By-pass check valve operation
T3-3-39
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
Emergency manual valve for lowering attachment operation
(R)
1
(H)
2
Ab
XAb 5
9
SM0993
1- Boom cylinder head side 6- Lock nut

2- Control valve 7- Shuttle valve
3- Hydraulic oil tank 8- To lever lock solenoid valve
4- Drain passage 9- To control pilot valve
5- Needle valve
T3-3-41
NOTE:
T3-3-42
SWING DEVICE E215B-E245B
OUTLINE
General view
THREAD FOR
M L EYE BOLT 2-M10
PB DEPTH 18
B RELIEF VALVE
(B PORT SIDE)
(SH)
IP
PG
RELIEF VALVE
A (A PORT SIDE)
DB
PA
SM0570
Tightening torque
Symbol Port name Port size
Nm (lbfft)
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)
PA, PB Pressure measuring port PF 1/4 36 (27)
PG 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)
T3-4-1
E215B-E245B SWING DEVICE
ANTI-REACTION
PB PA VALVE BLOCK
M DB
A,(B)
PG
IP
FILLING PORT
PT3/4
Grease
fitting
SM0571
PG
DB
PA PB
A B
Hydraulic diagram SM0572
T3-4-2
Specification
Model M5X130CHB10A41C/295
Swash-plate type, fixed-displacement plunger
Type
motor
Displacement cm3 129.2
Hydraulic motor
Working pressure MPa 32.4

Max. flow L/min 220
Braking torque Nm 655
Release pressure MPa 2.5~5.0
Relief set pressure MPa 29
Mass kg 49
Antireaction Type 2KAR6P72/240-712

valve block Mass kg 2.5
Hydraulic motor assy mass kg 51.5
Speed reduction type Planetary 2-stage
Reduction ratio 15.38
Reduction unit
Lubicate oil Gear oil SAE90 (API class GL4 grade)

Lubicate oil volume L 3.0
Grease Extreme pressure lithium base # 2 grease
Grease volume kg Approx. 1.0
Mass kg 145
Total mass kg Approx. 197
T3-4-3
CONSTRUCTION
Swing motor
993
VALVE CASING SECTION
702 712
ANTI
CAVITATION
PLUNGER
351 Arrangement of brake spring
355
051 RELIEF VALVE
469
051-1
488 ANTI-REACTION
VALVE BLOCK 401
052 151
303 162 171 161
985
163 985 444 984 131 451
712 A A
472 390 391
VIEW I
702
707
706
100
980
743
742
400-1
111
400-2 052
121
400
123 994 SECTION A-A
122
114 301
124 443 491 101
SM0573
T3-4-4
torque torque
No. Parts Q.ty No. Parts Q.ty
Nm Nm
(lbfft) (lbfft)
051 Relief valve; M33-P1,5 2 177 (130) 400 Anti-reaction valve; M22-P1.5 2 69 (51)
051-1 O-ring; 1B G30 2 400-1 O-ring; 1B P20 2
052 Anti-reaction valve sub 1 400-2 Backup ring 2
100 Casing for anti-reaction valve 1 401 Socket bolt; M2045 4
101 Drive shaft 1 443 Roller bearing 1 431 (318)
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2
121 Piston 9 469 ROMH plug; M30-P1,5 2 334 (246)
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 36 (27) 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; M855 4 29 (21) 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
T3-4-5
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
Apply Loctite #515. 19 2 28 15 16 3
6 SURFACE OF Be careful about

LUBE OIL
7 15 installation direction
of spring pin.
4 18
5 VIEW (II) (4 places)
8
Apply Loctite #515. 17
Be careful about 18
installation direction 20 Drive this spring pin
of retaining ring. 22 into 1mm lower than
10 the surface of spider.
9
Apply Loctite #515. 25
12 26
31
Install the filling port 27 Apply seal tape or
of this fitting toward Loctite #577.
motor side. 24
13
32
Fill up this space
with grease.
11
30
21
1
SM0574
torque torque
Nm Nm
(lbfft) (lbfft)
1 Pinion shaft 1 17 Needle bearing 4
2 #1 sungear 1 18 Washer 8
3 #1 pinion 3 19 Retaining ring 1
4 #2 sungear 1 20 Retaining ring 1
5 #2 pinion 4 21 Sleeve 1
6 Ring gear 1 22 Spring pin 4
7 Spider assy 1 23 Capscrew; M14X135 11 181 (134)
8 Spider 1 24 Cap 2
9 Shaft 4 25 Tube L=112 1
10 Spherical bearing 1 26 Elbow 1
11 Spherical bearing 1 27 Plug 1 69.1 (51)
12 Oil seal 1 28 Retaining ring 3
13 Housing 1 30 Oil seal 1
15 Thrust washer 6 31 Grease fitting 1
16 Needle bearing 3 32 Relief fitting 1
T3-4-6
HYDRAULIC MOTOR
Operation
If the high pressure oil flows into the cylinder
through the inlet port (a) of valve plate (131), as
shown on the figure on the right, the hydraulic
Cylinder block (111)
pressure acts upon piston (121) and creates force F
in the axial direction.
The force F may be divided into force F1 vertical to F2
shoe plate (124) via shoe (122) and force F2 at right F1
angles with the shaft. F
The force F2 is transmitted to cylinder block (111)
via pistons (121) and causes drive shaft to turn so
as to produce a rotating moment. Drive shaft (101)
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to drive
shaft by turns by pistons connected to inlet port of
high pressure oil.
If the oil supply and discharge directions are Valve
reversed, the drive shaft rotates in the opposite plate
direction. Shoe Shoe Piston (131)
Theoretical output torque T can be given by the plate (122) (121)
(122)
following equation. SM0575
PXq
T=
2X Low pressure oil High pressure oil
p: Effective differential pressure MPa

q: Displacement per revolution cc/rev
OUTLET INLET (a)
SM0576
T3-4-7
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. 351
The system has check plunger (351) and sucks in
deficient oil, in order to prevent cavitation from
occurring due to oil deficiency.
M port
Operation of relief valve
(Make-up port)
1. Consider where the relief valve is pressurized.
The pressure at the P, R ports is equal to the
tank pressure at the beginning, as shown in Fig.
SM0578.
The relief valve begins to operates when the DIRECTIONAL VALVE
hydraulic pressure that is determined by the SM0577
product of the pressure-receiving area A1 of
plunger (301) and the pressure P balances the
hydraulic pressure that is determined by the
Chamber h
product of the pressure-receiving area A2 of
Orifice m Spring (321) Piston 1 (302)
the plunger (301) and the pressure Pg of
chamber g.
Thereafter, the pressure of chamber g rises and
the piston 1 (302) begins to stroke. The load to P
spring (321) increases by this movement of the
piston. R
Pressure Chamber g
As the result, the relief pressure P is raised and receiving A3 A2
area A1 Plunger (301) A4
controlled in the pressure boost time t1 from P1 Orifice n
till Ps. SM0578
This process is explained in the following in the
relationships between the movements of the
components and the relief pressure:
a) Condition shown in Fig.SM0579. Chamber h
Orifice m Spring (321)
If the P port of the relief valve is pressurized, Pin (303) Piston 1 (302)
pressure is built up in chamber g via the
restrictor m of plunger (301).
The hydraulic pressure acting on plunger P
(301) increases and when it balances the
load Fsp of spring (321), the relief valve R
performs relieving action by the pressure Orifice n
Chamber g
Plunger (301)
P1.
This relationship is expressed as: SM0579
P1A1=Fsp1+Pg1A2
where Fsp1:
primary set load value of spring (321).
T3-4-8
b) Condition shown in Fig.SM0580.

The pressure of chamber g acts upon the
pressure-receiving area A3-A4 of piston 1 Chamber h
Orifice m Spring (321)
Pin (303) Piston 1 (302)
(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 P
the left while discharging the oil of chamber
h arranged between piston 1 and adjust plug R
(401) into chamber g via orifice n provided in Plunger (301)
Orifice n
Chamber g
piston 1 (302), chamber h serves as a
dumping chamber. SM0580
The load of the spring increases slowly till
piston 1 reaches the end of the adjust plug.
The relief pressure P rises smoothly.
Orifice m Spring (321) Pin (303) Piston 1 (302)
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 P
relief valve keeps its normal relieving action
whereby the relief pressure is held at P2. R
In the processes a. to c. above, the relief Plunger (301) Orifice n
Chamber g
pressure changes as shown in Fig.SM0582.
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
3. Operation of anti-reaction valve

a) Neutral condition
Fig.SM0583 illustrates the relationship
between the neutral condition of the anti-
reaction 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 ANTI REACTION
VALVE
passes through the passage L, the hole on
ANTI REACTION
the shaft of seat (313) and the passage m of VALVE
plunger (311) and is led to the n chamber.
When the pressure P rises above a value SM0583
(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. L
c) At anti-reaction action
When inertia load stops moving (point Y Fig.
k
SM0587), brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward 322 313 321 311 SM0584
the right return side by the action of spring
(321). Seat (313) tries to move to the right by
m n
the action of spring (322), but since
chamber p provides damping action by
orifice g, the return of the seat makes a time
P=PS
delay with regard to the return of the
plunger. L
Consequently, seat t opens. This makes a
passage connecting the AM port and BM
ports or both ports of the hydraulic motor by 322 313 321 311
SM0585
way of trk. The result is that the
pressures at the AM and BM ports become
equal (Pb), falling into the condition at point p t
Z in Fig.SM0582. This prevents the
hydraulic motor from swing shock by the
closing pressure of the AM port. P<PS
k
322 313 g r 321 311
SM0586
P Y
PS
PB
X
Z
T
SM0587
T3-4-10
BRAKE SECTION
Operation
The cylinder (111) is jointed by drive shaft (101) and
a spline. Separator plate (743) is fixed in its
712
circumferential direction by circular grooves
provided in casing (301).
Now, if the friction plate (742) splined to the outer
circumference of the cylinder is pressed against 702
casing (301) via separator plate (743) and brake
712 743
piston (702) by the action of brake spring (712),
frictional force is created between friction plate (742) 742
and casing (301) and between separator plate (743) 702
and brake piston (702). The frictional force bounds
111 301
the drive shaft to brake the motor.
In the meantime, when brake release pressure 743 742 101
301
applied to the oil chamber formed between brake SM0588
piston (702) and casing (301) overcomes the spring
force, the brake is released as brake piston (702)
moves till friction plate (742) is separated from
casing (301).
T3-4-11
SWING REDUCTION UNIT
Operation
The swing reduction unit is used to reduce the
rotating speed which is transmitted by the hydraulic Ring gear (Fixed) Planetary shaft
motor and to convert it to the strong turning force
(torque).
This swing speed reduction unit is equipped with
planetary speed reducing mechanism. Spider
The planetary mechanism is made up of sun gear,
planetary pinion, planetary shaft, spider and ring Sun
gear, as shown in in Fig.SM0589. gear
For the operation of the 1st stage planetary, the
hydraulic motor rotates #1 sun gear (2). Sun gear
(2) is engaged with planetary pinion (3) and rotates,
but since ring gear (6) is fixed, planetary pinion (3)
revolves about sun gear (2) with the planetary shaft
and spider (7).
Planetary pinion
SM0589
The role of spider is to hold the planetary pinion and
planetary shaft and transmits the power from the
planetary pinion to the spider through the planetary
shaft.
The #1 spider (7) is linked with #2 sun gear (4) by Swing motor
the involute spline, and transmits the power to the
2nd stage planetary mechanism. 3 2
For the operation of the 2nd stage planetary, the 6
power is transmitted to sun gear (4) planetary
pinion (5) spider (8) similarly to the 1st stage.
7
The #2 spider (8) is linked with pinion shaft (1) by the
involute spline, and pinion shaft (1) is engaged with 4
the swing gear fixed on the undercarriage (lower
frame) and rotates. 8
13
5
10
11 1
SM0590
T3-4-12
TRAVEL DEVICE E215B-E245B
OUTLINE
Characteristics
Item E215B E245B
Reduction gear unit Epicycloidal, three-stage planetary type
Model 710 C3 K
Gearbox ratio 1 : 55.2 1 : 43.2
Travel motor Two speed, axial piston swash plate type
Model MAG 170 VP MAG 170 VP
high speed 81.2 cm3/rev 112.6 cm3/rev

Displacement
low speed 129.3 cm3/rev 181.3 cm3/rev
Max. flow 220 L/min 246 L/min
high speed 38949 Nm 42827 Nm

Max. gearbox output torque
low speed 24469 Nm 25600 Nm
static 32060 Nm 25000 Nm

Parking brake torque
dynamic 26707 Nm 20900 Nm
Min. pressure parking brake release 11 bar
cracking 311 bar at 1.2 L/min

Relief valve set pressure
total flow 353 bar at 40 L/min
Mass 235 kg 262 kg
T3-5-1
E215B-E245B TRAVEL DEVICE
Hydraulic motor Planetary gearbox

Two speed hydraulic motor (axial piston swash plate Planetary gearbox, 3 stages, rotating housing type.
type) containing: The track drive is suitable to be used as track drive
- Integrated counterbalance valve; 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
Service ports
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 Pressure gauge ports
Pp PF 1/4
T3-5-2
Ports E245B
P1
T
Ps Pm1
Tin
Pm2 P2
Pp
1 A
2 SM0552
1 PF 3/4 Oil filling plug

2 PF 3/4 Oil draining plug
3 PF 3/4 Oil level plug
P1 PF 1
Service ports
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 Pressure gauge ports
Pp PF 1/4
T3-5-3
Hydraulic circuit E215B
Ps Pm2
T
P2
P1
Pp
Pm1 SM0553
Hydraulic circuit E245B
Ps Pm2
P2
R/G
P1
Pp
Tin Pm1 SM0554
T3-5-4
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
SM0556
1- Hydraulic motor
2- Reduction stages
T3-5-5
Hydraulic motor E215B
3
7 4
6
5
SM0557
1- Hydraulic motor base plate

2- Motor shaft, Cylinder block
3- Brake unit
4- Brake valve
5- Relief valve assy
6- Flushing valve
7- 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
Hydraulic motor and track drive E245B
SM0558
T3-5-7
Hydraulic motor E245B
SM0559
T3-5-8
1- Flange 52- Socket bolt (Q.ty 10)

2- Base plate 53- Oil seal
3- (Spool) Plunger 54- Disk plate (Q.ty 3)
4- Check valve 55- Friction plate (Q.ty 2)
5- Spring (Q.ty 2) 56- Brake piston
6- Plug (Q.ty 2) 57- O-Ring
7- O-Ring (Q.ty 2) 58- O-Ring
8- Spring seat(Q.ty 2) 59- Spring (Q.ty 6)
9- Spring (Q.ty 2) 60- Pin (Q.ty 4)
10- Spring seat (Q.ty 2) 61- Spring (Q.ty 2)
11- Cap (Q.ty 2) 62- Valve plate
12- O-Ring (Q.ty 2) 63- O-Ring (Q.ty 4)
13- Socket bolt (Q.ty 8) 64- O-Ring
14- O-Ring (Q.ty 2) 65- Name plate
15- Plug (Q.ty 2) 66- Rivet (Q.ty 2)
17- Relief valve assy (Q.ty 2) 67- Plug (Q.ty 2)
18- Plug (Q.ty 8) 68- Plug
19- Spool A: 2-speed change over 69- Plug
20- Spool C 70- Floating seal (Q.ty 2)
21- Spring 71- Angular bearing (Q.ty 2)
22- Plug 72- Housing (ring gear)
23- O-Ring (Q.ty 2) 73- Shim
24- Spring guide 74- Holder B
25- Plug 75- Washer (Q.ty 8)
26- Washer 76- Socket bolt (Q.ty 8)
28- Orifice 77- Thrust plate (Q.ty 4)
29- Orifice (Q.ty 3) 78- Inner race (Q.ty 4)
30- Orifice (Q.ty 2) 79- Needle bearing (Q.ty 4)
31- Plug (Q.ty 4) 80- Planetary gear B
32- O-Ring (Q.ty 4) 81- Thrust plate (Q.ty 4)
33- Ball (Q.ty 2) 82- Socket bolt (Q.ty 4)
34- Spring (Q.ty 2) 83- Sun gear B
36- Shaft 84- Snap ring
37- Cylinder Block 85- Holder A
38- Piston assy (Q.ty 9) 86- Thrust plate (Q.ty 3)
39- Plate 87- Inner race (Q.ty 3)
40- Holder 88- Needle bearing (Q.ty 3)
41- O-Ring 89- Planetary gear A
42- Sede molla 90- Thrust plate (Q.ty 3)
43- Spring 91- Thrust plate
44- Collar 92- Capscrew (Q.ty 3)
45- Pin (Q.ty 3) 93- Drive gear
46- Plate (swash plate) 94- Thrust plate
47- Ball (Q.ty 2) 95- Cover
48- Piston assy (Q.ty 2) 96- Bolt (Q.ty 16)
49- Ball bearing 97- Plug (Q.ty 3)
50- Ball bearing 98- O-Ring (Q.ty 3)
51- Pin 99- Pin (Q.ty 4)
T3-5-9
NOTE:
T3-5-10
SWIVEL JOINT E215B-E245B
OUTLINE
General view
E
A
F B
D
VIEW Y
VIEW Z
Z
SM0568
Specifications
Working pressure 34.3 MPa
High pressure ports A,B,C,D Max. impact pressure 51.5 MPa
Rated flow 255 L/min
Working pressure 0.49 MPa
Low pressure ports E
Rated flow 50 L/min
Working pressure 5 MPa
Low pressure ports F
Rated flow 30 L/min
Revolution 15 min-1
A,B,C,D (body) PF 1
A,B,C,D (stem) PF 3/4
Ports size
E PF 1/2
F PF 1/4
Length (height) 368 mm
Weight 24.5 kg
T3-6-1
E215B-E245B SWIVEL JOINT
CONSTRUCTION
E
2
H
C
13
D
H
6 E
A
1
B
D
VIEW Y
C
B 12
F
A
5
7
9 SECTION HH
3
E E 8
SM0569
1- Body 7- O-Ring
2- Stem 8- Capscrew; M8x20 (Q.ty 2) 30.4 Nm
3- Thrust plate 9- Capscrew; M8x30 (Q.ty 3) 30.4 Nm
4- Cover 12- Plug
5- Seal (Q.ty 5) 13- O-Ring (Q.ty 2)
6- Seal
T3-6-2
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
NOTE:
T3-6-4
CYLINDERS E215B-E245B
OUTLINE
General view
B
gth
en
e dl A
nd gth
e xte l en
ully ted
F rac
ret
lly
Fu
Part No. and Manufacturing No.

Stamp position
SM0560
Specifications
Center
distance of
Cylinder bore Dry
Stroke pins
Use Rod Dia. Cushion weight
Full extend B /
Full retract A
(mm) (mm) (mm) (kg)
With cushion
Boom 120 / 85 1345 3200 / 1855 176
on rod side
With cushion
Arm 135 / 95 1558 3637 / 2079 255
on both sides
With cushion
Bucket 120 / 80 1080 2684 / 1604 153
on rod side
Positioning 145 / 90 992 2662 / 1670 Without cushion 220
T3-7-1
E215B-E245B CYLINDERS
CONSTRUCTION
Boom cylinder
27 26 12 24 25
B
105 -0.5
105 -0.5
0
0
PT 1/4 28
28
SLIT
With hole
GREEN BLACK (1 place)
DETAIL 6 DETAIL B DETAIL C
9 8 7 6 4 5 3 11 10 2 1 13 14 15 17 16 18 19 20 21 22 23
SLIT
C Orientation of cut off part
of cushion bearing (13)
SM0561
1- Cylinder tube 16- Seal ring

2- Piston rod 17- Backup ring (Q.ty 2)
3- Rod cover 18- Slide ring (Q.ty 2)
4- Bushing 19- Slide ring (Q.ty 2)
5- Snap ring 20- Spessore
6- Buffer ring 21- Piston nut; M62 3 7280 Nm
7- U-Ring 22- Set screw; M12 56.9 10.7 Nm
8- Backup ring 23- Steel ball
9- Wiper ring 24- Pin bushing (Q.ty 2)
10- O-Ring 25- Wiper ring (Q.ty 2)
11- Backup ring 26- Pin bushing (Q.ty 2)
12- Socket bolt; M16 75 (Q.ty 12) 267 Nm 27- Wiper ring (Q.ty 2)
13- Cushion bearing 28- Grease fitting; M10 x 1 (Q.ty 2)
14- Cushion seal
15- Piston
T3-7-2
Arm cylinder
27 26 12 26 27
B
120 -0.5
120 -0.5
0
0
PT 1/4
PS 1/8
SLIT
With hole
9 8 7 6 3 4 5 11 10 2 1 13 14 15 16 17 18 19 20, 21 25
22
23 24
C SLIT
Orientation of cut off part

SM0562
1- Cylinder tube 15- Piston

2- Piston rod 16- Seal ring
3- Rod cover 17- Backup ring (Q.ty 2)
5- Snap ring 19- Slide ring (Q.ty 2)
6- Buffer ring 20- Set screw; M12 56.9 10.7 Nm
7- U-Ring 21- Steel ball
8- Backup ring 22- Cushion bearing
9- Wiper ring 23- Cushion seal
10- O-Ring 24- Stopper (Q.ty 2)
11- Backup ring 25- Snap ring
12- Socket bolt; M18 80 (Q.ty 12) 367 Nm 26- Pin bushing (Q.ty 4)
13- Cushion bearing 27- Wiper ring (Q.ty 4)
14- Cushion seal
T3-7-3
Bucket cylinder
25 24 12 24 25
107 -0.5
107 -0.5
0
0
27
26
SLIT
With hole
9 8 7 6 3 4 5 10 11 2 1 13 14 15 16 17 18 19 20 21 22 23
C SLIT
Orientation of cut off part

SM0563
1- Cylinder tube 15- Piston

2- Piston rod 16- Seal ring
3- Rod cover 17- Backup ring (Q.ty 2)
5- Snap ring 19- Slide ring (Q.ty 2)
6- Buffer ring 20- Shim
7- U-Ring 21- Piston nut; M62 3 7280 Nm
8- Backup ring 22- Set screw; M12 56.9 10.7 Nm
9- Wiper ring 23- Steel ball
10- O-Ring 24- Pin bushing (Q.ty 4)
11- Backup ring 25- Wiper ring (Q.ty 4)
12- Socket bolt; M16 75 (Q.ty 12) 267 Nm 26- Grease fitting; M10x1
13- Cushion bearing 27- Grease fitting; M10x1
14- Cushion seal
T3-7-4
Positioning
23 22 12 22 23
B
123 -0.5
128 -0.5
0
0
PT 1/4
24
SLIT
With hole
9 8 7 6 3 4 5 10 11 2 1 13 14 15 16 17 18 19 20 21
SM0564
1- Cylinder tube 15- Backup ring (Q.ty 2)

2- Piston rod 16- Slide ring (Q.ty 2)
3- Rod cover 17- Slide ring (Q.ty 2)
4- Bushing 18- Shim
5- Snap ring 19- Piston nut; M62 3 7280 Nm
6- Buffer ring 20- Set screw; M12 56.9 10.7 Nm
7- U-Ring 21- Steel ball
8- Backup ring 22- Pin bushing (Q.ty 4)
9- Wiper ring 23- Wiper ring (Q.ty 4)
10- O-Ring 24- Grease fitting; M10x1
11- Backup ring
12- Socket bolt; M20 80 (Q.ty 12) 520 Nm
13- Piston
14- Seal ring
T3-7-5
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 CUSHION RING (13) CHAMBER A PATH (B)
TANK
extend and retract.
PISTON (15)
ROD (2)
Operation of cylinder with cushion
HEAD ROD
CUSHION ON ROD SIDE SIDE SIDE
The cushion mechanism is provided to prevent the

generation of shock when the moving speed of CYLINDER HEAD (3)
CUSHION STROKE
piston (15) is not reduced and strikes cylinder head
(3).
An oil in chamber "A" returns to the tank by passing
SM0565
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".
TANK
At this time, an oil in chamber "A" passes clearance CLEARANCE D
"D" and mouth gap "C", an oil flow volume returning
to tank suddenly drops and the piston part
movement slows down.
MOUTH GAP C
SM0566
T3-7-6
CUSHION ON HEAD SIDE

This construction is similar to the one of cushion on
rod side. In a state of intermediate stroke pressing CUSHION SEAL (24)
rod side, an oil in chamber "A" returns to tank by
PATH B CUSHION BEARING (23)
passing through path "B" at a fixed flow rate. TANK
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.
CLEARANCE D
CHAMBER A
SM0567
T3-7-7
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
SOLAR RADIATION SENSOR COMPRESSOR DRIVE SOURCE
REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH
AIR-CON BLOWER REVOLUTION SIGNAL
AIR OUTLET SWITCHING SIGNAL CONTROLLER
INNER AIR SENSOR
EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL
OUTER AIR INTAKE

MOTOR
VENT ACTUATOR
INNER AIR
MOTOR
ACTUATOR
AIR CONDITIONER UNIT FACE
FOOT MOTOR BLOWER

ACTUATOR CONTROLLER
SM0024
T3-8-2
COMPONENT AND CONSTRUCTION
COMPONENT
27
33 30
27-1
40
32
39
27-6
27-3 27-5
27-2
35
35-7 35-6
35-1
35-2 35-5
34 35-8
35-10 35-9
SM0025
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: 15.5 1
27-3 Clamp 2 35 Air dryer assy 1 35-9 S tube: 16 1
27-5 Filter 1 35-1 Receiver dryer 1 35-10 L tube: 8.5 1
27-6 Tube assy 1 35-2 Bracket 1 39 Filter 1
30 Panel assy 1 35-5 S hose: 24.5 1 40 Solar radiation sensor 1
T3-8-3
CONSTRUCTION
(1) Air conditioner unit
49
48
6
47
46
44
31
42 31
41
50 F
3 1
45 1
43
32 G
1
1
28 1
39
37
38
B
36
27
H
9
40
A I
2
33
SM0022
Air conditioner unit (1/2)
T3-8-4
14
1 1 31 16
1 5
15
31
1
3
1 61
F 1
C 1
D
4
7
G
1 1
1
26 20 13
59
29
11
21 23
22
H
24 1
B
1
8 60
D
17
18 A
I
C
10
31
19
12
1
3
31 25
52
SM0021
Air conditioner unit (2/2)
T3-8-5
No. Parts Q.ty No. Parts Q.ty No. Parts Q.ty

1 Screw M516 23 19 Relay 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 M540 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 M430 9 52 Inner air filter 1
13 Intake door 1 32 Upper casing 1 55 Screw M625 10
14 MA intake lever 1 33 Lower casing 1 56 Screw M825 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
A 2 B
3 - Desiccant
4 - Suction pipe
5 - Filter
6 - Receiver tank
A - Refrigerant INLET
B - Refrigerant OUTLET
2 -M6
1
3
4
SM0037
T3-8-6
FUNCTION
Mechanism of cooling circuit
MECHANISM OF COOLING
In the cooling process, the refrigerant that flows HFC-134a (R134a)
through the cooling circuit changes its phases from CH2FCF3
Chemical formula
liquid to gas and vice versa during which process
heat is transferred from the low temperature part Molecular weight 102.03
(compartment) to the high temperature part (outside Boiling point 26.19 C
of the vehicle). Critical temperature 101.14 C
Critical pressure 4.065 MPa
Kind of Refrigerant Critical density 511 kg/m3
Many kinds of refrigerants that change in that way Density of saturated liquid (25 C) 1206 kg/m3
are available, but the following requirements are
Specific volume of saturated
needed for use in such applications: vapor (25 C) 0.0310 m3/kg
Latent heat of vaporization (heat of vaporization)
Latent heat of vaporization (0 C) 197.5 kJ/kg
is large.
Flammability Non flammable
It is easy to liquefy (condense). (It does not
require very high pressure for condensation.) Ozone destruction coefficient 0
It is easy to gasify (evaporate). (It evaporates
sufficiently at not too low pressure, i.e. cools
down an object.)
It has small specific heat. (Since the refrigerant
itself is cooled by the expansion valve, the loss
resulting from it must be held down to a
minimum.)
It has a high critical temperature and a low
solidification point.
It is stable chemically and does not corrode and
permeate into the circuit parts.
It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
It has small specific volume.
It is easy to find out leakage.
Out of refrigerants meeting the above-mentioned
requirements, ones having characteristics that suit
the intended cooling unit are chosen and used. If a
refrigerant other that those designated is used,
sufficient refrigeration will not be performed or the
equipment in which the refrigerant is used may be
broken. Therefore, always use a designated
refrigerant for the cooling unit.
Table shows the principal characteristics of the P (MPa)
R134a refrigerant that is used in this machine. 4 R134a
CHARACTERISTICS OF REFRIGERANT
3
In general, the fluid (general term of gas and liquid)
has the following qualities:
2 LIQUID
1. As a gas under certain pressure is cooled down,
it begins to condensate at a certain temperature GAS
to take a liquid state. The temperature at which 1
condensation begins is unique to each
substance (fluid) at a given pressure. The
temperature determined by a given pressure is 0 15 18 35 50 T (C)
called saturation temperature. SM0038
T3-8-7
2. Inversely to 1. above, the pressure at which a

gas condenses for a temperature is
determined. This pressure is called saturation
1
pressure.
Figure beside illustrates the relationships 2
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 3 9
righthand side of the curve in figure, the
refrigerant take a gaseous state, while at the
temperature and the pressure on the upper 6
lefthand side of the curve, the refrigerant takes
a liquid state.
Let us think of a case where an air-conditioner 4 5
is operated in the midst of summer. As the
refrigerant evaporates, it absorbs evaporation
7 8
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
SM0039
a lower temperature. It can be seen from the
figure that R134a under a pressure above the
1 - Inside of the compartment (cab)
atmospheric pressure is capable of cooling the
2 - Evaporator
inside of the compartment sufficiently. (If a
3 - Blower
refrigerant that requires a pressure below the 4 - Compressor
atmospheric pressure to cool it to a required 5 - Cooling fan
temperature is used, air is mixed into the 6 - Inside of engine room
circuits, thereby deteriorating the performance 7 - Condenser
of the cooling unit.) In the process in which 8 - Receiver dryer
gaseous refrigerant is brought back to a liquid 9 - Expansion valve
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.
Cooling circuit
The figure illustrates the cooling circuit of the car air-
conditioner.
In this circuit diagram, the portion that cools the air
of the compartment is the evaporator. The object air
is cooled off by utilizing the fact that the refrigerant
takes heat off the surrounding area as evaporation
heat as it evaporates in the cooling circuit. Since the
part at which vaporization of the refrigerant takes
place is the evaporator, cooled air is constantly
delivered to the circumference of the evaporator by
the blower fan. In the meantime, liquid refrigerant
(slightly wet vaporized refrigerant) is fed into the
evaporator, when "cooling" effect is attained. For
instance, in order to cool the air to 15 C, the
refrigerant can not absorb evaporation heat from the
air unless it evaporates at a temperature lower that Furthermore, the cooling effect deteriorates unless
15 C. For that purpose, it can be seen from the the feed rate of the refrigerant is controlled so that
figure that the pressure of the refrigerant in the all of the refrigerant supplied to the evaporator
evaporator must be less than 0.51 MPa. vaporizes and turns into dry vapor.
T3-8-8
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 1
the utilization of the latent vaporization heat of the
low-temperature, low-pressure liquid-state
refrigerant. Therefore, it is necessary that
satisfactory heat transfer between the object and
the refrigerant take place in the evaporator.
To that end, the evaporator is equipped with fins on
the air side in order to increase the heat transfer
area of the air side and thereby perform excellent
thermal transfer between the refrigerant and the air. 2
The humidity in the air condenses as the air cools
down and adheres to the outside of the evaporator
as water drops. The cooling effect deteriorates if the
water drops freeze. Therefore, how to discharge
water is an important point. 3
The amount of refrigerant supplied to the evaporator
is controlled by the expansion valve which is
described in the following. In order to attain proper
control, it is necessary to reduce the pressure drop 4
of the refrigerant of the evaporator. Accordingly, SM0026
reducing the pressure drop is one element that 1 - Evaporator
makes the evaporator attain its full performances. 2 - O-ring
3 - Expansion valve
EXPANSION VALVE 4 - Socket bolt M5 x 40
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
The expansion valve feeds the flowing high-

pressure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid 1
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
2
expansion valve is constructed. The temperature
sensing part is provided in the shaft of the
3
expansion valve to directly detect the refrigerant
temperature at the outlet of the evaporator. 4
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 5
the pressure abruptly as it passes through the valve
(throttling action). On that occasion, part of the 6
refrigerant evaporates by the very heat of the
refrigerant and cooled off. The result is that low- 7
pressure low-temperature damp refrigerant vapor is
fed to the evaporator. SM0040
The opening of the valve is determined by the 1 - Diaphragm

equilibrium between the pressure (low) of the 2 - Evaporator side
evaporator side, the action of the adjust spring and 3 - Refrigerant outlet
the pressing force of the diaphragm (the 4 - Shaft
5 - Refrigerant inlet
temperature of the refrigerant at the outlet of the
6 - Ball valve
evaporator to be sensed by the thermowell). The
7 - Spring
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 SM0041
refrigerant supply to the evaporator more securely.
The air-conditioner of this machine adopts a block
type expansion valve.
T3-8-10
COMPRESSOR
The compressor performs the following three
functions in the cooling circuit: 1
1. Suction action
2. Pumping action
3. Compressive action
2
1. The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling effect.
2. The pumping action serves to cause all the
refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling. 3
3. The compressive action, as combined with the
action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as the SM0042
pressure increases. For instance, it becomes 1 - D Hose

possible to cool down the refrigerant by the use 2 - S Hose
of an outer air of 35 C and liquefy it. The 3 - Compressor
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.
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
RECEIVER DRYER
1. Receiver Tank
On the air-conditioner, the revolution of the 1 2
compressor varies greatly which causes the
proper flow of refrigerant in the cooling circuit to 3
vary. It is the receiver tank that receives the
variations. When the cooling circuit does not
need much refrigerant, the receiver tank stores
extra refrigerant temporarily and supplies it
when the cooling circuit needs much
refrigerant. The receiver tank also stores an
4
extra amount of refrigerant to be used for filling
balance and supplement small amounts of
leakage of the refrigerant through penetration
into rubber hoses.
2. Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil,
corrodes the metallic parts of the circuit or clogs 5
the circuit as the water freezes in the expansion
valve. It is desirable that the amount of water 6
mixed in the refrigerant should be held below a
concentration of 30ppm. The air-conditioner
uses a molecular sieve as desiccant suited for
7
the circuit, in order to absorb water content that
intrudes into the circuit when the dryer is
installed or when refrigerant is charged.
3. Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the 8
only means of confirming the inside of the
circuit visually.
4. Filter
5. Pressure Switch
This machine employs pressure switches of
high/low pressure type. SM0043
The pressure switch protects the circuit by 1 - Refrigerant inlet
cutting off the power supply to the compressor 2 - Sight glass
when high pressure increases abnormally high 3 - Refrigerant outlet
(more than 3.14 MPa). 4 - Pressure switch
The pressure switch also detects the leakage of 5 - Desiccant
refrigerant by cutting the power supply to the 6 - Suction pipe
7 - Filter
compressor when the pressure of the circuit
8 - Receiver tank
falls below 0.196 MPa.
T3-8-12
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS TO BE EXERCISED IN
OPERATION
1. Special Refrigerator Oil
Unit: Nm (lbfft)
This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils TIGHTENING
PIPE FASTENING PART
TORQUE
other than SP20 may not be used. Since SP20
tends to absorb moisture and may corrode D hose and compressor (M8 bolt) 19.6~24.5 (14~18)
paint and resin, the following points must be D hose and condenser 19.6~24.5 (14~18)
noted:
L hose and condenser 11.8~14.7 (8.7~11)
1) Do not keep open all pipe connections on a
new compressor and the component parts L hose and receiver dyer (M6 bolt) 7.8~11.8 (5.8~8.7)
of the installed refrigeration circuit L hose and air-conditioner unit 11.8~14.7 (8.7~11)
(Remove valves and caps at the pipe
openings of the compressor, just before S hose and air-conditioner unit 29.4~34.3 (22~25)
connecting pipes. If you have removed a Expansion valve 1.96~2.45 (1.4~1.8)
pipe joint for repair, put a cap to both ports
immediately.)
2) Use care so SP20 does not adhere to the
painted surface and resin parts. In case Unit: Nm (lbfft)
SP20 has adhered to such surfaces, wipe it TIGHTENING
off immediately. SCREW SIZE
TORQUE
2. The receiver dryer is filled with desiccant to N4, T4 machine screw, M4 0.78~1.18 (0.58~0.87
absorb moisture in the circuit. Therefore,
remove the valve at the pipe port immediately N5, T5 machine screw, M5 1.96~2.45 (1.4~1.8)
before connecting pipes. M6 (mounting part of L hose
7.85~11.8 (5.8~8.7)
joint)
3. Tightening Torque
M6 (except mounting part of L
1) Pipe Joints 9.8~11.8 (7.2~8.7)
hose joint)
When connecting pipe joints, coat the O-ring
M8 (mounting part of S,D hose
with special oil (SP20) and fasten to the 19.6~24.5 (14~18)
joints)
tightening torque indicated in the table,
using a double spanner. M8 (mounting part of A/C unit) 9.8~11.8 (7.2~8.7)
2) Screws and Bolts M8 (other than those mentioned
11.8~15.7 (8.7~12)
Fasten to the tightening torque indicated in above)
the table M10 39.2~53.9 (29~40)
4. Amount of Oil for Compressor
The compressor SD7H (HD type) is filled with
135cc (8.2cuin) of oil. If the oil volume is small,
seizure at high revolution and shortening of REPLACED PARTS AMOUNT TO BE FILLED IN
service life will occur. If the oil volume is large, EVAPORATOR 40 cc (2.4cuin)
the cooling ability will be deteriorated.
Once the air-conditioner is operated, part of the CONDENSER 40 cc (2.4cuin)
oil is dispersed in the refrigeration circuit.
Therefore, when replacing the parts in right Drain out the volume of oil left in
Table, adjust the oil level to that of table. COMPRESSOR the compressor to be replaced,
from the new compressor.
5. Before performing operation, stop the engine
and turn off all power supplies to the equipment
related to the air-conditioner. RECEIVER DRYER 20 cc (1.2cuin)
6. After the operation is over, confirm that all faults HOSES 20 cc (1.2cuin)
have been repaired completely, by operating
the air-conditioner.
T3-8-13
DISASSEMBLY AND ASSEMBLY OF UNIT

1. Removing inner air filter
Slide the inner air filter (1) leftward and remove 7 2
it from the unit (2).
SM0027
2. Removing selector box

5 3
Remove 6 plus screws (3), remove connector 8
(4) connected to the mode actuator (5) on mode
selector box (6), and separate the mode
selector box from the unit (2).
3. Removing main harness

4
Pull out 3 harness clamps (7) from the unit (2),
and disconnect all connected connectors and 6 2
remove harness (8) on the body from the unit
(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 11 12
giving attention to the thermistor harness so
as not to be caught by the casing.
2b
10
2a
SM0029
T3-8-14
5. Replacing blower controller

1) Remove 2 plus screws (14) and remove the 2b
blower controller (15) from the upper unit
casing (2b).
2) Install new blower controller by the reverse
procedure of removal.
* Do not disassemble the blower controller.
14 15
SM0030
6. Removing heater core

16 17
1) After draining the coolant, remove heater
hos e from the heater core (16). 18
2) Remove 1 plus screw (17), and remove pipe 20
clam (18) which is used to secure the heater 19
core and then remove the heater core (16)
from the lower unit casing (2a).
3) Install it by the reverse procedure of
removal.
7. 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. 20
2) Remove evaporator sensor (21) with sensor
holder (22) from the removed evaporator
(20).
22
3) Insert the sensor holder into the new
evaporator at the position shown in Fig. 105mm
(4.1 inch)
SM0032 and install the evaporator sensor
(21) again.
A - 11th rows of fin 21
SM0032
T3-8-15
4) Remove 2 socket bolts M540 (23) with

Allen wrench (4 mm) and remove the
expansion valve from the evaporator (20). 20
5) Fit O-ring (24) (NF O-ring 5/8 and 1/2 one
each) to new evaporator.
A
* When assembling again, fit O-ring paying
attention so as not to be caught with others.
(Socket bolt M540 (2 pcs.) Tightening torque:
24
6.9Nm (5.1lbfft)
* 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 25
expansion valve (25) is disconnected from
expansion valve, similar careful work is
necessary.
23
9. Replacing motor actuator SM0033
1) Replacing mode actuator

a) Remove connector (26) connected to the 29
motor actuator (27).
28
b) Remove FACE rod (28) and VENT rod
(29) which is used to connect MA mode 30 26
lever (30) and mode cam from the
holder. 31
c) Remove 3 plus screws (31) and remove
the motor actuator (27) with lever MA 27
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
2) Replacing air mixing actuator SM0034
a) Remove connector (32) connected to the

motor actuator.
b) Remove rod air MIX (33) which is used to 33
connect the motor actuator (27) and the 36
lever MA air MIX.
c) Remove 3 plus screws (34) and remove
the motor actuator (35) with MA lever air 32
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
34
35 SM0035
T3-8-16
3) Replacing inner and outer air switching 40

actuator
a) Disconnect connector (37) connected to
the motor actuator (38).
b) Remove intake rod (39) from MA intake 39
41
lever (40).
c) Remove 3 plus screws and remove the
motor actuator (38) with MA intake lever
(40) from the unit. 37
d) Remove the MA intake lever (40) from
the removed motor actuator, and install it
on new motor actuator by the reverse
38
SM0036
T3-8-17
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
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. -26C (-15F)]. Therefore, handle
it with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
2. Storage and Transportation

1) Keep the service can (hereinafter called can) less than 40C (104F). 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 40C (104F).
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 40C (104F 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
OPERATING PROCEDURE
The change of refrigerant in the air conditioner - The "gas charging procedure" consists in the filing
requires a "vacuum generation procedure" and a the circuit with refrigerant, after applying a
"gas charging procedure". vacuum. the filling of the gas is not only depending
upon the cooling performance of the air
- The "vacuum generation procedure" consists in conditioner, but it influences also the useful
removing moisture from the air conditioner circuit. working life of the circuit components. An
In the event even a small quantity of moisture excessive overloading increases considerably the
remains in the system, it would freeze in the small pressure of the system and damages the cooling
orifices of the expansion valve when in operation. performance. On the contrary, a too low charging,
This causes a clogging of the circuit or the results in an insufficient circulation of lubricant oil
formation of rust, with a series of operational in the compressor, causing the wear of the moving
troubles. prior to filling the circuit with refrigerant, parts of the compressor.
apply the vacuum and cause the boiling and
vaporisation of the moisture. In this manner, WARNING
moisture is eliminated from the system.
The gas filling operation involves the handling of
highly compressed gases; it is dangerous to handle
the gas without complying strictly with the relevant
procedures. The procedures and the protections
described in this manual for the filling of refrigerant
gas must be strictly adhered to.
Vacuum making operatio Refrigerant filling operation
More than Leave it as it is,

30 min. for five minutes.
Begin vacuum Stop vacuum Check Fill in Check for Fill in

making making air-tightness refrigerant gas leak refrigerant
Lower than
-750m mHg Gauge indicates
abnormality
Charge refrigerant gas to a gauge
Check and correct joints pressure of 0.1 MPa
SM0194
T3-8-19
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" 2
and "S" as described in the figure. 1 3
6 5
WARNING
Never exchange by mistake the high pressure pipe 4
with the low pressure pipe when connecting them.
Install the pipe firmly until a click noise is heard. D
Connect the quick release joint of the charging pipe
with the service valve of the compressor. If the
charging pipe is connected in the opposite direction, S
mini-valve (9) of the compressor fails to open.
8 7
3. Connect the central valve of the gauge manifold
SM0016
with charging pipe (4) of the vacuum pump (7).
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 D S
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).
8 9
7. Cut-off the vacuum pump.
SM0017
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
PROCEDURE FOR THE CHARGING OF THE GAS

1. After applying the vacuum repeatedly,
exchange charging pipe (4) of the gauge 2
manifold (2), from the vacuum pump to the
service can (9). 11
2. Open the valve of service can (10). Close the

high and low pressure valves of the gauge
manifold. Press central bleeding valve (11) of 4
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 10
the pressure of the refrigerant. Proceed with
this operation until a whistle is heard coming 9
from the bleeder.
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 1 3
service valve (10).
WARNING D
Never start operating the compressor during this
work. The starting of the compressor causes the
blowing of the service can. 10
S
4. Check that there are no leakages of gas in the
cycle, using a gas leakage tester. Retighten
and eliminate all points of leakage. SM0019
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
9. Open low pressure valve (1) of the gauge

manifold and service valve can (10) and fill with 01
refrigerant until all air bubbles in sight window
(12) of the dryer disappear.
Total quantity of gas to be charged: 900 50 g.
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 A: Appropriate quantity of refrigerant
gauge, to a value of 1.0 MPa. B: The system is overloaded
c. Disconnect the red charging pipe from the C: Insufficient quantity of refrigerant
high pressure side, in the same manner as
described for the low pressure.
T3-8-22
ELECTRIC CIRCUIT
WIRING DIAGRAM AND CONNECTORS

Wiring Diagram
(A)(B)
2
(C)
12 3
(N)
(R) (D)
155(BR) 150(BP)
4
FUSE 20A 15 85E(WB)
18(RG) (E)
25(WG)
FUSE 5A
13 26(RL)
FUSE 15A
E24(B) 5
FUSE 5A
(Q) (M)
FUSE BOX
(L) (F)
6
(P) 11
(K)
10 (G)
14
7
9
(J) (H)
8
SM0044
(I)
1 - CCU(Operation Panel + Controller) 9 - Blower AMP

2 - Evaporator Sensor 10 - Blower Motor
3 - Air Inlet Sensor 11 - Blower Off Relay
4 - Solar radiation Sensor 12 - Pressure Switch
5 - Motor Actuator (for air mix) 13 - Main Key Switch
6 - Motor Actuator (for Mode) 14 - Compressor
7 - Motor Actuator (Rec/Fresh) 15 - Light Switch
8 - Compressor Relay
T3-8-23
Connectors
(A) JAE (B) JAE

HOUSING : IL-AG5-22D-S3C1 HOUSING : IL-AG5-14D-S3C1
TERMINAL : IL-AG5-C1-5000 TERMINAL : IL-AG5-C1-5000
(C) MAKER : YAZAKI CORP.

HOUSING No. : 7123-2228
(D) MAKER : YAZAKI CORP. (E) NIPPON AMP KK 174056-2
HOUSING No. : 7123-2228 TERMINAL : 175062-1
TERMINAL : 17111 TERMINAL : 17111
(F) JAE IL-AG5-7S-S3C1 (G) JAE IL-AG5-7S-S3C1 (H) JAE IL-AG5-7S-S3C1

TERMINAL : AG5-C1-5000 TERMINAL : AG5-C1-5000 TERMINAL : AG5-C1-5000
(I) MAKER : YAZAKI CORP. (J) MAKER : YAZAKI CORP. (K) MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249 HOUSING No. : 7123-2237 HOUSING No. : 7123-6020
TERMINAL : 17111 TERMINAL : 17111 TERMINAL : 7116-2871
(M) MAKER : YAZAKI CORP. (N) MAKER : YAZAKI CORP.

(L) MAKER : YAZAKI CORP. HOUSING No. : 7122-6060
HOUSING No. : 7123-6060-40
HOUSING No. : 7123-2249 REAR HOLDER : 7157-6260-30
TERMINAL : 17111 TERMINAL : 7114-2871 TERMINAL : 7116-2871
26 25 85E
150 E24 18
(P) (R) MAKER : SUMITOMO

MAKER : YAZAKI CORP. (Q) NIPPON AMP KK HOUSING No. : 6189-0094
7120-8019 170889-1 HARNESS SEAL : 7160-8234
CP3.96MA 170003-5 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
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 SM0047
control unit.
TERMINAL
NO. CONTINUITY
1 2 3 B
CONTINUED
+ -
(4.7 k 5%)
- + NOT CONTINUED
TESTER 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.

* The installing position is provided on the

left side of air-con unit.
SM0048
T3-8-25
3. Relay
Four-electrode relay is used for the blower OFF
relay and compressor relay.
1) Blower OFF relay
The blower OFF relay turns on after
receiving the signal from the control
amplifier. A
When the blower OFF relay turns on, the A
source voltage is supplied to the blower
motor and the blower motor starts running.
2) Compressor relay
The relay ONOFF is tripped by the control
amplifier and electronic thermostat control.
SM0049
3) Relay inspecting items
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay
because this relay has polarity.
5. Inspection: Inspect the continuity
between 3 and 4 according to the
conditions mentioned below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-
2:
Not continued
4. Air mix actuator
Air mix actuator is installed at the center of air-
con unit, and opens and closes air mix damper
through the link.
The air mix actuator contains potentiometer
which is switched by being coupled to the shaft
of actuator.
When the target air mix door position is CONTROL AMPLIFIER MOTOR ACTUATOR
determined through the temperature control LIMITER
switch, the control unit reads the level of COOL

POTENTIO 5V
potentiometer of the actuator, and determines POTENTIO

POTENTIO GND
the rotating direction of motor in either normal
rotation or reverse rotation. Then as the motor HOT
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 SM0050
rotating.
T3-8-26
5. 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
AMPLIFIER MOTOR ACTUATOR
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 INNER AIR SIDE
switch also rotates and makes it stop at the set
OUTER AIR SIDE
position of the inner and outer air damper.
LIMITER
6. Evaporator sensor
This sensor is used to control the evaporator SM0051
outlet temperature with the compressor ON-

OFF to protect the evaporator from freezing,
and this evaporator sensor functions as a
sensor of this control.
Evaporator sensor inspecting items
(Specification)
Terminal resistance:
at 0 degree C: 7.2 k
at 25 degree C: 2.2k
SM0052
7. Dual pressure switch
This dual pressure switch is attached on L-hose
and is used to turn OFF the compressor, and
employs dual type (for high and low pressure
control) to protect the cooler cycle from
possible failure at the time when abnormal
pressure was generated on the high pressure
side.
SPECIFICATION OF DUAL PRESSURE SWITCH
0.02MPa(2.9psi) 0.59MPa(86psi)
SM0053
ON
OFF
0.20MPa 3.14MPa
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
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
TROUBLESHOOTING
Note : M/A is motor
Air temperature does not fall. actuator
* is any of the
numbers 0 ~ 9
If AUTO switch or A/C switch is pushed, "HL.E" is indicated on the set
temp. display of the panel.
NO YES
"HL.*" is shown on the set temp. display Connector for air mix M/A is disconnected or in
of the panel poor contact.
Air mix M/A is failed.
NO YES Main harness shows poor continuity.
A snow mark ( ) on the A snow mark ( ) on

panel is flashing. panel is flashing. Inspect and correct or replace parts.
NO YES
Inner air sensor or harness is disconnected or shorted Both inner air sensor and evaporation
Inner air sensor connector is disconnected or in poor sensor are disconnected or shorted.
contact. Controller failed.
See section monitor mode. See section monitor mode.
Inspect and correct or replace parts.

A
NO YES
Blowout temp. falls if temp. is set at 18.0 C Evaporation sensor connector is

(64.4 F) (COOLMAX) and the blowout mode is disconnected or in poor contact.
changed to vent mode. Evaporation sensor is disconnected or
shorted.
NO YES Inspect and correct or replace parts.
Air mix damper is in Cool air flowing into inner

COOLMAX. air sensor Inspect and correct or replace parts.
NO YES
NO YES
If M/A is at stop halfway, Turn compressor clutch on
eliminate cause, correct and and off. Inspect and correct Controller is faulty Inspect duct or
measure operating force. electric circuits. or inner air sensor eliminate cause for
(less than 14.7N: OK) is faulty. cool air intrusion.
Refer to Troubleshooting for
refrigeration cycle.
Inspect and replace.
NO YES
Inspect, correct or replace M/A lever M/A failed or controller

link. is out of order.
After cleaning lever link, apply grease.
Replace.
T3-8-28
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
"HL.*" is shown on the set temp. display Connector for air mix M/A is disconnected or in
of the panel. poor contact.
Air mix M/A is failed.
NO YES Main harness shows poor continuity.
Inner air sensor or harness is disconnected or

shorted Inspect and correct or replace parts.
Inner air sensor connector is disconnected or in
poor contact.
See section monitor mode.
NO YES
NO YES
Blowout temp. rises at blowout
mode if temp. is set at HOT MAX
32.0 C (64.4 F)
NO YES
Air mix damper is in Warm air is flowing into

HOT MAX inner air sensor.
NO YES
NO YES
If M/A action is at stop, Inspect warm water piping.
eliminate cause, correct and Controller or inner Inspect duct or
measure operating force. air sensor is out of eliminate causes
(less than 14.7N: OK) order. for warm air entry.
Inspect and replace.
NO YES
Inspect, correct or replace M/A lever M/A failed or controller

link. is out of order.
Clean lever link and apply grease.
Replace.
T3-8-29
Blower motor does not run.
Note 1) At air flow HI, battery voltage acts across

both terminals (+) and (-) of blower motor.
NO YES
Battery voltage acts across red Blower motor fails.

(+) and body of blower motor.
NO YES Replace.
Note 2) Inspect blower motor relay. Blower Approx. 10V acts across light green wire
motor rotates if white / red wire and and grounding of blower amplifier.
red wire of blower motor relay are
direct connected.
NO YES
NO YES
Controller is out of order. Remove blower amplifier and check
Replace. for continuity across light green wire
Wire harness is faulty. and black wires; you get continuity.
Inspect and correct or
replace. NO YES
Eliminate cause Inspect and

Battery voltage acts across white / red and replace blower repair harness.
wire and body of blower motor relay. amplifier.
NO YES
Inspect and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES
Replace relay. 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
Blower motor speed does not change.
CASE (1)
"HL.*" is shown on the set temp. display of Note) * is any of the
the panel. numbers 0 ~ 9.
NO YES
Replace blower amplifier Inner air sensor or harness is disconnected or

controller. shorted.
Inner air sensor connector is disconnected or in
poor contact.
See section monitor mode.
CASE (2)
Does not blower motor speed change
because the setting mode is other face
NO YES
Is door or front window open? See CASE (1).
NO YES
The limiting or control operation See CASE (1).

is actuated by door switch or
front window switch
T3-8-31
Magnet clutch does not engage.
Snow mark ( ) lights if A/C

switch is pressed.
NO YES
Snow mark ( ) flickers and Voltage acts upon clutch.

E is shown on panel display. NO YES
To A On page T8-3-28. Voltage is applied to pressure switch Clutch faulty.

harness.
NO YES
Voltage acts across white / green wire Pressure switch is faulty or refrigerant
and Ground (Black) connector gas is under charged or overcharged.
connected to excavator.
Refer to troubleshooting for

NO YES
refrigeration cycle.
Inspect clutch fuses. 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 Connector of inner/outer air M/A is

matter or is broken. disconnected or in poor contact. Or
M/A failed or main harness failed.
NO YES
Inspect or replace.
M/A failed Remove foreign matter
and replace parts.
Replace
T3-8-32
Modes do not change.
Mode display (Mark of person) on

operating panel is flickering.
NO YES
M/A rod does not disengage. Mode M/A connector is disconnected

or in poor contact or M/A failed or
NO YES main harness is faulty.
Repair. Each damper lever does not
disengage. Inspect or replace.
NO YES
Repair. When rod is removed and cam is operated

by hand, it is heavy. (more than 19.6N.).
NO YES
M/A or controller is out of order. Cam or damper shaft includes foreign

matter or is broken
Erroneous motion occurs due to dirty
Replace.
grease.
Remove foreign matter or replace parts.

Clean cam and apply new grease.
T3-8-33
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. Oil comes out from piping and parts.
NO YES NO YES
Expansion valve is Expansion valve is frozen Natural leak from hose. Gas leaks from pipe
clogged or maladjusted. or intruded by water. joints and parts.
Adjust or replace After making vacuum, Charge gas. Retighten or replace

expansion valve. refill refrigerant and parts.
replace receiver.
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 YES
High pressure gets lower slowly. Condenser is fouled or clogged.
YES NO
High pressure circuit before receiver is Clean condenser. Air bubbles are hard to go out even if
clogged up. water is poured on condenser.
Remove clogging or Air is mixed. Make vacuum

replace parts. and refill refrigerant.
T3-8-34
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.
Check harness or connector to motor actuator for the
inner and outer air damper for disconnection.
Note: The above indication and flickering does not
function if the harness and connector were
disconnected under the condition the panel ON/
OFF switch is ON.
After the failure was occured, if the panel ON/
OFF switch is turned ON, it functions.
After correction of failure, if the starter switch is
SM0058 not switched from OFF to ON the error indication
and flickering are not released.
T3-8-35
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
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 SEGMENT FOR ONLY

MONITOR INDICATION
2. Operation of monitor mode
A B E
SM0063
C D
1. Press inner and outer air flow select switch (A) and ON/OFF switch (D) simultaneously for 1 second.
2. Press AUTO switch (E).
(After all segments are lit on for 1 second, the mode is switched into monitor mode.)
3. Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit
and 2nd digit of segment in three digits. The 1st digit is indicated by "H".
4. Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by
pressing UP or DOWN of blower switch (B) or (C), and the required sensor is selected from the list
below.
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
3. 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

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
indicates 2 (displays the solar radiation sensor
condition), since the segment indicates FF,the sensor is
in short-circuiting condition according to the list of 3
segments.
-->The solar radiation sensor is in short-circuiting
SM0067 condition.
4. List of 3 segments
SECOND SEGMENT
INNER AIR SENSOR DISCONNECTION

EVAPORATOR SENSOR DISCONNECTION
SOLAR RADIATION SENSOR SHORT-CIRCUITING
THIRD SEGMENT
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 4 OPERATIONAL PERFORMANCE TEST

Group 1 Introduction
Group 2 Standard Performances
Group 3 Test Procedures
Group 4 Mechatro Controller
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
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 Disagreement of measuring conditions, variations of
with standard specifications as compared to the data peculiar to a new machine, and measuring
performance standards. errors are to be evaluated. Determine generally at
what levels measured values are located, instead of
AT SPECIFIC SELF INSPECTION (RULE BY determining whether or not values fall within or run
COUNTRY) out of the reference values.
Use the data for the criterion, for the purpose of DETERMINING CORRECTION, ADJUSTMENT
correction, adjustment and replacement. OR REPLACEMENT
WHEN PERFORMANCES ARE DETERIORATED Machine performances deteriorate with time as
parts wear and some deteriorated performances
Determine whether it is caused by a fault or end of may be restored to new levels. Therefore, determine
service life after long hours of operation, to be used correction, adjustment or replacement, depending
for safety and economical considerations. upon the operating hours, kind of work and
circumstances in which the machine is placed, and
WHEN MAIN COMPONENTS ARE REPLACED
condition the machine performances to its most
For example, use data to restore performances of desirable levels.
pumps and others.
Other Cautions to be Exercised
Terminology
PARTS LIABLE TO DEGRADE
STANDARD VALUES
Rubber products, such as, hydraulic hoses, O-
Values to be used to condition or assemble a new Rings, and oil seals deteriorate with time; replace
machine. Where special notes are not given, these them at regular intervals or at overhauls.
values represent standard specifications (machine
with standard attachments and standard shoes). PARTS REQUIRING REGULAR REPLACEMENT
Out of critical hoses that are necessary to secure
REFERENCE VALUES FOR REMEDY
safety, we designate Very Important Parts (V.I.P)
Values at which readjustment is required. In order to and recommend that they should be replaced
ensure performance and safety it is strictly regularly.
prohibited to use the machine over the specified
values. INSPECTION AND REPLACEMENT OF OILS AND
GREASES
SERVICE LIMIT
In performing maintenance, it is necessary for the
This is the limit value at which reconditioning is user to familiarize himself with how to handle the
impossible without replacement of parts. If the value machine safely, cautions to be exercised and
is expected to exceed the service limit before next inspection/lubrication procedures. Refer to the
inspection and correction are performed, replace operators manuals as well.
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.
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. SM1231
3. 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 SM1232
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground
with leaking oil. Use oil pans to catch escaping
oil. Pay special attention to this when removing
hydraulic pipings.
Make precise measurement

1. Accurately calibrate test instruments in
advance to obtain correct data.
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
STANDARD PERFORMANCES E215B-E245B
PERFORMANCE INSPECTION STANDARD TABLE
NOTE: unless otherwise specified, measure it on "H" mode.
Measuring Position Standard Adjusting Measuring

Inspection Item Unit
Position Size Port Value Point Condition
NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank Class - Sampling
or less
Hydraulic oil temperature Tank surface 50 5 - Atmospheric
C temp
Std. Measuring condition
Water temperature Radiator surface 75 15 - 50 C ~ -10 C

H mode Lo idle 1000 50 Low throttle
H mode Hi idle 2000 50 Full throttle (Hi Idle)

Engine speed
Measure the engine speed at

Auto-Idle 1050 50 Adjustment
multi display on the gauge
cluster, or measure with diesel min-1 not
B mode Hi idle 2000 50 required Perform all
speed meter measurement with the
A mode Hi idle 2000 50 air-conditioner OFF
S mode Hi idle 1800 50
Pilot primary pressure circuit G pump a5 5.0 +0,5 PR1 HI idle

-0
P1 a1
valve pressure
ATT Travel 34.3 +0.7 MR1 Boom up

Main relief
-0,5
P2 a2
Power P1 a1
boost 37.8 +1.0 MR1
-0.5
P2 a2
H 39.7 +0
-5.9
OR3 Boom up
Boom a1
R 37.8 +0 OR4 Boom down
-4.0
High pressure circuit
H +0 OR1 Bucket digging

39.7
-5.9
Bucket a1
Over load relief valve pressure
Main pump
R PF 1/4 37.8 +0 MPa OR2 Bucket dump

-4.0
H +0 OR7 Arm in
37.8
-4.0
Arm a2
R 39.8 +0 OR8 Arm out
-5.9
LH OR5 Swing LH
Swing a2 +6.0
29.0 +0
RH OR6 Swing RH
Forward
RH a1 34.3 +0,7
Reverse -0,5 Simultaneous
Travel
Operation of travel RH
Forward and LH
LH a2 34.3 +0,7
Reverse -0,5
T4-2-1
E215B-E245B STANDARD PERFORMANCES
Measuring
Inspection Item Standard value Unit
condition
Sprocket revolution 1st speed 32~28
(RH, LH) min-1
E215B 2nd speed 50~45
Sprocket revolution 1st speed 28~24
(RH, LH) min-1
nd 45~40
E245B 2 speed
In 3.0~3.6
Arm
Out 2.3~2.9
Operating speeds
Operating time Digging 2.2~2.8

Bucket s (At no load)
of cylinder Dumping 1.7~2.3
In 2.9~3.5
Positioner
Out 4.1~4.7
Swing speed RH - LH 4.2~5.4 s / 3 rev

st Iron shoe 25.2~28.2
Travel speed 1 speed
E215B
2nd speed Iron shoe 16.9~18.9
Travel speed 1st speed Iron shoe 29.5~32.5

E245B nd Iron shoe 18.5~21.5
2 speed
Amount of travel
deviation 2nd speed 0~240 mm / 20 m
Parking brake drift 15 Gradient 0 mm / 5 min

Performance of Swing Neutral position after
55~75 degree
brake 180 full speed swing
Performance
Swing parking brake

15 Gradient 0 mm
drift
Tip of the bucket tooth 80
Boom cylinder 7
ATT amount of drift mm / 5 min (At no load)
Arm cylinder 6
- -
Amount of horizontal play at the bucket tooth 30~50 mm
NOTE: over load relief valves OR1~OR8 described in advance (8) (4)
correspond to the following operations.
(5) (6) (1) (2)
1. Bucket digging 5. Swing left
2. Bucket dump 6. Swing right (7) (3)
3. Boom up 7. Arm in
4. Boom down 8. Arm out
T4-2-2
TEST PROCEDURES E215B-E245B
MEASUREMENT OF ENGINE SPEED
Warming up of engine
Start engine to raise the coolant temperature of

engine to 60 to 90C (140 to 194F) 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 105C (149 to 221F), 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

GAUGE CLUSTER
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.
BUZZER STOP
4. The screen returns like No.45, No.44....each SWITCH
time the "Washer switch" is pushed.
WASHER
5. The display does not disappear unless the
SWITCH
starter switch is turned to"OFF".
WIPER
SWITCH
SCREEN CHANGE SWITCH SM0851
NO.2 ENG
G-3 SPEED SET 1000
MEAS 1000
G-5 ENG PRS. LIVE
WATER TEMP 20 C OFF
MODE H
H-1 ACCEL VOLT. 0.3 V
POS. 0%
G-1 MOTOR STEP 30
POS. 0%
COIL A 1.5 A
COIL B 1.5 A
G-2 LIMIT SW. OFF
SM0852
T4-3-1
E215B-E245B TEST PROCEDURES
MEASUREMENT OF HYDRAULIC
PRESSURE
Preparing to measure hydraulic pressure
HYDRAULIC EQUIPMENT
6.9 MPa (1000psi) pressure gauge: 1unit a5
49 MPa (7100psi) pressure gauge: 2 units
Pressure measuring equipment and instrument for B3
analysis: 1 set
Dr3 A3
MEASURING CLEANLINESS OF HYDRAULIC OIL

A2
PSV2 (A1)
WARNING
(PSV1)
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,
a1 a2 SM0853
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
Pressure adjustment position

MAIN CONTROL VALVE
Relief valve position on main control valve.
PLUG FOR
ARM (R) OPTIONAL RELIEF
OR8
FRONT
MACHINE
USE FOR YN30V00101

F1
MAIN RELIEF BOOM (H) BUCKET (R)

(ATT & TRAVEL) OR3 OR2
View from the top of the machine SM0854
BOOM (R) BUCKET (H)

OR4 OR1
MACHINE
FRONT
ARM (H) PLUG FOR

OR7 OPTIONAL RELIEF
View from the bottom of the machine SM0855
T4-3-3
PILOT RELIEF VALVE

The pilot relief valve PR1 is located on the gear
pump that is attached to the main pump.
B3
A3
a5
PR1 Dr3 SM0856
SWING OVER LOAD RELIEF SWING RIGHT

SWING LEFT
OVERLOAD RELIEF OVERLOAD RELIEF
The swing motor is equipped with plugs PA, PB for
OR5 OR6
pressure measurement, but the measurement is
carried out using gauge ports (a1) and (a2).
(B) (A)
PB
PA
SM0857
a5
B3
Dr3 A3
A2
PSV2 (A1)
(PSV1)
a1 a2 SM0853
T4-3-4
Procedure for adjusting relief valve
PILOT RELIEF VALVE

Adjust it with adjust screw (311).
: 24 mm
: 29.4 Nm (22 lbfft)
: 6 mm
311
No. of turns of adjust Pressure change MPa
screw (psi) LOCK NUT HEX24
SM0858
1 turn Approx. 2.1 (305)
2-STAGE MAIN RELIEF VALVE

(Commom for travel and ATT sections)
1 2
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. 4 3
: 32 mm
: 27.4~31.4 Nm (20~23 lbfft) SM0859
: 22 mm
: 27.4~31.4 Nm (20~23 lbfft)
: 19 mm Adjust screw
: 6 mm
No. of turns of adjust Pressure change MPa

screw (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 Nm (20~23 lbfft)
: 6 mm
No. of turns of adjust Pressure change MPa 2 1

screw (psi)
1 turn Approx. 17.7 (2560) SM0860
T4-3-5
OVER LOAD RELIEF VALVE (SWING)

When the adjustment of pressure is required,
loosen lock nut (1) and adjust the pressure with cap 1 2
(2).
: 30, 38 mm
: 118 Nm (87 lbfft)
: 12 mm
3
R
No. of turns of adjust Pressure change MPa SM0861

screw (psi)
1 turn Approx. 10 (1450)
OVER LOAD RELIEF VALVE (TRAVEL)

This valve was adjusted by valve maker. When 1
adjustment is required, loosen nut (1) and adjust the
pressure with adjusting screw (2).
: 17 mm
: 6 mm
SM0862
T4-3-6
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 ;45~55C (113~131F)
Crawler on the right and left sides are tensioned
evenly.
PREPARATION
Attach the reflection panel with a magnet to the
travel motor cover. SM0863
Swing the swing frame through 90 as shown in
Figure and make the crawler on one side take off the
ground, using the attachment.
MEASUREMENT REFLECTION
PANEL
Engine revolution: Hi idle
2-speed travel switch: 1st speed and 2nd
speed
Measuring points: Right and left
Method, example 1:
Measure revolution with a stroboscope
Method, example 2:
Measure the revolutions per minute visually.
SM0864
E215B
Sprocket revolution Unit: min-1
Reference
Measurement Standard Service
value for
item value limit
remedy
H mode 1st 32~28 25.2~22.8
20.4 or
RH& speed less
LH H mode 32.5 or
50~45 39~35.3
2nd speed less
E245B
Sprocket revolution Unit: min-1
Reference
Measurement Standard Service
value for
item value limit
remedy
H mode 1st 28~24 22~19 17 or less
RH& speed
LH H mode
45~40 34~31 29 or less
2nd speed
T4-3-7
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
(113~131F)
RH and LH crawler are tensioned evenly.
Firm, level ground Approx. 30~40 cm
Engine revolution: Hi idle.
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. Measure the max. deviation distance of the
circular arc in the 20m (66ft) length, excluding A
the preliminary run of 3~5m (10~16ft).
20m
2. Operate the travel lever at the same time.
Travel deviation Unit: mm (in)/20m (66ft)

Measuring Standard Reference value Service
SM0866
position value for remedy limit
240 (9.45)
A 480 (18.9) 720 (28.4)
or less
T4-3-8
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 15 degree slope
that it makes an angle more than 15 degree.
Hang a perpendicular in parallel with the guide SM0867
frame rib on the track frame and put a mark
(matching mark) on the shoe plate.
MEASUREMENT
Five minutes after the engine stops, measure the
movement distance of the matching mark.
Parking brake Units: mm (in)/5 min

Measuring Standard Reference value Service
position value for remedy limit
C 0 1 (0.04) 2 (0.08) ANGLE METER
GUIDE FRAME C
SM0868
T4-3-9
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: 45~55C
(113~131F)
PREPARATION
1. Place a stopper under the RH and LH travel FORWARD 90 o 10
sprockets. (3.54") (0.394")
2. Stop the engine and release pressure from the o 22 PIPE 40

(0.866") (1.57")
hydraulic circuit.
3. Connect a hose with the drain port of the travel RIB "A" 150
STOPPER (5.91")
motor and take drain in a container. "B"
o 80
(3.15")
MEASUREMENT AT TRAVEL LOCK ROTARY DIRECTION
SM0869
WARNING
Unless you observe the rotary force direction at
travel lock, rib "A" may be broken by stopper "B" in
some cases.
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.
E215B
Unit: (gal)
L/30 s
Measuring Standard Reference value SM0870
Service limit
position value for remedy
Drain rate 9 (2.4) 16 (4.2) 23 (6.1)
E245B
Unit: (gal)
L/30 s
Measuring Standard Reference value
Service limit
Drain rate 7 (1.6) 14 (3.5 21 (4.6)
T4-3-10
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
(113~131F)
Firm, level ground
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 SM0871

Service limit
Swing speed
4.2~5.4 5.4~6.9 7.2~
at min. reach
T4-3-11
Performance of swing brake
PURPOSE
Confirm the braking torque performances by the
swing relief valve.
ARM TOP BOOM FOOT
PIN PIN
CONDITIONS
(113~131F)
Firm, level ground
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.

1. When operating in regular swing speed, by
shifting lever to neutral position at pole position
the swing operation stops. MEASURING THE LENGTH OF THE ARC OVER
THE OUTER CIRCUMFERENCE OF OUTER RACE
2. Calculate the swing drift angle by the following MATCHING MARKS ON
equation, after the upper swing body stops, OUTER RACE
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:
Amount of deflection of
MATCHING MARKS
matching marks [m (ft-in)] ON INNER RACE
Swing drift
= x 360
angle () Circumferenzial lenght of
SM0873
swing race [m (ft-in)]
Swing brake performance Unit : degree

Service limit
Swing 180 75 85 90
T4-3-12
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
MEASUREING THE LENGTH OF THE ARC OVER
the inner race side. THE OUTER CIRCUMFERENCE OF OUTER RACE
MATCHING MARKS ON
OUTER RACE
When five minutes has passed after the engine
stops, measure the length of the movement of the
matching marks.
MATCHING MARKS
Performance of swing ON INNER RACE
Unit : mm(in)/5min
parking brake
Measuring Standard Reference value SM0875
Service limit
C 0 1 (0.04) 2 (0.08)
T4-3-13
Drain rate of swing motor
PURPOSE
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.
CONDITIONS
(113~131F)
Firm, level ground
PREPARATION
1. Stop the engine.
2. Release pressure from inside the hydraulic
circuit.
3. Disconnect the swing motor drain hose from its
end returning to the hydraulic oil tank and take
oil in a container. SM0876
4. Put a plug to the tank side.
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

Service limit
Drain rate 2.1 (0.55) 5.2 (1.4) 6.2 (1.6)
T4-3-14
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
(113~131F)
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 6
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 Unit : sec

Service limit
1 2.2~2.8 2.8~3.6 3.8~
2 1.7~2.3 2.2~2.9 3.0~ 30cm (1ft)
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~
9
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
10 4.1~4.7 5.2~6.0 6.3~
SM0877
T4-3-15
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
A
(113~131F) D
Firm, level ground
After cylinders are replaced, bleed off air from the ARM TOP PIN
SM0878
cylinders, before checking for oil tightness.
Retract the arm cylinder rod 50mm (2in) from stroke
end so that the piston does not match a same range
of the cushioning mechanism.
PREPARATION
Put the bucket empty. Extend the arm cylinder rod
50mm (2in) from the most retracted position. And
extend the bucket cylinders fully. Then hold the
boom so that the arm top pin is positioned at same
height with boom foot pin.
MEASUREMENT
Measure the items five minutes after the engine is
turned off.
Oil tightness of cylinder Unit: mm(in)/5min

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
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 LOCATION OF BEARING
MOUNTING BOLTS
fix it to the lower frame.
2. Direct the upper swing body and the lower
frame toward the travel direction, bring the SWING BEARING
probe of the dial indicator in contact with the A
bottom surface of the outer race on the swing
body side and set the reading at zero.
DIAL INDICATOR
LOWER FLAME
MEASUREMENT
Measuring position 1 and 2
Measure the displacement of the outer race in the SM0879
axial direction in position 1 [The arm at 90~110
and the crawler front is lifted by attachment about
30cm (1ft)] and in position 2, using a dial indicator.
Axial play of swing bearing Unit: mm (in)

Service limit
0.8~1.8 2.3~3.3
A
(0.03~0.07) (0.09~0.13)
3.6 (0.14) 90 ~100
30cm
SM0879
Position 1
ARM TOP BOOM FOOT

PIN PIN
SM0872
Position 2
T4-3-17
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 ARM TOP BOOM FOOT
pin. Then swing the bucket right and left by man PIN PIN
power.
But in this case, the gap of the attachment is
included.
Right and left movement of

Unit: mm (in) SM0872
the tip of bucket
Service limit
Position 3
30~50
Benna 80 (3.15) 120 (4.72)
(1.18~1.97)
T4-3-18
MECHATRO CONTROLLER E215B-E245B
ENGINE CONTROL INPUT/OUTPUT
M-2:
GOVERNOR MOTOR
E-1:
C-2: FUSE&RELAY
GAUGE CLUSTER BOX
ENGINE
ENGINE SPEED
SENSOR
PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER
SM0881
T4-4-1
E215B-E245B MECHATRO CONTROLLER
ENGINE CONTROL
Engine control assy
3
1
11 3
3
5
Section A-A
10
4
HIGH LOW
HIGH LOW
2
4
2
Section B-B
Detail aa
9 7 6 8
Section C-C 9
SM0882
1 - Governor motor
2 - Lever assy
3 - Sems-Bolt M8x25 (Q.ty 4) 23.5 Nm (17.3 lbf x ft)
4 - Bracket
5 - Capscrew (Q.ty 3) 19.6 Nm (14.5 lbf x ft) Apply Loctite #242
6 - Rod
7 - Nut M10 10.7 Nm (7.89 lbf x ft)
8 - Nut M10 10.7 Nm (7.89 lbf x ft)
9 - Nut M8 (Q.ty 2) 23.5 Nm (17.3 lbf x ft)
10 - Sems-Bolt M6x16 (Q.ty 2) 4.4 Nm (3.25 lbf x ft)
11 - Sems-Bolt M6x20 9.6 Nm (7.08 lbf x ft)
T4-4-2
ENGINE CONTROL EQUIPMENT
Governor motor and C1 controller
1. By operating accel dial, the input voltage

change issensed by CN1028 pin of C1 REDUCTION GEAR SECTION
controller. OIL SEAL
MOTOR SECTION
2. The C1 controller computes the input voltage, OUTPUT
SHAFT
andoutputs command to governor motor (M2),
and incline governor lever of engine to the
swing angle corresponding to accel dial set
value. CAM
3. The limit switch in the governor motor is the LIMIT
starting point of the governor motor. SWITCH
SM0883
Speed sensor
Installing place: engine flywheel housing.
CN-136F
Sensor attaching procedure: push it into place and
fix with partially self-sealing cylindrical screw
M6x12, tightening torque 82 Nm.
SM0884
Work mode select switch

If the work mode select switch is pressed, a signal
istransmitted to the C1 controller and changes the
work modes in the order of HBAS and back
to H again.
WORK MODE
SELECT SWITCH
SM0885
T4-4-3
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 valve, spool of
unloading valve.
Preparation
1. Raise the oil temperature to about 50C

(122F) 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
Adjusting procedure
MULTI DISPLAY
BUZZER STOP SWITCH WORK MODE SELECT 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, SM0887
P2 "PUMP PRESSURE" and "STEP" (stepping
command) are indicated.
T4-4-5
4. 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 FINISH ENG
unloading adjustment required later are not ENGINE SPEED
2000rpm
PUMP PRESSURE
performed, and default value is written.). C-1 2.0M C-2 2.0M
STEP
400
5. When normal HIGH idling speed is detected,
the adjustment is completed. And "FINISH
ENG" is displayed. SM0888
(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.)
ADJUSTMENT OF PUMP
("B" ADJUSTMENT)
PROCEDURE
1. The adjustment automatically shifts from
engine to pump, the speed shifts from LOW
idling to HIGH idling. And "MEMORY PUMP" is
displayed.
And the unloading proportional valve and pump
proportional valve actuate, accordingly the
loading of pump is increased.The "ENGINE
SPEED", P1, P2 "PUMP PRESSURE" and P1,
P2 pump "PROPO-VALVE" current (command
value) are indicated.
2. After detection of the engine rated speed, the FINISH PUMP
adjustment of pump is automatically ENGINE SPEED
completed. And "FINISH PUMP" is displayed. 2000rpm
PUMP PRESSURE
C-1 35.0M C-2 35.0M
(Press the buzzer stop switch on gauge cluster PROPO-VALVE
E-1 300mA E-2 300mA
while this display is appeared and the
adjustment is completed. The unloading
adjustment required later is not performed, and SM0889
default value is written.).
T4-4-6
ADJUSTMENT OF UNLOADING VALVE (C

ADJUSTMENT)
PROCEDURE
1. The adjustment shifts from pump to unloading,
and the unloading valve actuates, accordingly
MEMORY UNLOAD
the pump pressure is detected. ENGINE SPEED
And "MEMORY UNLOAD" is displayed.The 2000rpm
PUMP PRESSURE
C-1 2.0M C-2 2.0M
"ENGINE SPEED", P1, P2 "PUMP PROPO-VALVE
D-1 300mA D-2 300mA
PRESSURE" and P1, P2 "PROPO-VALVE"
voltage (command value) are indicated".
2. 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
2. 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
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
3. In cases where unloading valve can not be
performed; And "ERROR UNLOAD" is
displayed.
the pump pressure does not increase up to the
pressure in the range of the specified
adjustment. Or the increased pressure is held
as it is.
SM0892
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
T4-4-8
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,
MULTI DISPLAY
and hold it for 5~10 seconds, and then release (EXAMPLE)
it.
(If the engine is started, the following indication
is not displayed. Therefore do not start the
engine.)
2. Keep buzzer stop switch on gauge cluster
pressed for 5 seconds and release it and the
screen for selection of adjustment type is
displayed. And "ADJUST" is displayed.
When adjustment data is not entered in
mechatro controller, "READY" is indicated. If
the adjustment operation is once performed,
"FIN" is indicated.And the lever lock solenoid is
automatically released, disabling all operations.
3. Change the adjusting items with washer switch
( ) and wiper switch ( ), and select "ADJUST
UNLOAD".
Like the output adjustment, when adjustment
data is not entered in mechatro controller,
"READY" is indicated. If the adjustment
operation is once performed, "FIN" is indicated.
4. Press selector switch on gauge cluster to
display "START ENG". SM0893
"ENGINE SPEED", P1, P2 "PUMP

PRESSURE" and "STEP" (stepping command)
are indicated.
T4-4-9
5. After starting engine, press selector switch on

gauge cluster and "MEMORY UNLOAD" is MEMORY UNLOAD
indicated, the engine speed is automatically ENGINE SPEED
2000rpm
increased and the adjustment of unloading PUMP PRESSURE
C-1 2.0M C-2 2.0M
valve is performed. PROPO-VALVE
D-1 300mA D-2 300mA
"ENGINE SPEED", P1, P2 "PUMP
PRESSURE" and "PROPO-VALVE" are
indicated.
6. 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. SM0894
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 self-
pressure 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
TROUBLESHOOTING
M0103
TROUBLESHOOTING E215B-E245B
Section 5 TROUBLESHOOTING
Group 1 Troubleshooting (by Error Codes)
Group 2 Troubleshooting (by trouble)
Group 3 Troubleshooting (Trouble diagnosis mode)
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
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 SM0101
additional works.
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
Confirm the symptoms of the trouble
1. Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
flaws on the piston rod. And the method of using
the machines should be explained so that the
same kind of trouble does not reoccur.
2. Treatment of damaged parts
The damaged parts to be claimed and returned
are evidence so they should be handled with
care. Protect them from entry of water, soils, etc.
into port of hydraulic unit, etc. and return them.
And also use care not to flaw and damage those
surfaces. SM0103
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 Trouble Described

Code 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

Code page
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

Code 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
Table 1
Error code A015
Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment)
Judging condition Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting range.
Symptom Deviated from the reqired value, but no problem in normal operations.
Control in the
Rotate with the default engine.
event of failure
Returned in
The engine adjustment is completed normally.
normal condition
Screen No. 2 G-3 SPEED SET
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 Checking Carry out engine adjustment (A adjustment). When "ERROR ENG" was
displayed during adjustment, refer to the section "Adjustment procedure -
Measures to be taken with the adjustment failed"
2 Mechatro controller Check that the error is corrected after replacement of controller.
3
Table 2
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within the
Judging condition
adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation.
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition
Screen No. 9 E-1 P1 PUMP
Service diagnosis
Screen No. 9 E-2 P2 PUMP
checking screen
Screen No.
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"
3
T5-1-5
Table 3
Error code A035
Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting
Judging condition
range.
Symptom It is not normal output, but no problem in normal operation.
Control in the
Work with the aid of output by default proportional valve.
event of failure
Returned in
The adjustment of unload valve is completed normally.
normal condition
Screen
8 D-1 P1 UN-LOAD (BP-CUT)
No.
Service diagnosis Screen
checking screen No.
Screen
No.
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"
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.
checking screen No.
Screen
No.
2
3
T5-1-6
Table 5
Error code A225
Judging condition Check adjustment data, and judge the data is correct or not.
Control in the
Control can be done by default value.
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
2
3
Table 6
Error code A235
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
normal condition
Screen
No.
checking screen No.
Screen
No.
2
3
T5-1-7
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
normal condition
Screen
No.
checking screen No.
Screen
No.
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.
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
2
3
T5-1-8
Table 9
Error code B012
Trouble Boom up pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the sensor after
Judging condition
starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The boom up operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
5 B-1 BOOM RAISE
No.
checking screen No.
Screen
No.
1 Boom up pressure sensor SE-3 When B012 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 Wiring between boom up When B012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
Table 10
Error code B013
Trouble Boom up pressure sensors wiring disconnects.
Judging condition The input voltage from boom up pressure sensor is less than 0.1 V.
Symptom The boom up speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-1 BOOM RAISE
No.
checking screen No.
Screen
No.
1 Boom up pressure sensor SE-3 When B013 is cancelled and other error occurs after exchanging the connector
with other sensor.
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
T5-1-9
Table 11
Error code B014
Trouble Boom up pressure sensors 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
normal condition
Screen
5 B-1 BOOM RAISE
No.
checking screen No.
Screen
No.
1 Boom up pressure sensor SE-3 When B014 is cancelled and other error occurs after exchanging the connector
with other sensor.
2 Wiring between boom up
CN-126F
CN-101F
Table 12
Error code B022
Trouble Boom down pressure sensor outputs error.
Judging condition
Symptom The boom down operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
5 B-2 BOOM LOWER
No.
checking screen No.
Screen
No.
1 Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on after
SE-4 exchanging the connector with other sensor.
2 Wiring between boom down When B022 is displayed after turning the starter switch on after the connector
T5-1-10
Table 13
Error code B023
Trouble Boom down pressure sensors wiring is disconnecting.
Judging condition The input voltage from boom down pressure sensor is 0.1 V or less.
Control in the
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
normal condition
Screen
5 B-2 BOOM LOWER
No.
checking screen No.
Screen
No.
1 Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the connector
SE-4 with other sensor.
2 Wiring between boom down
CN-127F
CN-101F
Table 14
Error code B024
Trouble Boom down pressure sensors power source is shortcut.
Judging condition The input voltage from boom down pressure sensor is 4.7 V or more.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-2 BOOM LOWER
No.
checking screen No.
Screen
No.
1 Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on after
2 Wiring between boom down When B024 is displayed after turning the starter switch on after the connector
T5-1-11
Table 15
Error code B032
Trouble Arm-in pressure sensor outputs error.
Judging condition
Symptom The arm-out operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
5 B-3 ARM OUT
No.
checking screen No.
Screen
No.
1 Arm-out pressure sensor SE-8 When B032 is cancelled and other error occurs by turning starter switch on after
2 Wiring between arm-out pressure When B032 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
Table 16
Error code B033
Trouble Arm-out pressure sensors 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.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-3 ARM OUT
No.
checking screen No.
Screen
No.
1 Arm-out pressure sensor SE-8 When B033 is cancelled and other error occurs after exchanging the connector
with other sensor.
2 Wiring between arm-out pressure
sensor and controller
CN-131F
CN-101F
T5-1-12
Table 17
Error code B034
Trouble Arm-out pressure sensors 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.
Control in the
event of failure
Set output of P1, P2 unload proportional valves to 0 mA. (Valve emergency mode)
Returned in
normal condition
Screen
5 B-3 ARM OUT
No.
checking screen No.
Screen
No.
1 Arm-out pressure sensor SE-8 When B034 is cancelled and other error occurs by turning starter switch on after
2 Wiring between arm-out When B034 is displayed after turning the starter switch on after the connector
Table 18
Error code B042
Trouble Arm-in pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the arm-in pressure
Judging condition
sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
5 B-4 ARM IN
No.
checking screen No.
Screen
No.
1 Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch on after
2 Wiring between arm-in pressure When B042 is displayed after turning the starter switch on after the connector
T5-1-13
Table 19
Error code B043
Trouble Arm-in pressure sensors wiring is disconnecting.
Judging condition The input voltage from arm-in pressure sensor is 0.1 V or less.
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but
Symptom if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket
bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1 and P2 unload proportional valve to 0 mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200 mA.
Returned in
normal condition
Screen
5 B-4 ARM IN
No.
checking screen No.
Screen
No.
1 Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the connector
SE-7 with other sensor.
2 Wiring between arm-in pressure
sensor and controller
CN-130F
and repair it if necessary..
CN-101F
T5-1-14
Table 20
Error code B044
Trouble Arm-in pressure sensors power source is shortcut.
Judging condition The input voltage from arm-in pressure sensor is 4.7 V or more.
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if
Symptom attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket
bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1, P2 unload proportional valves to 0 mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200 mA.
Returned in
normal condition
Screen No. 5 B-4 ARM IN
Service diagnosis
Screen No.
checking screen
Screen No.
1 Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
2 Wiring between arm-in pressure When B044 is displayed after turning the starter switch on after the connector
CN-101F and repair it if necessary..
T5-1-15
Table 21
Error code B052
Trouble Bucket digging pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the bucket digging
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
5 B-5 BUCKET DIG
No.
checking screen No.
Screen
No.
1 Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on after
2 Wiring between bucket digging When B052 is displayed after turning the starter switch on after the connector
Table 22
Error code B053
Trouble Bucket digging pressure sensors 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.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-5 BUCKET DIG
No.
checking screen No.
Screen
No.
T5-1-16
Table 23
Error code B054
Trouble Bucket digging pressure sensors 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.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-5 BUCKET DIG
No.
checking screen No.
Screen
No.
Table 24
Error code B062
Trouble Bucket dump pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
Judging condition
Symptom The bucket dump operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
5 B-6 BUCKET DUMP
No.
checking screen No.
Screen
No.
T5-1-17
Table 25
Error code B063
Trouble Bucket dump pressure sensors 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.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-6 BUCKET DUMP
No.
checking screen No.
Screen
No.
Table 26
Error code B064
Trouble Bucket dump pressure sensors 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.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-6 BUCKET DUMP
No.
checking screen No.
Screen
No.
T5-1-18
Table 27
Error code B072
Trouble Swing pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the swing pressure
Judging condition
sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The swing operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
6 B-7 SWING
No.
checking screen No.
Screen
No.
1 Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on after
2 Wiring between swing pressure When B072 is displayed after turning the starter switch on after the connector
Table 28
Error code B073
Trouble Swing pressure sensors wiring is disconnected.
Judging condition The input voltage from swing pressure sensor is 0.1 V or less.
Control in the
event of failure
Returned in
normal condition
Screen
6 B-7 SWING
No.
checking screen No.
Screen
No.
T5-1-19
Table 29
Error code B074
Trouble Swing pressure sensors power source is shortcut.
Judging condition The input voltage from swing pressure sensor is 4.7 V or more.
Control in the
event of failure
Returned in
normal condition
Screen
6 B-7 SWING
No.
checking screen No.
Screen
No.
Table 30
Error code B092
Trouble Travel right pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the travel right
Judging condition
Symptom The travel right operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
6 B-9 TRAVEL (R)
No.
checking screen No.
Screen
No.
1 Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch on after
2 Wiring between travel right When B092 is displayed after turning the starter switch on after the connector
T5-1-20
Table 31
Error code B093
Trouble Travel right pressure sensors 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.
Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
normal condition
Screen
6 B-9 TRAVEL (R)
No.
checking screen No.
Screen
No.
T5-1-21
Table 32
Error code B094
Trouble Travel right pressure sensors 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.
Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
normal condition
Screen
6 B-9 TRAVEL (R)
No.
checking screen No.
Screen
No.
T5-1-22
Table 33
Error code B102
Trouble Travel left pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the travel left
Judging condition
Symptom The travel left operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
6 B-10 TRAVEL (L)
No.
checking screen No.
Screen
No.
1 Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on after
2 Wiring between travel left When B102 is displayed after turning the starter switch on after the connector
Table 34
Error code B103
Trouble Travel left pressure sensors 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.
Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
normal condition
Screen
6 B-10 TRAVEL (L)
No.
checking screen No.
Screen
No.
T5-1-23
Table 35
Error code B104
Trouble Travel left pressure sensors 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.
Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
normal condition
Screen
6 B-10 TRAVEL (L)
No.
checking screen No.
Screen
No.
T5-1-24
Table 36
Error code B113
Trouble Option selector position detect pressure sensors 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
normal condition
Screen
16 B-11
No.
checking screen No.
Screen
No.
1 Option selector position detect When B113 is cancelled and other error occurs by turning starter switch on after
pressure sensor exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 Wiring between option selector
When B113 is displayed after turning the starter switch on after the connector
position detect pressure sensor
is exchanged with other sensor.
and controller
CN-104F
T5-1-25
Table 37
Error code B114
Trouble Option selector position detect pressure sensors 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
normal condition
Screen
16 B-11
No.
checking screen No.
Screen
No.
1 Option selector position detect When B114 is cancelled and other error occurs by turning starter switch on after
pressure sensor exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
When B114 is displayed after turning the starter switch on after the connector
position detect pressure sensor
is exchanged with other sensor.
and controller
CN-104F
Table 38
Error code B162
Trouble P1 side option pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P1 side option
Judging condition
Symptom The P1 side option operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
6 B-16 P1 OPT.
No.
checking screen No.
Screen
No.
1 P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on after
2 Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
T5-1-26
Table 39
Error code B163
Trouble P1 side option pressure sensors 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.
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
normal condition
Screen
6 B-16 P1 OPT.
No.
checking screen No.
Screen
No.
T5-1-27
Table 40
Error code B164
Judging condition The input voltage from P1 side option pressure sensor is 4.7 or more.
Symptom The P1 side option does not work.
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
normal condition
Screen
6 B-16 P1 OPT.
No.
checking screen No.
Screen
No.
Table 41
Error code B172
Trouble P2 side option pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P2 side option
Judging condition
Symptom The P2 side option operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
6 B-17 P2 OPT.
No.
checking screen No.
Screen
No.
T5-1-28
Table 42
Error code B173
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.
Control in the
event of failure
Returned in
normal condition
Screen
6 B-17 P2 OPT.
No.
checking screen No.
Screen
No.
Table 43
Error code B174
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.
Control in the
event of failure
Returned in
normal condition
Screen
6 B-17 P2 OPT.
No.
checking screen No.
Screen
No.
T5-1-29
Table 44
Error code C012
Trouble P1 pump pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
Judging condition
Symptom The P1 pump operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
7 C-1 PUMP P1
No.
checking screen No.
Screen
No.
1 P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on after
2 Wiring between P1 pump When C012 is displayed after turning the starter switch on after the connector
Table 45
Error code C013
Trouble P1 pump pressure sensors 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
normal condition
Screen
7 C-1 PUMP P1
No.
checking screen No.
Screen
No.
T5-1-30
Table 46
Error code C014
Trouble P1 pump pressure sensors power source is shortcut.
Judging condition The input voltage from P1 pump pressure sensor is 4.7 V or more.
Returned in
normal condition
Screen
7 C-1 PUMP P1
No.
checking screen No.
Screen
No.
Table 47
Error code C022
Trouble P2 pump pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
Judging condition
Symptom The P2 pump operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
7 C-2 PUMP P2
No.
checking screen No.
Screen
No.
T5-1-31
Table 48
Error code C023
Trouble P2 pump pressure sensors wiring is disconnected.
Judging condition The input voltage from P2 pump pressure sensor is 0.1 V or less.
Returned in
normal condition
Screen
7 C-2 PUMP P2
No.
checking screen No.
Screen
No.
Table 49
Error code C024
Trouble P2 pump pressure sensors power source is shortcut.
Judging condition The input voltage from P2 pump pressure sensor is 4.7 V or more.
Returned in
normal condition
Screen
7 C-2 PUMP P2
No.
checking screen No.
Screen
No.
T5-1-32
Table 50
Error code C033
Trouble Boom head pressure sensors 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
normal condition
Screen
7 C-3 BOOM-HEAD
No.
checking screen No.
Screen
No.
1 Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on after
2 Wiring between boom head When C033 is displayed after turning the starter switch on after the connector
Table 51
Error code C034
Trouble Boom head pressure sensors 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
normal condition
Screen
7 C-3 BOOM-HEAD
No.
checking screen No.
Screen
No.
1 Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on after
2 Wiring between boom head When C034 is displayed after turning the starter switch on after the connector
T5-1-33
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
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
1 P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch on after
PSV-D exchanging the connector with other sensor.
2 Wiring between P1 unload When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
Table 53
Error code D013
Trouble P1 unload proportional valves wiring is disconnected.
The feed-back value from proportional valve is 100 mA or less.
Judging condition
(If output is 100 mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode).
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
PSV-D exchanging the connector with other sensor.
T5-1-34
Table 54
Error code D022
Trouble P2 unload proportional valve and output transistor ON are failure.
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
PSV-B exchanging the connector with other sensor.
T5-1-35
Table 55
Error code D023
Trouble P2 unload proportional valves wiring is disconnected.
Judging condition
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
PSV-B exchanging the connector with other sensor.
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
normal condition
Screen
8 D-3 S-TRAVEL
No.
checking screen No.
Screen
No.
1 Travel straight proportional When D032 is cancelled and other error occurs by turning starter switch on after
valve exchanging the connector with other sensor.
PSV-C Check sensor unit for possible failure. If failure found, replace it.
2 Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
T5-1-36
Table 57
Error code D033
Trouble Travel straight proportional valves wiring is disconnected.
Judging condition
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
normal condition
Screen
8 D-3 S-TRAVEL
No.
checking screen No.
Screen
No.
1 Travel straight proportional When D033 is cancelled and other error occurs by turning starter switch on after
PSV-C Check sensor unit for possible failure. If failure found, replace it.
2 Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
T5-1-37
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
normal condition
Screen
8 D-4 ARM IN-2-SPEED
No.
checking screen No.
Screen
No.
1 Arm-in spool 2 proportional When D062 is cancelled and other error occurs by turning starter switch on after
PSV-A Check sensor unit for possible failure. If failure found, replace it.
2 Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
T5-1-38
Table 59
Error code D063
Trouble Arm-in spool 2 proportional valves wiring is disconnected.
Judging condition
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
normal condition
Screen
8 D-4 ARM IN-2-SPEED
No.
checking screen No.
Screen
No.
1 Arm-in spool 2 proportional When D063 is cancelled and other error occurs by turning starter switch on after
PSV-A Check sensor unit for possible failure. If failure found, replace it.
2 Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
Table 60
Error code D152
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
1
2
3
T5-1-39
Table 61
Error code D153
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
1
2
3
Table 62
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Returned in
normal condition
Screen
9 E-1 PUMP P1
No.
checking screen No.
Screen
No.
1 P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on after
PSV-P1 exchanging the connector with other sensor.
When replacing of connector is executed, turn off power source once.
2 Wiring between P1 pump When E012 is displayed after turning the starter switch on after the connector
T5-1-40
Table 63
Error code E013
Trouble P1 pump proportional valves wiring is disconnected.
Judging condition
(If output is 100mA or less, judging is not done.)
Returned in
normal condition
Screen
9 E-1 PUMP P1
No.
checking screen No.
Screen
No.
T5-1-41
Table 64
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Returned in
normal condition
Screen
9 E-2 PUMP P2
No.
checking screen No.
Screen
No.
Table 65
Error code E023
Trouble P2 pump proportional valves wiring is disconnected.
Judging condition
Returned in
normal condition
Screen
9 E-2 PUMP P2
No.
checking screen No.
Screen
No.
T5-1-42
Table 66
Error code F011
Trouble ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition The feed-back signal is grounding level while exciting command is output.
Symptom ATT boost is not available.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Screen
3 F-1 POWER BOOST
No.
checking screen No.
Screen
No.
1 ATT boost solenoid valve When F011 is cancelled and other error occurs by exchanging the connector for
SV-2 other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 Wiring between ATT boost When F011 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
T5-1-43
Table 67
Error code F013
Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feed-back signal is 24 V level while exciting command is not output.
Symptom ATT boost is not available or is leaving available.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Screen
3 F-1 POWER BOOST
No.
checking screen No.
Screen
No.
1 ATT boost solenoid valve When F013 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
2 Wiring between ATT boost When F013 is displayed after the connector is exchanged with other solenoid
T5-1-44
Table 68
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Symptom Swing parking is not available.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is 24 V level while exciting command is output.
normal condition
Screen
3 F-2 SWING-BRAKE
No.
checking screen No.
Screen
No.
1 Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If failure
found, replace it.
2 Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
Table 69
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is grounding level while exciting command is output.
normal condition
Screen
3 F-1 POWER BOOST
No.
checking screen No.
Screen
No.
1 Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector
2 Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
T5-1-45
Table 70
Error code F031
Trouble Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is 24 V level while exciting command is output.
normal condition
Screen
3 F-3 1/2-TRAVEL
No.
checking screen No.
Screen
No.
1 Travel 1, 2 speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
2 Wiring between travel 1, 2
When F031 is displayed after the connector is exchanged with other solenoid
speed solenoid valve and
valve.
controller
CN-105F
T5-1-46
Table 71
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Screen
3 F-3 1/2-TRAVEL
No.
checking screen No.
Screen
No.
1 Travel 1, 2 speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
2 Wiring between travel 1, 2
When F033 is displayed after the connector is exchanged with other solenoid
speed solenoid valve and
valve.
controller
CN-122F and repair it if necessary..
CN-105F
Table 72
Error code F041
Trouble Option selector solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition
Screen
11 F-4 OPT SELECT
No.
checking screen No.
Screen
No.
1 Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector
2 Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid
T5-1-47
Table 73
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Symptom Option selector valve does not change to breaker side or it does not change from breaker to nibbler.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition
Screen
11 F-4 OPT SELECT
No.
checking screen No.
Screen
No.
1 Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector
2 Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid
Table 74
Error code G011
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
1
2
3
T5-1-48
Table 75
Error code G013
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
1
2
3
Table 76
Error code G023
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
1
2
3
T5-1-49
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
normal condition
Screen
2 G-3 MEAS 1 (for mechatro controller)
No.
2 G-3 MEAS 2 (receive from engine controller)
checking screen No.
Screen
No.
1 Engine speed sensor Measure the resistance between terminals of speed sensor.
SV-13 Normal value: 1.6~2.0k .
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
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
normal condition
Screen
2 G-3 MEAS 1 (for mechatro controller)
No.
2 G-3 MEAS 2 (receive from engine controller)
checking screen No.
Screen
No.
1 Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k .
2 Wiring between engine speed
sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-106F
(Controller is broken by only applying power to grounding of signal.).
T5-1-50
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
normal condition
Screen
2 H-1 ACCEL VOLT.
No.
checking screen No.
Screen
No.
1 Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6~2.4k
SE-16 Turn the potentiometer and measure resistance between signal and GND.
2 Wiring between accel
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
CN-102F
Table 80
Error code H014
Trouble Accel potentiometers 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
normal condition
Screen
2 H-1 ACCEL VOLT.
No.
checking screen No.
Screen
No.
1 Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6~2.0k .
Turn the potentiometer and measure resistance between signal and GND.
2 Wiring between accel
CN-102F
T5-1-51
Table 81
Error code H023
Trouble Boom angle potentiometers 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
normal condition
Screen
12 H-2 BOOM
No.
checking screen No.
Screen
No.
1 Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k .
Normal value: 0 to all resistance (4.0~6.0)k
2 Wiring between boom angle
CN-103F
T5-1-52
Table 82
Error code H024
Trouble Boom angle potentiometers power source is shortcut.
Judging condition The input voltage from boom angle potentiometer is 0.1 V or less.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
12 H-2 BOOM
No.
checking screen No.
Screen
No.
1 Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k .
2 Wiring between boom angle
CN-103F
T5-1-53
Table 83
Error code H033
Trouble Arm angle potentiometers wiring is disconnected.
Judging condition The input voltage from arm angle potentiometer is 0.1 V or less.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
12 H-3 ARM
No.
checking screen No.
Screen
No.
1 Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-18 4.0~6.0k .
2 Wiring between arm angle
CN-103F
T5-1-54
Table 84
Error code H034
Trouble Arm angle potentiometers power source is shortcut.
Judging condition The input voltage from arm angle potentiometer is 0.1 V or less.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
12 H-3 ARM
No.
checking screen No.
Screen
No.
1 Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-18 4.0~6.0k .
2 Wiring between arm angle
CN-103F
T5-1-55
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
normal condition
Screen
10 H-9 FUEL LEVEL
No.
checking screen No.
Screen
No.
1 Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15 EMPTY 95 .~ FULL 5
2 Wiring between fuel sensor and
controller Check wiring for possible failure according to the wiring checking procedure
CN-104F
Table 86
Error code H093
Trouble Fuel sensors 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
normal condition
Screen
10 H-9 FUEL LEVEL
No.
checking screen No.
Screen
No.
1 Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15 EMPTY 95 .~ FULL 5
2 Wiring between fuel sensor and
controller Check wiring for possible failure according to the wiring checking procedure
CN-104F
T5-1-56
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
normal condition
Screen
No.
checking screen No.
Screen
No.
1 Wiring between gauge cluster
and controller Check wiring for possible failure according to the wiring checking procedure
CN-101F
T5-1-57
Table 88
Error code K014
Trouble Battery relay contact welded.
The power 24 V is continuously supplied to controller for 40 seconds or more while the key switch ON
Judging condition
signal turned OFF.
Symptom The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF.
Control in the
Normal control with key switch OFF.
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24 V to mechatro controller is stopped.
Screen
4 K-1 AIS RELAY 2
No.
4 K-3 KEY SWITCH OFF
checking screen No.
Screen
No.
1 Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
R-1 relay coil. If 24 V power lives on battery relay secondary side, check on battery
CN-256F relay for failure and replace it if failed.
2 Auto idle stop relay 2 Turn off the key switch, and remove the connector (CN-256F) on the battery
R-24 relay coil side. If power of battery relay on secondary side falls, remove either
Alternator relay auto idling stop relay 2 or alternator relay.
The failure may be occurred in case where the power falls after the relay was
R-28
removed, and therefore check on the relay unit and replace it with new one if
failed.
3 Wiring between auto idle stop
relay/alternator relay and When K014 is left displayed with the relay removed.
controller Check that no power 24 V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
CN-109F, CN2-1
When no failure found after checking on wiring and K014 is left displayed
Fuse& relay box
Replace fuse/relay box.
E-1
T5-1-58
Table 89
Error code R014
Trouble Wiper motor arc prevention relay error.
The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
Judging condition
power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
25 PREVENT ARC
No.
checking screen No.
Screen
No.
1 Wiper motor arc prevention When error is cancelled after removing wiper motor arc prevention relay, check
relay relay unit for failure, replace it with new one if failed.
R-31 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 Wiring between wiper motor arc When R014 is left displayed with the relay removed.
prevention relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 checking procedure and replace it if necessary.
Fuse& relay box When no failure found after checking on wiring and R014 is left displayed.
E-1 Replace fuse/relay box.
T5-1-59
Table 90
Error code R024
Trouble Wiper motor forward rotation relay error.
The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
Judging condition
power source.
Symptom Wiper does not move.
Control in the
event of failure
Returned in
normal condition
Screen
25 CW MOTOR RLY
No.
checking screen No.
Screen
No.
1 Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay,
relay check relay unit for failure, replace it with new one if failed.
2 Wiring between wiper motor

forward rotation relay and When R024 is left displayed with the relay removed.
CN-109F, CN2-1
When no failure found after checking on wiring and R024 is left displayed.
Fuse& relay box
E-1
T5-1-60
Table 91
Error code R034
Trouble Wiper motor reverse rotation relay error.
The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
Judging condition
power source.
Symptom Wiper does not move after forward rotation.
Control in the
event of failure
Returned in
normal condition
Screen
25 CCW MOTOR RLY
No.
checking screen No.
Screen
No.
1 Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
relay check relay unit for failure, replace it with new one if failed.
2 Wiring between wiper motor

forward rotation relay and When R034 is left displayed with the relay removed
CN-109F, CN2-1
When no failure found after checking on wiring and R034 is left displayed
Fuse& relay box
E-1
T5-1-61
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
event of failure
Returned in
normal condition
Screen
25 MOTOR RELAY
No.
checking screen No.
Screen
No.
1 Washer motor relay When error is cancelled after removing washer motor relay, check relay unit for
R-32 failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
Fuse& relay box When no failure found after checking on wiring and R044 is left displayed
T5-1-62
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
event of failure
Returned in
normal condition
Screen
22 D13
No.
checking screen No.
Screen
No.
1 Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher
R-19 relay, check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal
condition.
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.
T5-1-63
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
event of failure
Returned in
normal condition
Screen
22 D14
No.
checking screen No.
Screen
No.
1 Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher
R-19 relay, check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal
condition.
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.
T5-1-64
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
event of failure
Returned in
normal condition
Screen
23 D15
No.
checking screen No.
Screen
No.
1 Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit for
2 Wiring between travel alarm When R154 is left displayed with the relay removed
Fuse & relay box When no failure found after checking on wiring and R154 is left displayed.
T5-1-65
Table 96
Error code R164
Trouble Auto idle stop relay 2 relay error.
Judging condition The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
event of failure
Returned in
normal condition
Screen
4 K-1 AIS RELAY 2
No.
checking screen No.
Screen
No.
1 Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay unit
R-24 for failure, replace it with new one if failed.
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
T5-1-66
Table 97
Error code R174
Trouble Engine forcibly stop relay error.
Judging condition The mechatro controller output line to engine forcibly stop is short-circuited with the power source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate..
Control in the
event of failure
Returned in
normal condition
Screen
4 K-3 ENG STOP
No.
checking screen No.
Screen
No.
1 Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check relay
R-25 unit for failure, replace it with new one if failed.
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
T5-1-67
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
event of failure
Returned in
normal condition
Screen
4 K-4 LOCK LEVER
No.
checking screen No.
Screen
No.
1 Safety lock lever relay When error R184 is cancelled after removing of safety lock lever relay, check
R-26 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is , it is in abnormal condition.
2 Wiring between safety lock lever When R184 is left displayed with the relay removed
T5-1-68
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
event of failure
Returned in
normal condition
Screen
4 K-2 SAFETY RLY
No.
checking screen No.
Screen
No.
1 Safety lock lever relay When error R214 is cancelled after removing of safety relay, check relay unit for
2 Wiring between safety lock lever When R214 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
T5-1-69
[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 TROUBLESHOOTING (BY TROUBLE)
1. All controls do not function/slow

No. Sections Contents/normal value Corrective action, others
1 Fuse Check fuse No.4 If the fuse is blown out, check

(10 A) on the short-circuited section.
2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch by
switch diagnosis Push down the lever and it turns on, push tester, or check that the power
up and it turns off. voltage is lowered by pushing
the lever down.
3 Safety lever lock Check that the Measure both terminals of solenoid Check solenoid unit for
switching solenoid is switched connector. 24 V by pushing the lever possible failure.
correctly down, 0 V by pushing it up Check harness for possible
failure.
4 Safety lever lock Carry out service No.4 K-4 lock lever: Check action of relay by tester
relay diagnosis Push down the lever and it turns off, push
up and it turns on.
5 Pilot pressure sensor Stop engine stop and key is on Check 5 V power for controller
position.
All pilot low pressure sensors are 0
MPa to 0.1 MPa.
6 Solenoid valve for Measure pressure About 0 MPa by pushing the lever up, Replace solenoid valve
safety lock lever of solenoid A1 port and 4 MPa or more by push it down.
7 Pilot line filter Disassemble and Check filter for clogging Clean filter
check it visually
8 Pilot gear pump Measure pilot Check that it is 4 MPa or more in high Check gear pump and the
primary pressure at idling relief valve for possible failure
gear pump
9 Multi control valve (in Change position Since all are blocked due to poor
case that travel is switching performance, check that the
operable) lever select pattern is set to the proper
position.
10 Actual measuring Carry out service No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/ diagnosis D-1 P2 unload valve (cut valve) largely differed from the
P2 unload See Service Diagnosis Data List actually measured value,
proportional valve Operation No.3 Boom up full lever & check proportional valve and
relief controller for possible failure.
11 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2 MPa in boom up full lever and high
directly at the ports idling operation
A7 and A5 of 8
sections solenoid
block
12 Actual measuring Carry out service No.9 E-1 P1 pump In case where the reading is
current value of P1/ diagnosis. E-2 P2 pump largely differed from the
P2 pump See Service Diagnosis Data List actually measured value,
proportional valve Operation No.18 Travel right full lever check proportional valve and
& idling controller for possible failure.
Operation No.19 Travel left full lever &
idling
T5-2-2
13 Secondary pressure Measure the pump Check that pump proportional valve Replace proportional valve
of pump proportional proportional valve secondary pressure is 2.7 MPa or more
valve secondary pressure in right (left) travel full lever and high
directly in idling idling operation
operation. (Ports a3, Right travel: P1 pump proportional valve
a4) Left travel: P2 pump proportional valve
14 Main relief pressure Carry out service See Service Diagnosis Data List Measure the relief pressure
diagnosis Operation No.3 Boom up full lever & relief actually
15 Check set pressure Check that P1 and P2 pump pressures Reset or replace
are 32 MPa in boom up full lever, high
idling and H mode operation.
16 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding.
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage, etc.
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
current value of P1/ diagnosis E-2 P2 pump largely differed from the
proportional valve Operation No. 1 Operation is nil check proportional valve and
controller for possible failure.
2 Secondary pressure Measure the pump Check that P1/P2 pump proportional Replace proportional valve
of P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 0.5 to 1.0 MPa in control lever neutral
directly (Ports a3, and high idling operation.
a4)
3 Pressure sensor of Check pressure See Service Diagnosis Data List Check pressure sensor and
P1, P2 pump Operation No. 1 Operation is nil replace it if necessary
Operation No.3 Boom up full lever &
relief
resistance against sliding
Free from abnormal damage, etc on outside
surface

T5-2-3
3. Move at lever neutral position
1 Pilot pressure Carry out service Check that targeted pilot pressure of Check remote control valve
sensor diagnosis sensor is 0MPa in high idling
2 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
3 Main spool Check targeted Check that spool is free from abnormal Replace
spool visually damage and spring is free from
breakage
4 Over load relief Check targeted Free from dust entered in port relief Replace
valve spool visually valve. Seat is free from abnormality
5 Lock valve poppet Check targeted Seat is free from abnormality Replace
(in case of boom and poppet visually
arm)
6 Lock valve selector Exchange lock Check that the trouble is reversed Replace
(in case of boom and valve selector of
arm) boom/arm and
boom/arm
7 Holding valve spool Check that smooth Free from abnormal resistance against Replace
for boom sliding of spool in sliding Do not pull spool out of sleeve
(in case of boom) sleeve forcibly.
8 Holding valve relief Check targeted Filter free from abnormal contamination Replace
valve for boom spool visually
(in case of boom)
9 Cylinder Check targeted Make sure of no problem of seals by Replace cylinder or seals
cylinder visually disassembling and investigation
4. Poor fine operability
1 Pressure sensor Carry out service See Service Diagnosis Data List Replace pressure sensor
diagnosis Operation No. 1 Operation is nil
All low pressure sensors are 0MPa to
0.1 MPa
3 Secondary pressure Measure the Check that P1/P2 unloads secondary Replace proportional valve
of unload proportional valve pressures is within the range of 2.7 MPa
proportional valve secondary pressure or more in control lever neutral and high
A7 and A8 of 8
sections solenoid
block
T5-2-4
of P1, P2 pump proportional valve valve pressures are within the range of Check regulator
proportional valve secondary pressure 0.5 to 1.0 MPa in control lever neutral
directly. (Ports a3, and high idling operation
a4)
6 Command current Carry out service No.15 D-15 In case where the reading is
value of short-circuit diagnosis. See Service Diagnosis Data List largely differed from the
Operation No. 1 Operation is nil. actually measured value,
check proportional valve and
7 Secondary pressure Measure the Control lever is neutral, high idling and Replace proportional valve.
of proportional valve secondary pressure secondary pressure is within the range
in short-circuit valve. of proportional of 0.5 -1.0 MPa.
valve in short-circuit
valve directly. (G
Port)
8 Slow return check Visual check Check that slow return check valve Clean and replace
valve of pilot line installed on pilot line is free from dust
(in case of boom up entered
or arm out)
9 Short-circuit valve Visual check When removing, free from abnormal Replace (Check on the casing
spool. resistance against free from abnormal site for damage).
damage, etc on outside surface Spring
is free from breakage, damage, etc.
5. Slow boom up, insufficient power
1 Boom up pressure Carry out service See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.3 boom up full lever and sensor
relief Check remote control valve
2 Remote control Measure directly Check that pressure is 3.0 MPa or more Check remote control valve
valve remote control in boom up full lever and high idling When equipped with multi
pressure of boom operation control valve, check it while
up changing lever pattern
3 Pump pressure Carry out service See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, P2 Operation No.4 boom up full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high
operation. pressure sensor.
proportional valve Operation No.3 Boom up full lever & check proportional valve and
T5-2-5
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2 MPa in boom up full lever and
directly at the ports high idling operation
A7 and A5 of 8
sections solenoid
block
proportional valve Operation No.4 boom up full lever & in check proportional valve and
operation controller for possible failure.
proportional valve secondary pressure 1.8 to 3.0 MPa in boom up full lever and
directly (Ports a3, high idling operation
a4)
8 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is No problem for sliding ability of internal
low. piston (Check it through PBp2 port.)
valve breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1 and P2 Free from abnormal damage, etc on damage)
pressures are low. outside surface
11 Conflux check valve Visual check When removing, free from abnormal Replace
Only P2 pressure is Free from abnormal damage, etc on damage)
high. outside surface
12 Holding valve for Visual check When removing, free from abnormal Replace
boom (poppet) resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
Both P1 and P2 outside surface
pressures are high.
13 Boom spool Visual check When removing, free from abnormal Replace
Only P1 pressure is Spring is free from breakage. damage)
high.
14 Check boom spool Disassembly and Free from abnormal resistance against Replace spool assembly
and recirculation investigation sliding
<Trouble> Spring is free from breakage.
Only P1 pressure is
low.
15 Conflux spool Visual check When removing, free from abnormal Replace
Only P2 pressure is Spring is free from breakage. damage)
high. Free from abnormal damage, etc on
outside surface
T5-2-6
16 Main relief valve Check set pressure See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is relief
low.
17 Over load relief Visual check (Head Pressure is 32 MPa or more in boom up When only relief pressure of
valve side) full lever and high idling. Free from dust boom up is low, replace valve
<Trouble> entered in over load relief valve. Seat is
Relief pressure is free from abnormality
low.
6. Slow boom down, insufficient power for lifting up body
1 Boom down Carry out service See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.5 boom down full lever sensor.
& in operation Check remote control valve.
2 Remote control Measure remote Check that pressure is 3.0 MPa or more Check remote control valve
valve control pressure of in boom down full lever and high idling When equipped with multi
boom down directly operation control valve, check it while
changing lever pattern.
3 Actual measuring Carry out service P1 unload valve (cut valve) In case where the reading is
current value of P1 diagnosis See Service Diagnosis Data List largely differed from the
unload proportional Operation No.5 boom down full lever actually measured value,
valve & in operation check proportional valve and
4 Secondary pressure Measure the Check that P1 unload secondary Replace proportional valve
of P1 unload proportional valve pressures are within the range of 0.8 to
proportional valve secondary pressure 1.2 MPa in boom down full lever and
A7 of 8 sections
solenoid block.
pump proportional Operation No.5 boom down full lever actually measured value,
valve & in operation check proportional valve and
6 Secondary pressure Measure the pump Check that P1 pump proportional valve Replace proportional valve
of P1 pump proportional valve pressures are within the range of 2.0 to
proportional valve secondary pressure 2.5 MPa in boom down full lever and
a4)
7 Actual measuring Carry out service Check that the value is not change Check pressure sensor of
current value of diagnosis regardless of operation travel
travel straight See Service Diagnosis Data List In case where the reading is
proportional valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value,
& idling check proportional valve
Operation No.19 Travel left full lever & and controller for possible
idling failure.
T5-2-7
8 Travel straight Measure directly High idling pressure is 0.8 MPa or less Replace proportional valve
proportional valve the travel straight regardless neutral/operation
secondary pressure proportional valve
secondary
pressure.
current value of diagnosis regardless of operation No 15 D-15 travel.
short-circuit valve. See Service Diagnosis Data List In case where the reading is
Operation No. 1 Operation is nil. largely differed from the
Operation No.18 travel right full lever actually measured value,
& idling. Operation No.19 travel left full check proportional valve
lever & idling and controller for possible
failure.
10 Secondary pressure Measure directly High idling pressure is 0.8 MPa or less Replace proportional valve
of proportional valve the travel straight regardless neutral/operation
in short-circuit valve proportional valve
secondary
pressure. (G Port)
valve breakage
12 Lock valve poppet Visual check When removing, free from abnormal Replace
Boom down is low. Free from abnormal damage, etc on damage)
outside surface
13 Holding valve Visual check When removing, free from abnormal Replace
(poppet) resistance against sliding Free from (Check on the casing side for
<Trouble> abnormal damage, etc on outside damage)
Boom down is slow. surface
14 Boom spool Visual check When removing, free from abnormal Replace
Boom down is slow. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
15 Check boom spool Disassembly and Free from abnormal resistance against Replace spool assembly
Machine can not be
lifted by supporting
with boom.
16 short-circuit valve Visual check. When removing, free from abnormal Replace (Check on the casing
is free from breakage.
T5-2-8
low.
18 Over load relief Visual check Free from dust entered in port relief Replace
valve valve.
<Trouble> Seat is free from abnormality
Machine can not be
lifted by supporting
with boom.
7. Slow arm in, insufficient power
1 Arm in pressure Carry out service See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.6 arm in full lever and sensor
valve pressure remote control in arm in full lever and high idling When equipped with multi
pressure of arm in operation control valve, check it while
changing lever pattern
sensor diagnosis for P1, P2 Operation No.7 arm in full lever and in between P1 and P2 pump
pump pressures in operation pressures, check high
operation. pressure sensor
proportional valve Operation No.6 Arm in full lever & check proportional valve and
proportional valve secondary pressure 1.2 MPa in arm in full lever and high
directly at the ports idling operation.
A7 and A5 of 8
sections solenoid
block.
proportional valve Operation No.7 Arm in full lever & in check proportional valve and
T5-2-9
of P1, P2 pump proportional valve valve pressures are 2.0 MPa or more in
proportional valve secondary pressure arm in full lever and high idling
directly. (Ports a3, operation. (Secondary pressure is
a4) affected by oil temperature and
attachment weight)
8 Actual measuring Carry out service See Service Diagnosis Data List In case where the reading is
current value of arm diagnosis Operation No. 1 Operation is nil largely differed from the
in spool 2 Operation No.6 Arm in full lever & actually measured value,
proportional valve relief check proportional valve and
Operation No.7 Arm in full lever & in controller for possible failure.
operation
9 Secondary pressure Measure directly Check that secondary pressure of Replace proportional valve
of arm in spool 2 the proportional proportional valve secondary pressures
proportional valve valve secondary are within the range of following
pressure at the Lever neutral: 0 MPa
ports A8 (arm 2 Motion in the air: 1.7 to 2.2 MPa
spool) of 8 sections Arm in relief: 2.5 MPa or more
solenoid block.
idling failure.
11 Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve
of travel straight the proportional regardless of neutral/operation
proportional valve valve secondary
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block
valve breakage
low.
14 Over load relief Visual check (Head Pressure is 32 MPa or more in arm in When only relief pressure of
valve side) and relief. arm in is low, replace valve
<Trouble> Free from dust entered in over load relief
P1, P2 pressure is valve.
low. Seat is free from abnormality
T5-2-10
15 Over load relief Visual check (Rod Pressure is 32 MPa or more in arm out When only relief pressure of
valve side) and relief. arm out is low, replace valve
P1, P2 pressure is valve.
low. Seat is free from abnormality.
16 Arm 1 spool Visual check When removing, free from abnormal Replace
P1, P2 pressure is Free from abnormal damage, etc on damage)
P1, P2 pressure is Free from abnormal damage, etc on damage)
high or low. outside surface
18 Check arm 2 spool Disassembly and Free from abnormal resistance against Replace spool assembly
Arm in power is
poor.
19 Check lock valve Visual check Free from abnormal resistance against Replace
poppet sliding (Check on the casing side for
Both P1, P2 outside surface
pressures are high.
8. Slow independent arm out (in the air)
No
Sections Contents/normal value Corrective action, others
.
1 Arm out pressure Carry out service See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.8 arm out full lever and sensor
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
sensor diagnosis for P1, P2 Operation No.9 arm out full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high
proportional valve Operation No.8 Arm out full lever & check proportional valve and
T5-2-11
No
.
proportional valve secondary pressure 1.2 MPa in arm out full lever and high
A7 and A5 of 8
sections solenoid
block
proportional valve Operation No.9 Arm out full lever & in check proportional valve and
proportional valve secondary pressure 1.5 to 2.7 MPa in arm out full lever and
a4) (Secondary pressure is affected by oil
temperature and attachment weight)
idling failure.
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block
valve breakage
low.
12 Over load relief Visual check (Rod Pressure is 32 MPa or more in arm out When only relief pressure of
valve side) and relief. arm out is low, replace valve
P1, P2 pressure is valve. Seat is free from abnormality
low.
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
T5-2-12
No
.
outside surface
15 Check arm 2 spool Disassembly and Free from abnormal resistance against Replace spool assembly
<Trouble> (spring side) Spring is free from breakage.
Both P1, P2
pressures are low.
16 Check lock valve Visual check Free from abnormal resistance against Replace
poppet sliding (Check on the casing side for
Both P1, P2 outside surface
pressures are high.
9. Slow bucket digging
1 Bucket digging Carry out service See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.12 bucket digging full sensor
lever and relief Check remote control valve
2 Remote control Measure directly Check that pressure is 3.0M Pa or more Check remote control valve
valve remote control in bucket digging full lever and high When equipped with multi
pressure of bucket idling operation control valve, check it while
digging changing lever pattern
sensor diagnosis for P1, P2 Operation No.13 Bucket digging full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high
proportional valve Operation No.12 Bucket digging full check proportional valve and
lever & relief controller for possible failure.
proportional valve secondary pressure 1.2 MPa in bucket digging full lever and
A7 and A5 of 8
sections solenoid
block
proportional valve Operation No.13 Bucket digging full check proportional valve and
lever & in operation controller for possible failure.
of P1, P2 pump proportional valve pressures is 2.7 MPa or more and P2
proportional valve secondary pressure pump proportional valve pressure is 1.6
directly (Ports a3, to 2.2 MPa in bucket digging full lever
a4) and high idling operation.
T5-2-13
8 Attachment boost Carry out service No.3 POWER BOOST Check harness
solenoid command diagnosis Bucket digging COMP OFF, MEAS OFF Replace solenoid valve
9 Attachment boost Measure switching Check that pressure is 0 MPa in bucket Replace solenoid valve
solenoid secondary valve secondary digging full lever and high idling
pressure pressure operation
current value of diagnosis Operation No.12 Bucket digging full largely differed from the
travel straight lever & relief actually measured value,
proportional valve check proportional valve and
11 Secondary pressure Measure directly Check that travel straight secondary Replace proportional valve
of travel straight the proportional pressure is 2.7 MPa or more in bucket
proportional valve valve secondary digging full lever and high idling
pressure at the operation
ports A6 (travel
straight) of 8
sections solenoid
block
12 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
13 Check stroke limiter Visual check When piston is removed from cover, it is Replace
<Trouble> free from abnormal resistance against (Check on the casing side for
Both P1, P2 sliding damage.)
pressures are high. Free from abnormal damage, etc on
outside surface
valve breakage
Operation No.3 Boom up full lever and
relief
16 Travel straight spool Visual check When removing, free from abnormal Replace
outside surface
17 Bucket spool Visual check When removing, free from abnormal Replace
Both P1, P2 Free from abnormal damage, etc on damage)
pressures are high. outside surface
18 Over load relief Check targeted Free from dust entered in over load relief Replace
valve spool visually valve.
Seat is free from abnormality.
T5-2-14
10. Slow bucket dump
1 Bucket dump Carry out service See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.14 Bucket dump full sensor
valve remote control in bucket dump full lever and high idling When equipped with multi
pressure of bucket operation control valve, check it while
dump changing lever pattern
sensor diagnosis for P1, P2 Operation No.15 Bucket dump full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high
proportional valve Operation No.14 Bucket dump full check proportional valve and
lever & relief controller for possible failure.
proportional valve secondary pressure 0.5~1.2 MPa in bucket dump full lever
directly at the ports and high idling operation. Replace
A7 and A5 of 8 proportional valve
sections solenoid
block
proportional valve. Operation No.15 Bucket dump full check proportional valve and
lever & in operation controller for possible failure.
of P1, P2 pump proportional valve pressures is 2.7 MPa or more and P2
proportional valve secondary pressure pump proportional valve pressure is 0.9
directly (Ports a3, to 1.4 MPa in bucket dump full lever and
a4) high idling operation.
current value of diagnosis Operation No.14 Bucket dump full largely differed from the
travel straight lever & relief actually measured value,
of travel straight the proportional pressure is 2.7 MPa or more in bucket
proportional valve valve secondary dump full lever and high idling operation
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block
T5-2-15
10 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
low. piston (Check it through PBP2 port.)
11 Check stroke limiter Visual check Free from abnormal damage and wear Replace
<Trouble> on outside of piston inside cover (Check on the casing side for
Pilot pressure is low. damage.)
valve breakage
<Trouble> Operation No.3 Boom up full lever and
low.
outside surface
15 Bucket spool Visual check When removing, free from abnormal Replace
Both P1, P2 Free from abnormal damage, etc on damage)
pressures are high. outside surface
valve spool visually valve.
11. Swing operation not functioned/slow
1 Swing pressure Carry out service See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.11 Swing full lever and sensor
in operation Check remote control valve
valve remote control in boom up full lever and high idling When equipped with multi
pressure of swing operation control valve, check it while
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP ON, MEAS ON Check harness
Swing: COMP OFF, MEAS OFF
4 Swing parking brake Measurement of Lever neutral: 0 MPa Replace solenoid valve
solenoid solenoid valve A2 In operation: 4 MPa or more
port
T5-2-16
5 Shuttle valve Visual check No contamination on spool cover (short Clean or replace
<Trouble> side) and orifice
Pilot pressure is low. No damage on spool cover (long side)
and shuttle
6 Pump pressure Carry out service See Service Diagnosis Data List Check high pressure sensor
sensor diagnosis for P2 Operation No.11 Swing full lever and
pump pressures in in operation
operation
unload proportional Operation No.11 Swing full lever & in actually measured value,
valve operation check proportional valve and
8 Secondary pressure Measure the Check that P2 unload secondary Replace proportional valve
of P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2 MPa in swing full lever and high
A5 of 8 sections
solenoid block
pump proportional Operation No.11 Swing full lever & in actually measured value,
valve operation check proportional valve and
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)
(Check this trouble Operation No.18 Travel right full lever actually measured value,
by only swing & idling check proportional valve
operation) Operation No.19 Travel left full lever & and controller for possible
idling failure.
(Check this trouble pressure at the
by only swing ports A6 (travel
operation) straight) of 8
sections solenoid
block
T5-2-17
13 Command current Carry out service Check that the value is not change Check pressure sensor of
value of short-circuit. diagnosis regardless of operation No 15 D-15 travel.
See Service Diagnosis Data List In case where the reading is
failure.
14 Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve.
of proportional valve the secondary regardless of neutral/operation.
in short-circuit valve. pressure of the
proportional valve
in short-circuit
valve. (G Port)
valve breakage
P2 pressure is low. Free from abnormal damage, etc on damage)
outside surface
17 Swing spool Visual check When removing, free from abnormal Replace
outside surface
18 Short-circuit valve Visual check. When removing, free from abnormal Replace (Check on the casing
damage, etc on outside surface
19 Swing relief valve Check set pressure See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever and
low.
20 Swing motor Visual check Inner parts (cylinder block, piston, valve Replace
brake etc) are to be free from abnormal
resistance against sliding.
outside surface (brake plate etc)
21 Swing reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
gear oil from swing metal powder. reduction gear
reduction gear drain
22 Swing reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
T5-2-18
12. Noise during swing operation
1 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure
brake solenoid diagnosis Lever neutral: COMP ON, MEAS sensor
ON Check harness
Swing: COMP OFF, MEAS OFF
2 Measurement of Lever neutral: 0 MPa Replace solenoid valve

solenoid valve A2 In operation: 4 MPa or more
port
3 Boost check valve Visual check When removing, free from abnormal Replace
(Sound of resistance against sliding
cavitation at Spring is free from breakage.
stopping)
4 By-pass check Visual check When removing, free from abnormal Replace
valve resistance against sliding
(Sound of Spring is free from breakage.
cavitation at
stopping)
5 Swing motor Visual check Disassemble and inspect abnormal Replace

(Brake valve/ wear and scuffing
friction plate)
6 Swing motor Visual check When removing, free from abnormal Replace
piston resistance against sliding
7 Swing reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
gear oil from swing metal powder. reduction gear
reduction gear
drain.
8 Swing reduction Visual check Tooth surface has no abnormally Replace

worn and chipped.
13. Swing on a slope drifts when control lever is in neutral position
1 Swing pressure Carry out service Engine stop & starter key ON Check and replace pressure
sensor diagnosis All pilot low pressure sensors are sensor
within range of 0 to 0.1 MPa.
valve breakage
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP ON, MEAS ON Check harness
Swing: COMP OFF, MEAS OFF Check parking brake release
switch
4 Measurement of Lever neutral: 0 MPa Replace solenoid valve

solenoid valve A2 In operation: 4 MPa or more
port
T5-2-19
5 Swing motor Visual check Disassemble and inspect abnormal Replace

(Brake valve/friction wear and scuffing
plate)
6 Parking brake Visual check Piston and friction plate do not have Replace
abnormal resistance against sliding
Free from spring damage
14. Swing drifts when swing operation is stopped
No
.
1 Shuttle valve Visual check No contamination on spool cover Clean or replace

<Trouble> (short side) and orifice. No damage
Pilot pressure is on spool cover (long side) and
low shuttle.
2 Swing pressure Carry out service Engine stop & starter key ON Replace pressure sensor
sensor diagnosis All pilot low pressure sensors are
within range of 0 to 0.1 MPa.
3 Swing relief valve Check set See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.10 Swing full lever
Relief pressure is and relief
low.
4 Anti-reaction valve Visual check Free from dirt entering Clean or replace
Sliding part should be free from
foreign matter entering, abnormal
damage and wear.
5 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is free
valve from breakage
6 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
15. Slow travel speed/weak
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
valve remote control in travel right (left), forward (reverse) full
pressure of travel lever and high idling operation
right and left
T5-2-20
idling
proportional valve secondary pressure followings in travel right (left), forward
directly at the ports (reverse) full lever and high idling
A7 and A5 of 8 operation
sections solenoid Travel right (P1 unload): 0.5 to 1.0 MPa
block Travel left (P2 unload): 0.5 to 1.0 MPa
idling
6 Secondary pressure Measure the pump Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 pump proportional valve pressures are within the range of
directly (Ports a3, (reverse) full lever and high idling
a4) operation
Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more
7 Actual measuring Carry out service Check that the value is not change Check voltage of low
current value of diagnosis regardless of operation pressure sensor other than
travel straight See Service Diagnosis Data List sensor for travel
proportional valve Operation No. 1 Operation is nil In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value,
Operation No.19 Travel left full lever & check proportional valve
idling and controller for possible
failure
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
failure.
10 Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve.
of proportional valve the secondary regardless of neutral/operation.
in short-circuit valve. pressure of the
proportional valve
in short-circuit
valve. (G Port)
T5-2-21
valve breakage
Check sealing ability of shuttle valve and
entry of dust in orifice
outside surface
13 Travel spool Visual check of When removing, free from abnormal Replace
<Trouble> targeted spool resistance against sliding (Check on the casing side for
Pump pressure is Free from abnormal damage, etc on damage)
14 short-circuit valve Visual check. When removing, free from abnormal Replace (Check on the casing
is free from breakage
15 Travel motor relief Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel
valve 32 MPa or more in right and left travel motorfs relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel
locked crawler belt) and high idling motorfs relief valve is failed.
16 Travel motor Visual check Inner parts (piston, cylinder block, valve Replace
plate, brake valve spool) are to be free
from abnormal resistance against
sliding.
17 Parking brake in Visual check When removing, free from abnormal Replace
travel motor resistance against sliding
No sticking on friction plate and
separator plate
18 Travel reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
gear oil from travel metal powder. reduction gear
19 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
T5-2-22
16. Travel deviation
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
valve remote control in travel right (left), forward (reverse) full
pressure of travel lever and high idling operation
right and left
3 Actual measuring Carry out service Check that the value is not change Check voltage of low
current value of diagnosis regardless of operation pressure sensor other than
travel straight See Service Diagnosis Data List sensor for travel
proportional valve Operation No. 1 Operation is nil In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value,
Operation No.19 Travel left full lever & check proportional valve
idling and controller for possible
failure.
pressure
idling
directly at the ports (reverse) full lever and high idling
A7 and A5 of 8 operation
sections solenoid Travel right (P1 unload): 0.5 to 1.0 MPa
block Travel left (P2 unload): 0.5 to 1.0 MPa
idling
8 Secondary pressure Measure the pump Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 pump proportional valve pressures are within the range of
directly (Ports a3, (reverse) full lever and high idling
a4) operation
Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more
T5-2-23
9 Exchange P1 for P2 Exchange delivery Check the direction of deviation If the direction is changed,
pipe of P1 for P2 inspect a pump. If the
direction is not changed,
inspect a valve and travel unit.
valve breakage
Check sealing ability of shuttle valve and
entry of dust in orifice
outside surface
Spring is free from breakage
12 Travel spool Visual check of When removing, free from abnormal Replace
<Trouble> targeted spool resistance against sliding (Check on the casing side for
Pump pressure is Free from abnormal damage, etc on damage)
13 Travel motor relief Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel
valve 32 MPa or more in right and left travel motorfs relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel
locked crawler belt) and high idling motorfs relief valve is failed.
Replace as necessary
14 Travel motor Visual check Inner parts (piston, cylinder block, valve Replace
plate, brake valve spool) are to be free
from abnormal resistance against
sliding.
15 Travel reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
gear oil from travel metal powder. reduction gear
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
resistance against sliding
outside surface

T5-2-24
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.)
1 Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed Check pressure sensor
switching solenoid diagnosis No.3 F-3 1/2-TRAVEL Check harness
Lever neutral COMP OFF, MEAS OFF Check travel 1/2 speed switch
Travel operation COMP ON, MEAS ON on gauge cluster
2 Travel 1/2 speed Measure A3 port Lever neutral: 0 MPa Replace solenoid valve
switching solenoid pressure on In operation: 4 MPa or more
solenoid valve
3 1/2 speed switching Visual check Check that spool is free from abnormal Replace
spool in travel motor damage and spring is free from (Check on the casing side for
breakage damage)
4 1/2 speed switching Visual check Free from entry of dust Remove dust or replace
orifice in travel motor
5 Tilting piston in Visual check Free from abnormal wear on piston and Replace
travel motor seal (Check on the casing side for
damage)
18. Travel parking on a slope is not held
1 Pilot pressure Carry out service Engine stop & starter key switch is ON Check pressure sensor and
sensor diagnosis Targeted pilot low pressure sensor is replace as necessary
in range of 0 to 0.1 MPa Check remote control valve
valve breakage
3 Parking brake in Visual check When removing, free from abnormal Replace
travel motor resistance against sliding
4 Orifice of passage Visual check Free from entry of dust Remove dust or replace
for parking brake in
travel motor
19. Travel does not run straightly when both crawlers and attachment operated simultaneously .
1 Actual measuring Carry out service No. 8 D-3 S-TRAVEL is should be Check voltage of low
current value of diagnosis COMP 557 mA and MEAS 55730 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
2 Secondary pressure Measure directly Check secondary pressure is within Replace proportional valve
of travel straight the proportional range of 1.7 to 2.1 MPa in both travel full
proportional valve valve secondary lever and in boom-up full lever at high
pressure idling. (Command value is changed
according to operation. Above
mentioned values indicate while boom-
up and full lever operation are
performed).
3 Command current Carry out service No 15 D-15 is should be COMP 530 mA Check voltage of low
value short-circuit diagnosis. and MEAS 53030 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)
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
6 Short-circuit valve Visual check. When removing, free from abnormal Replace (Check on the casing
is free from breakage.
20. Slow breaker (crusher) operation, weak power (In case of conflux, check p1 unload/pump and travel
straight)
1 Pressure sensor for Carry out service See Service Diagnosis Data List Check and replace pressure
optional attachment diagnosis Operation No.16 P2 side OPT full sensor
valve remote control in optional attachment full lever and high
pressure of travel idling operation
right and left
current value of P1/ diagnosis Operation No.16 P2 side OPT full largely differed from the
P2 unload lever and relief actually measured value,
T5-2-26
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.
of travel straight the proportional pressure is 2.7 MPa or more in optional
proportional valve valve secondary attachment full lever and high idling
pressure at the operation
ports A6 (travel
straight) of 8
sections solenoid
block
7 P1 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
8 Relief pressure Check set pressure See Service Diagnosis Data List Reset or replace
Operation No.16 P2 side OPT full
lever and relief
(Set value of factory shipment is 24.5
MPa.)
9 Remote control Check targeted Check sealing ability of shuttle valve and Replace
valve remote control entry of dust in orifice.
valve
outside surface
11 Spool for optional Visual check When removing, free from abnormal Replace
attachment resistance against sliding (Check on the casing side for
P1, P2 pressures outside surface
are high. Spring is free from breakage.
valve spool visually valve
T5-2-27
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")
1 N&B selector spool Visual check When removing, free from abnormal Replace
outside surface
2 N&B selector Screw for Check that the error indication is Replace solenoid valve
solenoid emergency disappeared by turning emergency
screw
3 N&B selector Carry out service No.11 F-4 Option selector is B mode Check solenoid valve
solenoid diagnosis COMP ON, MEAS ON Check harness
Spool position BRK
Selector switch BRK
4 N&B selector Carry out service No.16 B-11 Check pressure sensor
pressure sensor diagnosis Data List Check harness
3.0 MPa at B mode and 0.0 MPa at A
mode
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")
1 N&B selector spool Visual check When removing, free from abnormal Replace
outside surface
2 N&B selector Carry out service No.11 F-4 Option selector is A mode Check solenoid valve
solenoid diagnosis COMP OFF, MEAS OFF Check harness
Spool position NIB
Selector switch NIB
T5-2-28
Table 1 - Action of optional selector solenoid valve

Safety Optional Selector
Safety
lock selector valve
Engine lock lever Work Spool Failure diagnosis
No. lever valve detecting Warning display
condition SW's
relay's
mode COMP.
position pressure
display
input
output MEAS. sensor
1 Running ON OFF A OFF Nibbler Normal
"SELECTOR VALVE [F042] displayed
2 Running ON OFF A ON Breaker Normal
FAILURE" simultaneously
"SELECTOR VALVE
3 Running ON OFF A OFF Breaker Normal
FAILURE"
4 Running ON OFF A ON Nibbler Normal [F042] displayed
5 Running ON OFF B ON Breaker Normal
"SELECTOR VALVE [F043] displayed
6 Running ON OFF B OFF Nibbler Normal
FAILURE" simultaneously
"SELECTOR VALVE
7 Running ON OFF B ON N&B Normal
FAILURE"
8 Running ON OFF B OFF Breaker Normal [F043] displayed
"SELECTOR VALVE [B113] displayed
9 Running ON OFF Failure
FAILURE"
10 Stopping
11 OFF
12 ON
T5-2-29
2. ELECTRIC SYSTEMS
2.1 WIRING CHECKING PROCEDURE

Check for continuity between connector terminals, CONNECTOR
presence or absences of short-circuit with other
wires, and presence or absences of short-circuit
with machine body grounding.
1. Checking for disconnection between WIRE
connectors.
(When both ends measurement is easy
because of short distance between connectors) TESTER
SM0104
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is zero (0), it is in normal
condition.
(When both ends measurement is difficult

because of long distance between connectors)
JUMPER
Measure the resistance using tester. WIRE
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 TESTER
condition. FRAME BODY GROUNDING
The resistance is 1 M or more when the SM0105
terminal on one side is not connected to frame

body grounding with jumper wire, it is in normal
condition.
2. Checking for presence or absence of short-

circuit with machine body
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 short-

circuit between wirings.
When the resistance is 1 M or more, it is in
normal condition. TESTER
SM0107
T5-2-30
4. Checking connector terminal for contact

Insert male terminal into female terminal unit, INSERT
and then check that the inserting force is
equivalent to other female terminals.
If looseness is there, replace the female MALE TERMINAL FEMALE TERMINAL
terminal with new one.
SM0108
Clean the dirt terminal.
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
a. Check the terminal crimped condition. PART
Pull one electric cable with the about 3kg

force, and make sure that the cable does RUBBER
not come out of the terminal. PLUG
RECEPTACLE.
When came out, replace the terminal and CONTACT
crimp it again. PLUG
SEALING
b. Check connector for imperfect insertion (is housed in plug)
Check that all top ends form a line on the DOUBLE LOCK
PLATE FOR PLUG
same position as seen from the connector DOUBLE LOCK
engaged side. PLATE FOR CAP
When moved along, push it in further CAP

through wire inserting hole.
TAB.CONTACT
SM0109
c. Check connector for intruding of water. RUBBER PLUG
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
7. 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.
SM0110
T5-2-32
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
1. Engine does not stop.

No
.
1 Starter key switch Check signal of No.4 K-3 Key switch Check continuity between
starter key switch OFF at starter key switch OFF terminals of starter switch
ON by carrying position using tester
out service ON at starter key switch ON position
diagnosis.
2 Engine forcible When ON is No.4 K-3 Key switch Check on engine forcible
stop relay displayed with the OFF at starter key switch OFF stop relay
starter switch position
OFF, then pull out ON at starter key switch ON position
R-25 engine
forcible stop relay
and carry out the
service diagnosis.
3 Wiring Voltage between 0 V when starter switch is OFF Check harness
line No.62 among Check diode D-9 between
starter switch, starter switch and auto
engine forcible idling stop relay 1
stop relay,
enginestop
solenoid and the
body grounding
2. "CPU DATA COMMUNICATION ERROR" is displayed on multi display.

No
.
1 Fuse No.1 fuse (5 A) Not blown fuse Check harness
Replace fuse
2 Mechatro Accel control Engine speed varies according to Check mechatro controller
controller accel potentiometer operation. and replace as necessary
(Use remote control because the
auto accel function is working.)
3 Wiring Transmission See WIRING CHECKING Repair wiring
circuit line No.770 PROCEDURE"
from mechatro
controller to
gauge cluster
4 Gauge cluster Gauge cluster Replace gauge cluster
T5-2-34
3. Auto accel does not actuate. (The engine speed does not automatically slow down.)
No
.
1 Engine coolant Check engine No.2 G-5 WATER TEMP Replace engine coolant
temperature coolant Auto accel does not work in the sensor
temperature by temperature -15 C or less.
carrying out Warm up and raise the coolant
service diagnosis. temperature to 15 C or more
2 Gauge cluster Indication of auto Mark "Display/not display" for auto Replace gauge cluster
accel accel switches by auto accel switch
operation on gauge cluster.
3 Low pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
sensor No.6 is in the range of 0~0.1 MPa at
control lever neutral position.
4. Auto accel does not actuate. (The engine speed does not automatically speed up.)
No
.
1 Low pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
sensor No.6 is raised with control lever
operated.
T5-2-35
5. Wiper does not function.
Wiping range of
forward and
reverse movements
Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position
SM0111

1 Fuse Check fuse No.20 Replace fuse
2 SW-19: Service diagnosis No.19 D125 Check wiper interlock switch
Wiper interlock Wiper switch display (D125) is OFF with front window closed. and repair it if necessary
switch Check according to "WIRING
CHECKING PROCEDURE"
and repair it if necessary
3 Rise up limit switch Service diagnosis No.25 Wiper system Check according to "WIRING
built-in wiper motor CHECKING PROCEDURE"
Reverse limit switch Switch action in operation
Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF
4 R-31: Service diagnosis No.25 Wiper system

Arc prevention relay
When started by forward rotation: STOP START (STOP) (REVERSE) (STOP) (FORWARD)
R-29: Arc prevention relay OFF ON ON ON ON OFF ON ON ON OFF ON
Forward rotation Forward rotation relay OFF ON ON ON ON OFF OFF OFF OFF OFF ON
relay Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
R-30: Check that the relay is worked as shown in the table. Check that the relay is excited.
* When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
Reverse rotation from the wiper startup, turn OFF all relay's outputs. if necessary.
relay
T5-2-36
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) E215B-E245B
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 TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
No.1 No.2 No.3

SELECT SWITCH
LANGUAGE/LOGO 8 FAULT DIAG MODE DIAG MODE 1
ADJUSTING MODE 1 DIAG MODE 2 BUZZER STOP SWITCH
PRESET BY FACTORY
FEED SCREEN CHANGE SWITCH
CASE OF DIAG MODE 1
SENSOR CHECK START ENG LOWER BOOM DIAG MODE 1

ENGINE SPEED
RELEASE LOCK In diagnosis
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND LEVER START operation
PROPO-VALVE About 15 minutes
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
For
Forthe
tthediagnosing
diagnosingitems,
items,see
seeTable
Table 48-1.
1.
When
Whenrequired
requiredto
tostop
stopin indiagnosis
diagnosis
Turn engine on operation,press
operation, pressthe
thebuzzer
buzzerstop
stopswitch
switch
manually. BACK TO No.3 and
andthetheoperation
operationisisforcedly
forcedlystopped.
stopped.
The data at the time of judgment

can be confirmed with the select
RESULT OF DIAGNOSIS RESULT OF DETAIL switch.
When
DIAG MODE 1 not failed, DIAG MODE 1 1 P1 UNLOAD
ENGINE SPEED
END
0000 rpm
ENGINE STOP OK O K PRESSURE
C-1 00.0M C-2 00.0M
PROPO-VALVE
DATA END FEED E-1 005mA
D-1 300mA
E-2 005mA
D-2 300mA
The other judgments can be

Engine stops confirmed with the feed button.
automatically. RESULT OF DIAGNOSIS
When failed,
DIAG MODE 1 RESULT 1 1 P1 UNLOAD
ENGINE SPEED
P1 UN-LOAD PSV NG
NG
0000 rpm
PRESSURE
P1 UN-LOAD SPOOL NG C-1 00.0M C-2 00.0M
PROPO-VALVE
DATA END FEED DATA END FEED E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
The suspected trouble sections are displayed in order of

possibility. The suspected three sections in maximum are
BACK TO No.3 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
No.4 CASE OF DIAG MODE 2
SENSOR CHECK START ENG

ENGINE SPEED
LOWER BOOM DIAG MODE 2
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND START
PROPO-VALVE
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
Turn engine on
Example: Case of boom up
manually. AT CONTROL LEVER IS
NEUTRAL WHEN FINISHING OF
DIAGNOSIS IS REQUIRED.
BOOM UP BOOM UP
OK BACK TO No.3
PRESSURE 0.0 MPa PRESSURE 1.5 MPa PRESSURE 3.0 MPa
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 "UN-
LOAD PSV NG" is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not
appear. If necessary, examine the presence or absence of trouble referring to the trouble history.
T5-3-3
Table 1 - Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that the flow rate at P1 side is minimum
1 1 P1 UNLOAD
and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the minimum flow rate is relieved at
2 2 P1 UNLOAD
P1 side?
Is normal pressure generated in the condition that the unload valve is fully opened,
3 3 P1 UNLOAD
and P1 side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency
4 1 P2 UNLOAD
position, and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the minimum flow rate is relieved at
5 2 P2 UNLOAD
P2 side?
Is normal pressure generated in the condition that the unload valve is fully opened,
6 3 P2 UNLOAD
and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the flow rate at P1 side is
7 1 P1 PUMP
emergency and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and
8 2 P1 PUMP
P1 side flow rate is minimum?
9 3 P1 PUMP
position, and P1 side flow rate is maximum?
Is normal pressure generated in the condition that the flow rate at P2 side is
10 1 P2 PUMP
emergency and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and
11 2 P2 PUMP
P2 side flow rate is minimum?
12 3 P2 PUMP
position, and P2 side flow rate is maximum?
Is normal pressure generated in the condition that P1 side flow rate is minimum,
13 1 TRAVEL-S
unload valve is emergency position and travel straight is stroked fully?
Is normal pressure generated in the condition that P2 side flow rate is minimum,
14 2 TRAVEL-S
unload valve is emergency position and travel straight is stroked fully?
Is rated engine speed obtained in the condition that P1 side flow rate increases little
15 1 P1 ENGINE
by little when P1 side flow rate is relieved?
Is rated engine speed obtained in the condition that P2 side flow rate increases little
16 2 P2 ENGINE
by little when P2 side flow rate is relieved?
Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Check each pressure sensor by
SENSOR CHECK Disconnection of pressure sensor, Short
service diagnosis and replace it if
NG 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 Stuck at full-stroke side Check P1 unload spool and replace it
NG Stuck at neutral side if necessary
T5-3-4
Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
against the command Check P2 unload proportional valve
P2 UN-LOAD PSV NG
against the command
P2 UN-LOAD SPOOL Stuck at full-stroke side Check P2 unload spool and replace it
NG Stuck at neutral side if necessary
Stuck at closing side Check P1 by-pass cut valve and
P1 B-P CUT NG
Stuck at neutral side replace it if necessary
Stuck at closing side Check P2 by-pass cut valve and
P2 B-P CUT NG
against the command Check P1 pump proportional valve
P1 PUMP PSV NG
against the command
Delivery rate is excessive large against the Check P1 pump regulator and
command replace it if necessary.
P1 PUMP NG
Delivery rate is excessive small against the Check P1 pump and replace it if
command necessary.
against the command Check P2 pump proportional valve
P2 PUMP PSV NG
against the command
Delivery rate is excessive large against the Check P2 pump regulator and
command replace it if necessary.
P2 PUMP NG
Delivery rate is excessive small against the Check P2 pump and replace it if
command necessary.
against the command Check travel straight proportional
S-TRAVEL PSV NG
Secondary pressure is excessive low valve and replace it if necessary
against the command
Stuck at full-stroke side Check travel straight spool and
S-TRAVEL SPOOL NG
PUMP 1 PRESS. SEN- Check P1 high pressure sensor and
Pressure is recognized lower than it is
SOR NG replace it if necessary
PUMP 2 PRESS. SEN- Check P2 high pressure sensor and
Pressure is recognized lower than it is
SOR NG replace it if necessary
Set pressure decreases Check main relief valve and replace it
MAIN RELIEF NG
Set pressure increases if necessary
Check engine and replace it if
ENGINE NG Output is lowered
necessary
Check engine speed sensor and
E/G R SENSOR NG Characteristics is misaligned
replace it if necessary
T5-3-5
[MEMO:]
T5-3-6
REPAIR INSTRUCTIONS
M0103
REPAIR INSTRUCTIONS E215B-E245B
Section 1 GENERAL INFORMATION

Group 1 Precautions for Disassembly and Assembly
Group 2 Tightening Torque
Section 2 UPPERSTRUCTURE
Group 1 Upperstructure
Group 2 Pump device
Group 3 Control valve
Group 4 Swing device
Group 5 Pilot valve
Section 3 UNDERCARRIAGE
Group 1 Swing bearing
Group 2 Travel device
Group 3 Swivel joint
Group 4 Track adjuster
Group 5 Front idler
Group 6 Upper and lower roller
Group 7 Tracks
Section 4 FRONT ATTACHMENT

Group 1 Front attachment
GENERAL INFORMATION
CONTENTS
Group 1 - Precautions for Disassembly Group 2 - Tightening Torque

and Assembly Torque Chart .......................................... W1-2-1
Precautions for Disassembly and Piping Joint............................................. W1-2-4
Assembly .......................................... W1-1-1
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY E215B-E245B
PRECAUTIONS FOR DISASSEMBLY AND

ASSEMBLY
PREPARATIONS FOR DISASSEMBLY - If it is unavoidably necessary to disassemble and

modify, it should be carried out by experts or
- Thoroughly wash the machine before bringing it
personnel qualified through service training.
into the shop. Bringing a dirty machine into the
shop may cause machine components to be - Make match mark on parts for reassembling.
contaminated during disassembling/assembling, - Before disassembling, read Disassembling
resulting in damage to machine components, as Instruction in advance, and determine if the
well as decreased efficiency in service work. disassembly and assembly are permitted or not.
- Be sure to thoroughly understand all - For parts which are required to use jig and tools,
disassembling/assembling procedures dont fail to use the specified jig and tools.
beforehand, to help avoid incorrect disassembling - For parts which can not be removed in the
of components as well as personal injury. specified procedure, never force removal. First
- Check and record the items listed below to check for the cause.
prevent problems from occurring in the future. - Inspecting parts. Measure the wear of parts and
1. The machine model, machine serial clearance, and record the measured values.
number, and hour meter reading. - If an abnormality is detected, repair or replace the
2. Reason for disassembly (symptoms, failed parts.
parts, and causes).
- The removed parts should be put in order and
3. Clogging of filters and oil, water or air leaks, tagged so as to install on proper places without
if any. confusion.
4. Capacities and condition of lubricants. - For common parts, pay attention to the quantity
5. Loose or damaged parts. and places.
- Prepare the necessary tools to be used and the
area for disassembling work.
REASSEMBLING HYDRAULIC EQUIPMENT
- Wear appropriate clothing, safety shoes, safety
helmet, goggles, and clothes with long sleeves. - During the parts cleaning, ventilate the room.
- Confirm the position of first-aid kit and fire - Remove adhering oil by compressed air, and
extinguisher, and also where to make contact for apply hydraulic oil or gear oil, and then assemble
emergency measure and ambulance to prepare them.
for accidents and fire. - Replace the removed O-ring, back-up rings and
- Attach "Dont operate" tag to control lever, and oil seal with new ones, and apply gear oil on them
begin a meeting before starting the work. before assembling.
- Removes dirt and water on the surface on which
liquid sealant are applied, decrease them, and
DISASSEMBLING AND ASSEMBLING
apply liquid sealant on them.
HYDRAULIC EQUIPMENT
- Before assembling, remove rust preventives on
- Before removing pipes, release the pressure of new parts.
hydraulic oil tank, or open the cover on the return
- Use special tools to fit bearings, bushing and oil
side to tank, and take out the filter.
seal.
- Drain the oil in the removed pipes into pan to
- Assemble parts matching to the marks.
prevent the oil from spilling on the ground.
- After completion, check that there is no omission
- Pipes with plugs or caps to prevent oil leaking,
of parts.
entry of dust, etc.
- 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
manufactures 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, dont 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.
B
2. If incorrectly assembled, oil leakage or damage SM0172
will occur. Be sure to do the following, to
prevent trouble.
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 RIGHT
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 WRONG
(B) seating.
SM0173
RIGHT WRONG
a
A a
b b
a=b ab
SM0174
W1-1-3
E215B-E245B PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
ELECTRICAL EQUIPMENT
- The disassembly of electrical equipment is not
allowed.
- Handle equipment with care so as not to drop it or
bump it.
- Connector should be removed by unlocking while
holding the connector.
Never stress in tension to the caulked section by
pulling wire.
- Check that connector is connected and locked
completely.
- Engine key off before removing and connecting
connector.
- Engine key off before touching terminals of starter
and alternator.
- Wash machine with care so as not to splash water
on electrical equipment and connector.
- When water has entered in the waterproofed
connector, the removing of water is not easy. So
check the removed waterproofed connector with
care to protect it from entry of water. If moisture
adheres on it, dry it completely before connecting.
- Remove battery grounding terminal before
beginning work close to battery and battery relay
with tools.
WARNING
Battery fluid is dangerous. The battery fluid is
dilute sulfuric acid, and causes scald and loss of
eyesight by adhering on eyes, skin and clothes.
When the fluid has adhered on them, take an
emergency measure immediately and see a
doctor for medical advice.
- When it has adhered on skin:
wash with soap and water.
- When it has got in eyes:
wash in water for 10 minutes or more
immediately.
- When it was swallowed:
drink milk or water.
W1-1-4
TIGHTENING TORQUE E215B-E245B
TORQUE CHART
WARNING
Use tools appropriate for the work to be done.
Makeshift tools and procedures can create safety
hazards. For loosening and tightening nuts and
bolts, use the correct tools. Avoid bodily injury
caused by slipping wrenches.
Bolt Types
Tighten nuts or bolts correctly to torque
specifications. Two kinds of bolts, hexagon bolts T
and socket bolt, each made of different material, are
used. Make sure to employ the correct bolts and
tighten them to specification when assembling the
machine or components.
Hexagon T Bolt Socket Bolt
SM0175
Specified Tightening Torque Chart
T Bolt,
Hexagon
Wrench Socket
Bolt Dia. Wrench
Size bolt
Size
(Nm)
M18 13 6 29.5
M10 17 8 64
M12 19 10 108
M14 22 12 175
M16 24 14 265
M18 27 14 390
M20 30 17 540
M22 32 17 740
M24 36 19 930
M27 41 19 1370
M30 46 22 1910
M33 50 24 2550
M36 55 27 3140
W1-2-1
E215B-E245B TIGHTENING TORQUE
IMPORTANT
1. Apply lubricant (i. e. white zinc B dissolved into
spindle oil) to nuts and bolts to stabilize their
friction coefficients.
2. Torque tolerance is 10%.
3. Be sure to use bolts of correct length. Bolts that
are too long cannot be tightened, as the bolt tip
comes into contact with the bottom of the bolt
hole. Bolts that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart are for general
use only.
Do not use these torques if a different torque is
given for a specific application.
5. Make sure that the nut and bolt threads are
clean before installing. Remove dirt or
corrosion, if any.
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 Tighten from center and diagonally
1.4 1 12 9 4 1 6 7 14
6 3
4 5
2.3
2 13 8 5 2 3 10 11
SM0176
W1-2-2
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 SM0177
defects cannot be polished out, replace the
component.
2. Be sure to use only specified O-rings. Inspect
WRONG
O-rings for any damage. Take care not to file O-
ring surfaces. When installing an O-ring into a
groove, use grease to hold it in place.
3. Loosely assemble split flange halves. Make
sure that the split is centrally located and
perpendicular to the port. Hand-tighten the
bolts to hold the parts in place. Take care not to
pinch the O-ring.
4. Tighten bolts alternately and diagonally, as SM0178
shown, to ensure even tightening.
5. Do not use air wrenches. Using an air wrench
often causes tightening of one bolt fully before
tighten the others, resulting in damage to O-
rings or uneven tightening of bolts.
Nut and Bolt Lockings SM0179
Lock Plate
RIGHT WRONG
IMPORTANT: do not reuse lock plates. Do not try to
bend the same point twice.
Cotter Pin
Do not bend it round
Bend along edge sharply
IMPORTANT: do not reuse cotter pins. Match the
holes in the bolt and nut while tightening, not while
loosening.
RIGHT RIGHT WRONG
Lock Wire
IMPORTANT: apply wire to bolts in the bolt-
tightening direction, not in the bolt-loosening
direction.
Bend along edge sharply
SM0180
RIGHT RIGHT WRONG
RIGHT WRONG
Loosen
Tighten
SM0181
W1-2-3
PIPING JOINT
Pipe Thread Connection / Union Joint
Tightening Torque Specifications 1 4 3 5 2
Union Joint
Metal sealing faces (4) and (5) of adaptor (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
Joint Body SM0182
IMPORTANT
1. Do not over-tighten union nut (3). Excessive
force will be applied to metal sealing surfaces
(4) and (5), possibly cracking adaptor (1). Be 37
sure to tighten union nut (3) to specifications.
37
2. Scratches or other damage to sealing surfaces
(4) or (5) will cause oil leakage at the joint.
Take care not to damage them when
connecting /disconnecting. Male Union Joint Female Union Joint
SM0183
Wrench Size Tightening Torque

Type
Union Nut Joint Body (Nm)
37 Union Joint 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
O-Ring Seal Joint

O-Ring (6) seats against the end face of adaptor (7)
to seal pressure oil. 7 6 9
IMPORTANT
1. Be sure to replace O-Ring (6) with a new one
when reconnecting.
2. Before tightening union nut (9), confirm that O- 8 10 Joint body
SM0184
Ring (6) is seated correctly in O-Ring groove
(8). Tightening union nut (9) with O-Ring (6)
displaced will damage O-Ring, resulting in oil
leakage.
3. Take care not to damage O-Ring groove (8) or
sealing face (10). Damage to O-Ring (6) will
cause oil leakage.
4. If union nut (9) is found to be loose, causing oil
leakage, do not tighten it to stop the leak.
Instead, replace O-Ring (6) with a new one,
then tighten union nut (9) after confirming that
O-Ring (6) is securely seated in place.
Wrench Size Tightening Torque

Union Joint
(Nm)
Nut Body
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
Screwed-In Connection
IMPORTANT: many types of screwed-in connec- PT PF

tions are used for hose connections.
Be sure to confirm that the thread pitch and thread 30
type (tapered or straight) are the correct type before
using any screw-in connection.
Male Tapered Thread Male Tapered Thread Male Straight Thread
Wrench Tightening Torque SM0185
Joint Body (Nm)

17, 19 34
22 49
27 93
36, 32 157
41 205
50 320
60 410
Seal Tape Application

Seal tape is used to seal clearances between male Internal Thread
and female threads, so as to prevent any leakage
between threads.
Clearance
Be sure to apply just enough seal tape to fill up
thread clearances. Do not overwrap. External Thread SM0186
Application Procedure
Leave one to two pitch threads uncovered
Confirm that the thread surface is clean, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap
seal tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs
SM0187
depending on the type of clamp.
See below for correct tightening torque of each type
of low-pressure-hose clamp. 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 SM0189
W1-2-6
Connecting Hose
WARNING
WRONG RIGHT
1. When replacing hoses, be sure to use only
genuine parts. Using hoses other than genuine
hoses may cause oil leakage, hose rupture or
separation of fitting, possibly resulting in a fire
on the machine.
2. Do not install hoses kinked. Application of high
oil pressure, vibration, or an impact to a kinked
hose may result in oil leakage, hose rupture or SM0190
separation of fitting.
Utilize print marks on hoses when installing
hoses to prevent hose from being installed WRONG RIGHT
kinked.
Rubbing Against Each Other
3. If hoses rub against each other, wear to the
hoses will result, leading to hose rupture. Take
necessary measures to protect hoses from
rubbing against each other.
Take care that hoses do not come into contact SM0191
with moving parts or sharp objects.
WRONG RIGHT
Clamp Clamp
Rubbing
SM0192
WRONG RIGHT
Rubbing
Clamp
SM0193
W1-2-7
NOTE:
W1-2-8
UPPERSTRUCTURE
CONTENTS
Group 1 - Upperstructure Group 2 - Control valve

Removal and installation of Removal and installation of control valveW2-3-1
upperstructure....................................... W2-1-1 Preparation ....................................... W2-3-1
Preparation ....................................... W2-1-1 Removal of control valve................... W2-3-1
Removal of upperstructure ............... W2-1-1 Installation of control valve................ W2-3-2
Removal and installation of the cab ....... W2-1-2 Control valve ports ................................. W2-3-3
Removal of the cab ........................... W2-1-2
Assembly and disassembly of control
Installation of the cab ........................ W2-1-3 valve...................................................... W2-3-12
Removal and installation of Preparation for disassembly................... W2-3-12
counterweight........................................ W2-1-4
Removal of counterweight ............... W2-1-4 Disassembly........................................... W2-3-13
Installation of counterweight ............ W2-1-5 Inspection after disassembly.................. W2-3-25
Disconnecting hoses of swivel joint Assembly................................................ W2-3-25
lower side.............................................. W2-1-6
Maintenance standards.......................... W2-3-32
Swivel joint lower side hoses ................. W2-1-7
Group 4 - Swing device
Removal and installation of main frame. W2-1-8
Removal of main frame..................... W2-1-8 Removal and installation of swing deviceW2-4-1
Installation of main frame.................. W2-1-9 Preparation ....................................... W2-4-1
Removal............................................ W2-4-2
Group 2 - Pump device Installation......................................... W2-4-3
Removal and installation of hydraulic Disassembly and assembly of swing
pump device.......................................... W2-2-1 motor ..................................................... W2-4-4
Preparation ...................................... W2-2-1 Preliminary operations ...................... W2-4-5
Removal............................................ W2-2-1 Disassembly...................................... W2-4-5
Installation ........................................ W2-2-1 Assembly .......................................... W2-4-7
Disassembly and assembly of pump Disassembly and assembly of swing
device.................................................... W2-2-2 reducer .................................................. W2-4-9
Disassembly hydraulic pump device ..... W2-2-3 Preliminary operations ...................... W2-4-10
Assembly .......................................... W2-2-7 Disassembly...................................... W2-4-10
Assembly .......................................... W2-4-13
Maintenance standard ........................... W2-2-11
Maintenance standards.......................... W2-4-18
Disassembly and assembly of regulator W2-2-12
Swing motor ...................................... W2-4-18
Disassembly of regulator .................. W2-2-14
Swing reduction gear ........................ W2-4-19
Assembly of regulator ....................... W2-2-18
Disassembly and assembly of pto gear Group 5 - Pilot valve
casing.................................................... W2-2-21
Removal and installation of right and
Disassembly ..................................... W2-2-22 left pilot valve ........................................ W2-5-1
Assembly .......................................... W2-2-23 Preparation ....................................... W2-5-1
Maintenance standard ...................... W2-2-23 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. Remove the front equipment and the boom
cylinders, performing the operations described
in the procedure at pages W4-1-1 (Refer to:
2. To drain the hydraulic pressure from the Section 4 - Front Attachment).
Hydraulic System, refer to procedure
Releasing the hydraulic pressure at page T2-
1-47. 2. Remove the cab, performing the operations
described in the procedure at page W2-1-2
3. Cut-off the engine. Press the valve located on
the hydraulic oil cap to release any residual 3. Remove the counterweight, performing the
pressure present in the tank itself. Remove operations described at page W2-1-6.
hydraulic oil tank cap. Connect a vacuum pump
to maintain negative pressure in the hydraulic
4. Disconnect the hoses of swivel joint lower side,
oil tank.
performing the operations described in the
procedure at page W2-1-6.
NOTE: be sure to run the vacuum pump
continuously while working. 5. Remove the main frame performing the
operations described in the procedure at page
W2-1-8.
W2-1-1
E215B-E245B UPPERSTRUCTURE
REMOVAL AND INSTALLATION OF THE CAB
Removal of the cab

1. Remove floor mat.
2. Remove cover (1). 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 3
T2, group 3) 2
1) Disconnect connectors of cluster gauge
harness: (CN-5F), (CN-6F), (CN-61F), (CN-
62F) and earth wire (P-1) at rear right of cab.
2) Disconnect antenna cable coming from SM0259
backside of tuner at rear left of cab.

5. Remove the plastic tube for the window washer Disassembly and assembly of cover (1)
from the rear left of cab. and cover assy (2)
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 9
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. 3
4) With harnesses are connected condition,
install key switch cover (9) to bracket (11) of 10
5
rear cab temporally. (See Fig. SM0261).
4 7
5) Disconnect harness connectors of work light
switch on right panel (7), air conditioner 10 6
panel and cigarette lighter, and remove right 5
panel (7) and (8).
6) Loosen sems bolts (12) M6x16 and (13) 10
M6x40, one each, and remove front panel 4
(14) with air conditioner duct. 8
: Plus driver
12
14
13 SM0261
Disassembly and assembly of right panels

(8), (9) and (14)
W2-1-2
7. 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 11
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)
SM0261
17 15
installation of the cab
Install it in reverse order of removing according to
the Tightening Torque Table. 15
Tightening
Allen wrench
Tightening position torque
HEX
Nm (lbfft)
Nut M16 - (17) 24 191 (140) 16
Capscrew - (2), (9) 19 79.4 (60)
15
Sems bolt M6 - Torxdriver
8.5 (6.3) Smontaggio e rimontaggio
15 dei bulloni di fissaggio
(5), (6) T30
cabina
Sems bolt M6 - 15
Plus driver 5.0 (3.7) SM0262
(12), (13)
18
18
SM0263
W2-1-3
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. 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. SM0264
Wire with hook:
Length 1.5 m, dia. more than 16 mm (2 pcs.).
3. Remove 4 bolts (4) M30.

Lift counterweight using a crane or hoist.
: 46 mm 2
4. Remove shim (5), (6), (7) from the frame. 3
5
6
7
4 SM0265
5. Lower the counterweight on proper stand.
SM0266
W2-1-4
Installation of counterweight
NOTE: approx. weight of counterweight: 4600 kg
1. Attach lifting tools (2) to eye-bolts (3) of

counterweight. 2
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 7
and tighten temporarily.
: 46 mm
4 SM0265
5. Remove wire rope. 1

Tighten the bolts (4) with a power wrench and
torque wrench.
: 46 mm
: 1570+200
-100
Nm
6. Remove eye-bolts (3) and install plugs (1) onto

the counterweight.
4 SM0267
W2-1-5
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
4. Disconnect the two hose (6). (F Port: PF1/4)

: 19 mm
Tightening torque: 29.4 Nm
A B B
E
C D D
F F F
F F D
C
B
A
E E
SM0268
W2-1-6
SWIVEL JOINT LOWER SIDE HOSES
4 2 3 5
A A
4 6 6 5
2 3
section A - A
SM0269
W2-1-7
REMOVAL AND INSTALLATION OF MAIN

FRAME
Removal of main frame
NOTE: approximate mass of main frame 5000 kg.
1. Insert two upper swing body lifting jigs (2) and

two counterweight fastening cap screws (M30) 3
(1) into the counterweight mounting holes from
4
above.
2. Attach two chain blocks (4) to the boom foot 2

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 ST. No. 38xxxxxxx SM0270
4. Put matching marks (M) on swing bearing and M

main frame.
SM0271
W2-1-8
5. 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
OUTER (S) ZONE POSITION
Confirm the reamer bolt position (X) referring to Fig
SM0274.
4. Apply Loctite # 262 onto thread of bolts (5)

then, install bolts.
X
: 30 mm 19,5
5. Apply Loctite # 262 onto thread of reamer bolts

(6) then, install reamer bolt.
: 30 mm
(*) SM0274
(*) Apply Loctite # 515 to the shared area
W2-1-9
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.
Preparation 3. Cut-off the engine. Press the valve located on

the hydraulic oil cap to release any residual
1. Park the machine on a firm, level surface..
pressure present in the tank itself. Remove
2. To drain the hydraulic pressure from the
oil tank.
1-47. NOTE: be sure to run the vacuum pump
continuously while working.
Removal Installation
1. Remove all protection panels and doors to give 1. Lift the hydraulic pump device by means of
access to the Hydraulic Pump Device. hoist and ropes.
2. Disconnect all electrical connectors. NOTE: hydraulic pump device weight: 143 kg.
3. Remove all hoses and collector from hydraulic 2. Install the hydraulic pump device to the engine
pump device. by means of related bolts.
: 19, 22, 30, 36 mm : 17 mm
: 8, 10 mm : 431 43.1 Nm
4. Fasten the hydraulic pump device by means of 3. Install all hoses and collector to the hydraulic
hoist and lifting ropes. pump device.
: 19 mm
NOTE: hydraulic pump device weight: 143 kg. : 29,4 Nm
5. Remove the fixing bolts of hydraulic pump : 22 mm
device and draw it from engine. : 39,2 Nm
: 17 mm : 30 mm
: 137,2 Nm
: 36 mm
: 156,9 Nm
: 8 mm
: 64 Nm
: 10 mm
: 108 Nm
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
534
702 412 406
531 261
548 792 413
774
789 732 532 710
9
535 271
953
886
806
728
717 468 717
724
113 313
127 808 124
954 546
123 407 325
824 901
725
710
490
262 490
111
251 727 885
401
312
116 717 886 8
124
127 314 710
141
157
156 725 727
151 153 7
885 886 467 6
152
211 466 5
214
212 6 435
435
4
10 11
SM0275
NOTE: the number in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
4 - Pilot pump 407 - Socket bolt M655 (Q.ty 3)
5 - PTO gear casing 412 - Socket bolt (Q.ty 2)
6 - O-Ring (Q.ty 2) 413 - Socket bolt (Q.ty 2)
7 - Cover 435 - Socket bolt (Q.ty 2)
8 - Socket bolt (Q.ty 2) 466 - Plug VP PF 1/4 (Q.ty 2)
9 - Regulator 467 - Plug VP PF 3/8 (Q.ty 2)
10 - Short-circuit valve 468 - Plug VP PF 3/4 (Q.ty 4)
11 - Socket bolt 490 - Plug nptf 1/16 (Q.ty 27)
111 - Shaft (F) 531 - Tilt Pin m242 (Q.ty 2)
113 - Shaft (R) 532 - Servo piston M242 (Q.ty 2)
116 - 1st gear 534 - Stopper (Q.ty 2)
123 - Roller bearing (Q.ty 2) 535 - Stopper (Q.ty 2)
124 - Needle bearing (Q.ty 2) 546 - Spacer (Q.ty 2)
127 - Bearing spacer (Q.ty 4) 548 - Feed back Pin (Q.ty 2)
141 - Cylinder block (Q.ty 2) 702 - O-Ring (Q.ty 2)
151 - Piston (Q.ty 18) 710 - O-Ring (Q.ty 2)
152 - Shoe (Q.ty 18) 717 - O-Ring (Q.ty 2)
153 - Plate (Q.y 2) 724 - O-Ring (Q.ty 18)
156 - Spherical bushing (Q.ty 2) 725 - O-Ring (Q.ty 6)
157 - Cylinder spring (Q.ty 18) 727 - O-Ring (Q.ty 3)
211 - Shoe plate (Q.ty 2) 728 - O-Ring (Q.ty 4)
212 - Swash plate (Q.ty 2) 732 - O-Ring (Q.ty 2)
214 - Tilting bushing (Q.ty 2) 774 - Oil seal
251 - Swash plate support (Q.ty 2) 789 - Backup ring (Q.ty 2)
261 - Cover (front) 792 - Backup ring (Q.ty 2)
262 - Cover (rear) 806 - Hex. nut M16 (Q.ty 2)
271 - Pump casing (Q.ty 2) 808 - Hex. nut M20 (Q.ty 2)
312 - Valve block 824 - Snap ring (Q.ty 2)
313 - Valve plate (front) 885 - Valve plate pin (Q.ty 2)
314 - Valve plate (rear) 886 - Spring pin (Q.ty 4)
325 - Sensor Block 901 - Eye bolt M10 (Q.ty 2)
401 - Socket bolt M20210 (Q.ty 8) 953 - Set screw M1630 (Q.ty 2)
406 - Socket bolt M820 (Q.ty 4) 954 - Set screw M20 (Q.ty 2)
W2-2-2
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 435
pump surface with wash oil.
435
Drain out the oil in the pump casing by removing
drain port plugs (466 and 468).
:19, 36 mm
311
312
466 SM0276
1. Removing piloto pump.

Remove the socket bolts (435), then remove
pilot pump (4).
: 8 mm
5
2. Removing PTO gear casing. 435
Remove the socket bolts (435), then remove
PTO gear casing (5).
: 8 mm
SM0278
3. Removing regulator.
Remove the socket bolts (412) e (413), then
remove regulator (9). 9
: 6 mm
SM0277
W2-2-3
4. Loosen socket bolts (401) that fasten swash

plate support (251), pump casing (271) and 312 271
valve block (312). 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 312 271
block (312).
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

(271) in parallel to shaft (111). At the same time
141(151)(157)
draw out piston (151), plate (153), spherical
bushing (156) and cylinder spring (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
7. 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 271

plate support (251) from the pump casing (271)
side and separate the swash plate support from
the pump casing.
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 251
shaft from the swash plate support.
111
(113)
SM0285
W2-2-5
11. Remove valve plate (313 and 314) from valve

block (312).
NOTE: the valve plate may come off during the 312
separation of pump casing from valve block.
314
(313)
SM0286
12. If necessary, remove stoppers (534 and 535),

531
servo piston (532) and tilting pin (531) from
pump casing (271), and remove needle bearing
(124) from valve block (312).
534
806 535
532
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 808
mating part between them. Use care so as not to
score the servo piston by applying unreasonable 124
312
force. 271
Do not draw out needle bearings except when their
service life has ended.
Do not loosen hex nuts (806 and 808) of valve block 251
(312) and swash plate support (251). A set flow rate
changes.
SM0287
W2-2-6
Assembly
1. Assembly is a reverse order of disassembly,
but notice the following:
- Repair scored parts at disassembly. Get
replacements ready beforehand
- Wash parts sufficiently in cleaning oil and dry
them with jet air.
- Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
- In principle, replace sealing parts such as O-
Rings and oil seals.
- Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
- Do not mix up front pump parts with rear
pump parts.
2. Attach swash plate support (251) to pump

casing (271) by tapping the swash plate 271
support lightly with a plastic hammer.
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
251
down. Insert the tilting bushing of the swash 271 (531)
plate into tilting pin (531), and fit swash plate
(212) to swash plate support (251) properly.
NOTE: Confirm by your both hands that swash plate

moves smoothly.
The shaft be installed easily if grease is applied to 212
the sliding parts of swash plate and swash plate
support.
Do not damage the sliding surfaces of shoe plate.
SM0289
W2-2-7
4. 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 123
the end by using a steel rod and others.
127,824
111
SM0290
5. nstall seal cover (261) to pump casing (271)

and fix it with socket bolts (406).
: 6 mm 271
: 29.4 Nm
261
NOTE: Coat the oil seal in seal cover with a thin film 406
of grease.
Handle the oil seal with sufficient care so it is not
scored.
SM0291
6. Assemble the piston cylinder sub compound to

the cylinder block (141), piston (151), shoe
(152), plate (153), spherical bushing (156) and 141(151,152,157)
cylinder spring (157).
Align the spherical bushing with the cylinder 156
spline and insert them into the pump casing.
153
SM0292
W2-2-8
7. 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 312 271
(401). 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 SM0294
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,
9
then install the regulator and fasten socket bolt
(412) e (413).
: 6 mm
: 29,4 Nm
IMPORTANT: do not mistake the front regulator for

the rear regulator.
SM0295
W2-2-9
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 SM0276
W2-2-10
MAINTENANCE STANDARD:
Unit: mm (poll.)
Recommended
Standard
Part name and inspection item value for Remedy
dimension (mm)
replacement (mm)
Clearance between piston and cylinder
0.039 0.067 Replace piston or cylinder.
bore (D-d)
SM0520
Gap between piston and caulked part of

0 ~ 0.1 0.3 Replace piston shoe assy.
shoe (d)
SM0521
Thickness of shoe (t) 4.9 4.7 Replace piston shoe assy.
t
SM0522
Free height of cylinder spring (L) 41.1 40.3 Replace cylinder spring.
L
SM0523
Combined height of retainer plate and Replace a set of spherical bushing

23.0 22.0
spherical bushing (H-h) or retainer plate.
SM0524
Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section). Surface roughness requiring

3-Z
Swash plate (shoe plate face). correction.
Cylinder (sliding section). Standard surface roughness
Less than 0.4 Z (lapping)
Roughness of each surface. (correction value)
W2-2-11
DISASSEMBLY AND ASSEMBLY OF REGULATOR
626
625
624
753
627
623
621 D 728
B 645
611
622 F
733 874 646
732 613
875 644
631
898 612
652 875
A 643
651
836 G E
897 C
655
654
653
814
630
438
629
763
802
628
756
801
924
412
656 413
438 757
Y
W
Z D
418 079 E
041 876
755 X 615
601 755
722 858
466 496 734
755 G
887
708 F
A 876
662 B 724 614
439 C
642 730 725 8-724 755
858
041 755
755 466
466 755
641 SM0296
NOTE: the number in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
W2-2-12
041 - Check valve 646 - Pilot spring

079 - Solenoid proportional reducing valve 651 - Sleeve
412 - Socket bolt M850 (Q.ty 2) 652 - Spool
413 - Socket bolt M870 (Q.ty 2) 653 - Spring seat
418 - Socket bolt M512 (Q.ty 2) 654 - Return spring
438 - Socket bolt M620 (Q.ty 8) 655 - Set spring
439 - Socket bolt M625 (Q.ty 5) 656 - Block cover
466 - Plug PF 1/4 (Q.ty 3) 662 - Spring
496 - Plug (Q.ty 18) 708 - O-Ring
541 - Seat (Q.ty 2) 722 - O-Ring (Q.ty 3)
543 - Stopper (Q.ty 2) 724 - O-Ring (Q.ty 8)
545 - Steel ball (Q.ty 2) 725 - O-Ring
601 - Casing 728 - O-Ring
611 - Feed back lever 730 - O-Ring
612 - Lever 1 732 - O-Ring
613 - Lever 2 733 - O-Ring
614 - Fulcrum plug 734 - O-Ring
615 - Adjust plug 753 - O-Ring
621 - Compensating rod 755 - O-Ring (Q.ty 7)
622 - Piston case 756 - O-Ring
623 - Compensating rod 757 - O-Ring
624 - Spring seat 763 - O-Ring
625 - Outer spring 801 - Nut M8 (Q.ty 2)
626 - Inner spring 802 - Nut M10
627 - Adjust stem 814 - Snap ring
628 - Adjust screw 836 - Snap ring
629 - Cover 858 - Snap ring (Q.ty 2)
630 - Lock nut M301.5 874 - Pin 411.7 L
631 - Sleeve 875 - Pin 48 L (Q.ty 2)
641 - Pilot cover 876 - Pin 5x8 L (Q.ty 2)
642 - Spool 887 - Pin
643 - Pilot piston 897 - Pin 419 L
644 - Spring seat 898 - Pin 7.5x11 L
645 - Stelo di regolazione 924 - Socket bolt M820
Tightening torque of bolt, plug and nut

Tightening torque
No. Thread size
Nm (lbfft)
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
Disassembly of regulator
1. Proceed with disassembly operations in a clean

place.
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 438 656 413 629 412
pump body.
: 6 mm
4. Remove socket bolt (438) and separate the port

plate (656).
: 5 mm
438
5. 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 SM0298
W2-2-14
6. After removing the cover (629) sub assy, take

out outer spring (625), inner spring (626) and (A) 645
spring seat (624) from the compensating part.
644,646
Then take out adjust stem (645), pilot spring
(646) and spring seat (644) from the pilot part.
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

654,
(836).
651(836)
When removing snap ring (814), return spring (654)
comes out, use care so as not to lose it.
SM0502
9. Remove snap ring (858) and take out fulcrum

plug (614) and adjust plug (615).
858
615
614
SM0503
W2-2-15
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 ( 4 x 100) so as not to interfere with lever
(612).
611
SM0506
611
SM0507
W2-2-16
12. Remove lever 1 (612).

612
611
874
897
NOTE: do not draw out pin (875). 875 613
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 466

opposite side of the piston casing if compensating
rod (623) is pushed out.
662
15. Remove VP plug (466) from pilot cover (641) 642
and draw out spool (642) and spring (662).
466
641
SM0509
W2-2-17
Assembly
1. Assembly is the reverse order of disassembly.

Do the work paying attention to the following:
623
- Repair those parts that were damages during 612
disassembly and prepare replacement parts 611
beforehand. 874
- Clean parts thoroughly in cleaning oil, blow 897
875 613
them with jet air and assemble parts in a
clean place. 875
- 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. SM0510
2. Assemble compensating rod (623) into the

compensating hole of casing (601). 652
651
3. Put the pin mounted in lever 1 (612) into the 836
groove of the compensating rod. Then
655
assemble the lever to the pin that is pressed in
the casing (601). 654
653
4. Assemble spool (652) and sleeve (651) into the

spool hole of the casing.
814
NOTE: Make sure that the spool and the sleeve SM0511
move smoothly in the casing.

Beware of the direction of the spool.
5. 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
611
feedback lever.
652
SM0512
W2-2-18
6. Assemble pilot piston (643) into the negative

control hole of the casing.
NOTE: make sure that the pilot piston moves

smoothly.
613(875)
7. 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 SM0514
gap is not large and that the lever moves smoothly.
858
615
614
SM0515
W2-2-19
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
: 11.7 Nm 622(621)
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 642
adjust stem (645) into the pilot hole. Then
assemble spring seat (624), inner spring (626)
and outer spring (625) into the compensating 466
hole.
641
SM0509
NOTE: do not mistake the direction of the spring
seat.
644,645,646
14. Attach cover (629) fitted with adjust screws 626
(628 and 925), adjust stem (627), lock nut
(630), nut (801) and socket bolt (924). Then 625(624)
fasten them with socket bolts (438).
: 5 mm
: 12 Nm
15. Attach block cover (656) and tighten screws

SM0517
(438).
: 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
SM0518
W2-2-20
DISASSEMBLY AND ASSEMBLY OF PTO GEAR CASING
128 435 711 262 414

117
126 886
826
128
885
886 728
115
468
326
435
125
118
825 125 SM0519
115 - Idle shaft 435 - Flange socket M1020 (Q.ty 4)

117 - 2nd gear 468 - VP plug PF3/4
118 - 3rd gear 711 - O-Ring
125 - Ball bearing (Q.ty 2) 728 - O-Ring
126 - Roller bearing 825 - Snap ring
128 - Bearing spacer (Q.ty 2) 826 - Snap ring
262 - Cover 885 - Spring pin
326 - Gear casing 886 - Pin (Q.ty 2)
414 - Socket bolt M1020 (Q.ty 2)
W2-2-21
Disassembly
1. Proceed with disassembly operations in a clean

place.
414
2. Remove dust, rust, etc, on pump surface with

wash oil (468). 262
: 27 mm
: 74 Nm 468
3. Remove the socket bolts (414). Then remove SM0525
the cover (262).

: 8 mm
: 33.3 Nm
115
4. Remove snap ring (885) and idle shaft (115).

117
Then draw out 2nd gear (117), roller bearing
(126, 128)
(126) and bearing spacer (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).
125
NOTE: ball bearing (125) can not be separated from
3rd gear (118).
118
SM0527
W2-2-22
Assembly
Assembly is a reverse order of disassembly, but

notice the following:
- Repair scored parts at disassembly. Get
replacements ready beforehand.
- Wash parts sufficiently in cleaning oil and dry
them with jet air.
- Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
- In principle, replace sealing parts such as O-Rings
and oil seals.
- Tighten socket bolts and plugs to specified
torques in this Manual.
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.
1
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. 2
: 17
: 23 Nm (17 lbf.ft)
SM1251
W2-2-23
NOTE:
W2-2-24
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.
Preparation 3. Cut-off the engine. Press the valve located on

1. Park the machine on a firm, level surface.
oil tank.
Releasing the hydraulic pressure at page. T2- NOTE: be sure to run the vacuum pump
1-47. 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). 2

: 19 mm
2
NOTE: control valve assembly mass: 232 kg. 2 SM0528
4. Remove the control valve.
W2-3-1
Installation of control valve
1. Install control valve (1) to frame and tighten the

bolts (2).
: 19 mm
: 235 Nm
2. Connect all hoses, pipes and connectors to the 1

control valve.
2 SM0528
Connector / Bolt Hose nut
Tread size Ports Tightening Tightening Remarks

Opposing Opposing
Name torque torque
flats flats
Pss, PLc2, PBp1, PBp2, PL, PB1, PTb,
PF 1/4 19 36 (27) 19 29 (21)
PCa, PCb, PCc, XAb
PAa1, PBa1, Pab, PBb, Pac, PBc, PAL,
ORS
PF 3/8 PBL, Par,PBr, Pas, PBs, PAa2, PBa2, 22 74 (55) 22 49 (36)
Joint
Pao, Pbo, DR
162
PF 3/4 MU 36 36 118 (87)
(119)
Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc 14 42,4 (31) - -
M10
Ab, Bb, Ao, Bo Sems 14 57 (42) - -
P1, P2 bolt 17 62,2 (45) - -
M12
T1, T2 17 96 (70) - -
3. Install the panel protecting the control valve

using the relevant securing screws.
: 19 mm
: 108 Nm
W2-3-2
CONTROL VALVE PORTS (1/2)
Functions Ports Ports on upper sides Ports Functions

LEFT RIGHT PBp1 P1 bypass cut
P2 bypass cut PBp2 PBa2 Arm 2 in
Option PAo Mu Make-up line
Arm (R) relief valve - - Bucket (R)relief valve
Arm 1 out PBa1 XAb Boom lowering valve
PBb Boom down

Swing (LH) PBs
- Boom (H) relief valve
Boom conflux PB1
PAr Travel right forward
Travel left forward PAL
- Main relief valve
Tank return T2 PCb P1 unload
Ports on rear sides (on machine)
LEFT RIGHT
P1 P1 pump
P2 P2 pump
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
CONTROL VALVE PORTS (2/2)
Function Ports Ports on left side (on machine) Ports Function

LOWER UPPER
SIDE SIDE
Option Bo Ao Option
Ba Arm 1 out
Arm 1 in Aa PLc2 Arm in lock release
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
Arm (H) relief valve - - Boom (R) relief valve
Arm in PAa1 - Bucket (H) relief valve
Option PBo PAc Bucket digging
PAa2 Arm 2 in
SM0530
W2-3-4
Control valve (1/6)
A
B
273x10 T2
H 273x10 H
P1 unload PCb PAL
(Travel priotity) Travel left
C C
USE FOR YN30V00101F1 PAr
PB1 Boom conflux
Travel right (P2 unload)
D D
PBs
Boom Swing
E PCc
PBb E
PBa1 Pss
Bucket Arm 1
F F
PBa2 PAo
PA
Arm 2 MU Option
G G
K PBp1 PBp2 K
(P3)
B A
PBa2 PAo
PBp1 PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2 PBo
273x10 273x10 SM0531
W2-3-5
Control valve (2/6)
J
154 164 101
P2
T2 T1
PAL JJ PBL
YT1
PB1 YBG1
PCa
P2-20
PBs PAs
YS1
Pss
PBa1 PAa1
YA1
PAo PBo
YP1
SECTION A-A
(P4)
163 162 163 169 155 162
154 164
P1
102
973 973
PTb PCb
P1-20
973 973
PBr PAr
YT1
973
PAb PBb
YB1
973 973
PBc PCc
PAc
YK1
974
973
PAa2 PBa2
YAG
1
974
(P3)
SM0532 162 162 169 155 163 162 SECTION B-B
W2-3-6
Control valve (3/6)
202 P1 unload Travel left 201

333 PCb PAL
331 333
336 331
329
327 336
601 MR 324
331
261 323
309
PL 331
261
306
159 AL 163
162
512
511
522 521
CP2
552
CMR2 551
562 164
562 162
CMR1
BL
552
163
522
512
307
261
331 264
PBL
327 205
329 SECTION C-C
336
331
333 Travel priority
202 PTb
201 Travel right Boom conflux
333 202
331 PAr PB1
333
336 331
324
323 339
326
331 325
261
331
306 261
511
161 521
CCb
163 Ar 551
164
511
305
521
CP1
551 551
164 164
163
Br
161 310
164
154
(T3)
261
264 331
PBr
327
205
329
SECTION D-D 336
331
333
PCa
SM0533 P2 unload 202
W2-3-7
Control valve (4/6)
Swing 204
203 PBs
Boom 333
333
336 Pss 331
331
336
603 322
211 321 322
AbR
279 x 3 266 321
331
331
215 XAb 261 261
160 303
514 161
524
As 162
CRb
556 Ab
163
164 511
511 523
521 LCs
LCb 556
164
551
Bb 162
164 Bs
161
301
266
264
264
602 PAb
160 PAs
206
205 BbR
SECTION E-E
551 Bucket
164 201
209 333
216 PCc Arm 1 331
333 PBa1 336
331 322
PBc
336
322 321
321 BaR 603
602 BcR 171
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc
LCa
551 551
164 164
Ac
162 Aa
302
161
264 264
603 PAc PAa1 205
205 SECTION F-F 605
AcR AaR SM0534
W2-3-8
Control valve (5/6)
201 Arm 2 Option 201

333 PBa2 PAo
333
331
340 331
328
321 336
331 324
261 AoR
323
604
308 MU 331
162
261
162
162 311
511
521 Ao
LCAT2 511
551
164 521
515
LCo
521 551
LCAP2
551 164
164
Bo
162
161
604
BoR
264 264
PAa2 PBo
205 205
SECTION G-G
T2
161
P1
511
T1
521 163
CT1 163
551
162
511
164 P2
521
CT2
551
164
SECTION H-H SM0535
W2-3-9
Control valve (6/6)
207 266
160
278 x 5 264
264
528
527
T2 518
T1
517
SECTION J-J
PBp1 PBp2
606
606
163
SM0536
SECTION K-K
W2-3-10
Tightening torque Tightening torque

No. Parts Name Q.ty No. Parts Name Q.ty
101 Casing A 1 321 Spring 5
102 Casing B 1 322 Spring 4
220~250 (162~184) 154 Plug PF3/4 3 323 Spring 3
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
164 O-ring 19 331 Spring seat 24
16~18
169 O-ring 2 333 Spacer bolt 12
Loctite #262
9,8~14 (7.2~13) 171 Socket bolt 336 Stopper 10
204 Cover 1
Back pressure check
207 1 515 Poppet 1
valve cover
209 Cover 1 517 Boost check valve 1
9.8~14 (7.2~13) 211 Lock valve selector sub 2 518 Poppet 1
215 Boom dowering valve 1 523 Spring 1
264 O-ring 10
25~34 (18~25) 273 Socket bolt 40 230~260 (170~192) 551 Plug 13
98~120 (72~89) 274 Socket bolt 4 130~150 (96~111) 552 Plug 2
98~120 (72~89 275 Socket bolt 4 230~260 (170~192) 556 Plug 3
25~34 (18~25) 278 Socket bolt 5 562 O-ring 2
9.8~14 (7.2~13) 279 Socket bolt 3
301 Boom spool sub 1 69~78 (51~58) 601 Main relief valve 1
302 Arm 1 spool 1 69~78 (51~58) 602 Over load relief valve 2
303 Swing spool 1 69~78 (51~58) 603 Over load relief valve 3
Plug assy for relief valve
304 Bucket spool 1 69~78 (51~58) 604 2
hole
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
311 Option spool 1
W2-3-11
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. Tools Q.ty Remarks

a Vise 1
1 of each
b Box and wrench 24 mm, 27 mm, 32 mm
size
1 of each
c Allen wrench 5 mm, 6 mm, 10 mm, 12 mm, 14 mm, 22 mm
size
d Spanner 1 32 mm
e Loctite # 262 1
f Spatula 1
g Pincers 1
h Adjustable wrench 1
W2-3-12
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
2. Disassembling the travel spool (left travel

and right travel)

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).

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
3. Disassembling the boom conflux spool
3.1 Loosen socket bolts (273) and remove

spring cover (201) for boom conflux and O-
ring (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).

use care so as not to score casing A (101).
SM0545
3.3 Fix the boom conflux spool with vise via a

(339) from boom conflux spool (305).
SM0546
4. Disassembling the boom spool

spring cover (203) for boom spool and O-
ring (261), (266).
4.2 Draw out the assy of boom spool (301),

stopper (336) and bolt (333) from casing B
(102).

take care so as not to score casing B (102).
SM0547
W2-3-15
4.3 Fix the boom spool assy with vise via a

(336) from boom spool (301). Do not
disassemble boom spool (301) further
unless there is special reason.
SM0548
5. Disassembling the swing spool

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),
stopper (336) and bolt (333) from casing A
(101).

use care so as not to score casing A (101). SM0549
5.3 Fix the swing spool assy with vise via a

(336) from swing spool (303).
SM0550
W2-3-16
6. Disassembling bucket spool

bucket spring cover (209) and O-ring (261).
SM0801
6.2 Draw out the assy of bucket spool (304),

stopper (336) and bolt (333) from casing B
(102).

use care so as not to score casing B (102).
SM0802
6.3 Fix the bucket spool assy with vise via a

(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
7. 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).

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

spring cover (201) and O-ring (261) of arm 2
spool.

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

from arm 2 spool (308). Do not disassemble
arm 2 spool (308) further unless there is
special reason.
SM0807
W2-3-18
9. Disassembling option spool

spring cover (201) and O-ring (261) of
option spool.

option spool (311), spring seat (331), spring
(323, 324), stopper (336) and bolt (333)
from casing A (101).

SM0808
9.3 Fix the option spool assy with vise via a

from option spool (311).
SM0809
10. Disassembling travel straight spool

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).

take care so as not to score the casing B (102).
SM0810
10.3 Fix the travel straight spool assy with vise
via a protective plate (aluminum plate,
etc.). Remove bolt (333) and separate
spring seat (331), springs (327, 329) and
stopper (336) from travel straight spool
(307).
W2-3-19
11. Disassembling P2 unload spool

spring cover (202) of P2 unload spool and
O-ring (261).

P2 unload spool (310), spring seat (331),
spring (327, 329), stopper (336) and bolt
(333) from 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
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
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
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
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
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 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.

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 SM0823

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
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
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
specified torque. (1 place)
3. Load check valve of arm 2 section
specified torque. (1 place)
4. Lock valve section
5. Main relief valve section
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
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:
apply Loctite #262 when tightening bolt (333).
take care not to deform P2 unload spool (310) because of careless over clamping.
2. 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,
torque.
NOTE:
Take care not to deform travel priority spool (307) because of careless over clamping.
2. 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
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:
take care not to deform option spool (311) because of careless over clamping
2. 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
Assembling arm 2 spool

1. Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.),
NOTE:
take care not to deform arm 2 spool (308) because of careless over clamping.
2. 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
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:
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
W2-3-28
Assembling bucket spool

1. Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum plate, etc.),
NOTE:
take care not to deform bucket spool (304) because of careless over clamping.
2. 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
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.),
NOTE:
take care not to deform swing spool (303) because of careless over clamping.
2. 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
W2-3-29
Assembling boom spool

1. Hold the mid section of boom spool (301) with vise provided with protection plate (aluminum plate, etc.),
NOTE:
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
Assembling boom conflux spool

1. Hold the mid section of boom conflux spool (305) with vise provided with protection plate (aluminum plate,
torque.
NOTE:
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
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.),
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
W2-3-30
Assembling P1 unload spool

1. Hold the mid section of P1 unload spool (309) with vise provided with protection plate (aluminum plate,
torque.
NOTE:
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
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
MAINTENANCE STANDARDS
Inspection of components
Part name Inspection item Criterion and remedy

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
1. Look for scratches, rusting and O-ring.
Casing
corrosion. 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. If a detectable defect with your fingernail is
1. Look for scratches, galling, rusting and
found on the sliding part of the outer
corrosion.
Spool 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.
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,
Poppet 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.
1. Look for rust, corrosion, deformation,
Spring and related parts and breakage of the spring, spring 1. If damaged heavily, replace.
seat, stopper, spacer bolt and cover.
1. Look for rust and damage on outer
1. Replace.
surface.
Main relief valve,
2. Inspect the contact face of the valve
Port relief valve, 2. If damaged, replace.
seat.
By-pass cut valve
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
REMOVAL AND INSTALLATION OF SWING DEVICE
WARNING
Preparation

1-47.

oil tank.
NOTE: be sure to run the vacuum pump

continuously while working.
W2-4-1
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 5 4
drain port Dr.
: 27 mm
1
3. Remove the hoses (4 and 5) from the elbows of

the A, B port. 2
: 36 mm 3
SM0701
4. Remove the hose (6) from the elbow of the PG

port.
8 8
: 19 mm
5. Put in plugs into the opened ports on the swing

motor unit. 7
6. 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

SM0702
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
Installation
1. Clean mating surfaces of swing motor unit and

upper frame. 8 8
2. Apply Loctite FAG3 on entire mounting surface

of swing motor unit.
7
3. Place the swing unit on the upper frame.
NOTE: swing unit weight: 192 kg
4. Remove the lifting eye bolts and inserts on the

holes, the plastic caps (8) M12, previsiously SM0702
removed.
5. Fix the swing unit to the frame by tightening the

screws (7) (q.ty 13). 6
: 30 mm 5 4
: 539 54 Nm
1
6. Install the hoses (4 and 5) on the elbows of port
A and B.
2
: 30 mm
: 108 Nm 3
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
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
33
27 44
20 1
21
31
2
15 3 17 13-14
16 43 29 42 12 30
19 A A
43 32
38
37
35
36
4
41
6
25 40
26 8
24 9
7
A-A
45
18
11 28 34 5 10
SM0703
1- Relief valve (q.ty 2) 16 - O-Ring (q.ty 2) 33 - O-Ring (q.ty 2)

2- O-Ring (q.ty 2) 17 - Socket bolt (q.t: 4) 34 - Oil seal
3- Swing shockless valve 18 - Swing motor casing 35 - Brake piston
4- Shockless valve casing 19 - Valve casing 36 - O-Ring
5- Drive shaft 20 - Plunger (q.ty 2) 37 - O-Ring
6- Cylinder 21 - Spring (q.ty 2) 38 - Brake spring (q.ty 16)
7- Spring 24 - Swing shockless valve (q.t: 2) 39 - Friction plate (q.tty 3)
8- Piston (q.ty 9) 25 - O-Ring (q.ty 2) 40 - Separation plate (q.ty 4)
9- Shoe 26 - Backup ring (q.ty 2) 41 - Plug (PF 1/4)
10 - Set plate 27 - Socket bolt (q.ty 4) 42 - Roller bearing
11 - Shoe plate 28 - Roller bearing 43 - Plug (PF 3/4) (q.ty 3)
12 - Valve plate 29 - Plug (PF 3/8) 44 - Plug (PT 1/2)
13 - Plug (q.ty 2) 30 - Pin (q.ty 2) 45 - Plug (PT 3/4)
14 - O-Ring (q.ty 2) 31 - Plug (q.ty 2)
15 - O-Ring (q.ty 2) 32 - O-Ring
W2-4-4
Preliminary operations
1. Hydraulic components are precision products 3. Study the structural drawing before the work
and have small clearance. Therefore, begins and prepare necessary parts according
assemble and disassemble in a less dusty to your purpose and the scope of work. Seals
clean place. Use clean tools and cleaning oil and O-Rings once removed can not be used
and handle components with full care. again.
2. If a component is removed from the main body, 4. The piston and the cylinder block are shop fitted
clean the area around the ports thoroughly and when new. If you intend to reuse them, put a
plug them up so no dust and water do not enter. matching mark on the piston and the cylinder
When fitting them back to the body, do not block.
remove the plugs till piping is completed.
Disassembly
1. Remove the drain plug and drain hydraulic oil

from casing (18). 3
17 12
2. Fix the motor on a work bench so the drive shaft 19 1
(5) end comes down. On that occasion, put a
matching mark on the mating parts of casing 38
(18) and valve casing (19).
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. Loosen relief valve (1) and separate it from 18

valve casing (19).
: 41 mm
4. Loosen anti-reaction valve sub assy (3) and

remove from valve casing (17).
: 6 mm 5 SM0704
5. Separate plugs (31) from valve casing (19) and

draw out springs (21) and plungers (20).
: 17 mm 27
6. 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 20

(19).
21
: 17 mm
31
SM0705
W2-4-5
8. Draw out brake spring (38) from brake piston

(35). 38
9. Draw out the brake piston (35) with the special

tool (xxxxxxxxx).
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 11 7 8
(28) from casing (18), by lightly tapping the
steel rod from the oil seal (34) housing side.
c. Separate the outer race of roller bearing (42)
from valve casing (19), using a slide hammer
bearing puller.
IMPORTANT: do not reuse the bearing.

5
10 39 40 6
SM0707
34
28
18
SM0708
W2-4-6
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).

5 34 28 18
SM0709
3. Insert shoe plate (11).
4. Set the set plate (10) and spring (7), then set
piston sub (8, 9) assy. 8 6
9 7
5. Assemble piston sub assy (8, 9) fixed in
retainer plate (10) into cylinder (6), match it to
the spline of drive shaft (5) and insert it in place.
6. Place casing (18) with oil seal facing downward 11

and assemble separator plate (40) and friction 10
plate (39) into casing (18).
SM0710
39
40
SM0711
W2-4-7
7. Fit O-rings (36), (37) to casing (18).
8. Assemble brake piston (35) into casing (18). 36 37
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.
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
17 42 12
12. Install valve casing (19) to casing (18) and
fasten them with socket bolts (27). 19 1
: 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).
: 14 mm 18
: 334 Nm
14. Fit relief valve (1) to valve casing (19).

: 41 mm
:177 Nm 5 SM0713
15. Fit anti-reaction sub assy (3) to valve casing

(19).
: 6 mm 27
: 29 Nm
20
21
31
SM0705
W2-4-8
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
1- Pinion shaft 11 - Spherical bearing 22 - Spring pin (q.ty: 4)

2- #1 sun gear 12 - Oil seal 23 - Socket bolt (q.ty: 11)
3- #1 pinion (q.ty: 3) 13 - Housing 24 - Cap (q.ty: 2)
4- #2 sun gear 15 - Thrust washer (q.ty: 6) 25 - Tube
5- #2 pinion (q.ty: 4) 16 - Needle bearing (q.ty: 3) 26 - Elbow
6- Ring gear 17 - Needle bearing (q.ty: 4) 27 - Plug
7- #1 spider assy 18 - Thrust washer (q.ty: 8) 28 - Snap ring (q.ty: 3)
8- #2 spider assy 19 - Snap ring 30 - Oil seal
9- Shaft (q.ty: 4) 20 - Snap ring 31 - Grease fitting
10 - Spherical bearing 21 - Sleeve 32 - Relief fitting
W2-4-9
Preliminary operations:
1. Before disassembly, clean thoroughly the

swing reduction unit outer, checking for no
damage or scratches. 23
2. Drain out the gear oil from reduction unit.
3. Remove the draining pipe.

x
4. In order to case the re-assembly, before x

27
disassembly put a matching mark (X) on the
parts to be connected on the reduction casing.
SM0715
Disassembly
7 2
1. Place the reduction unit assy on a stable work
bench as shown in figure, remove plug (27),
drain out oil put a matching mark on the
matching surface of the figure on the right side.
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 flat-
blade screwdriver in the groove of the flange. SM0716
: 12 mm
3. Remove #1 sun gear (2).
4. The spider assy (7) [consisting of thrust

6
washers (15), #1 pinions (3), needle bearings
(16) and snap rings (28)] can be removed from
13
the spline easily if it is lifted up in that condition.
5. 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 SM0717
circumference of the ring gear with a plastic
mallet.
4 8
6. Draw out #2 sun gear (4) and remove the #2
spider assy (8).
SM0718
W2-4-10
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 20 1

(12) are left in the housing.
9. 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
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.
11. Remove oil seal (12) from housing (13). 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 16 28 15
13. Disassembling #2 spider assy performing the

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
24
18
22
SM0724
W2-4-12
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
30
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 21

shaft (1) lightly to prevent seizure.
6. Seal sufficient grease in spherical bearing

(lower) (11) and force it in pinion shaft (1) by SM0725
means of special tool (xxxxxxxxx).
Press force: 4~5 t
NOTE: since the bearing is formed with a partition at

the center section, seal grease in it from both sides.
21 30
SM0726
xxxxxxxxx
1 11
SM0727
W2-4-13
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 SM0728
downward and fit oil seal (12) in housing (13) by

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
10. Press fit spherical bearing (upper) (10) in pinion

shaft (1) and housing (13) at the same time by 1 10 xxxxxxxxx
11. Attach retaining ring (20).
12. Assemble #1 Spider assy performing the

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. 13
b. Fit thrust washers (15), pinions (3) and fit
snap rings (28) by means of pliers.
SM0731
20
SM0732
3 16 28 15
15
SM0733
W2-4-15
13. Assemble #2 Spider assy performing the

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 6 - 7 mm
14. Insert #2 spider assy (8) in spline axis of pinion
shaft.
8 9 18
15. Install #2 sun gear (4) directing the spline 5

upward.
17
22
SM0734
SM0735
SM0736
W2-4-16
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
17. Mesh the #1 spider assy (7) with ring gear (6) 13
and set them in place.
x
18. Mesh #1 sun gear (2) with #1 pinions (3) and
set them in place.
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 6

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.
: 12 mm SM0738
: 181 Nm
23
x 25
x
27
SM0739
W2-4-17
MAINTENANCE STANDARDS
Swing motor
Unit: mm (poll.)
Recommended
Standard
Item value for Remedy
dimension (mm)
replacement (mm)
Clearance between piston and cylinder
bore (D-d)
D 0.027 0.052 Replace piston or cylinder.

d
Gap between piston and caulked part of

shoe (d)
0 0.3 Replace piston and shoe assy.
Thickness of shoe (t)
5.5 5.3 Replace piston and shoe assy.
Thickness of friction plate (t)
2.0 1.8 Replace.
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

Standard surface Surface roughness
Name of parts
roughness requiring correction
Shoe 0.8Z (Ra=0.2) (lapping) 3Z (Ra=0.8)
Shoe plate 0.4Z (Ra=0.1) (lapping) 3Z (Ra=0.8)
Cylinder 1.6Z (Ra=0.4) (lapping) 12.5Z (Ra=3.2)
Valve plate 0.8Z (Ra=0.2) (lapping) 6.3Z (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 reduction gear
A D
C
D
C
B
SM0740
Code Item Repairable level (mm) Service Limit (mm) Remedy
0 Replace entire
A Wear in #1 planetary shaft 39 -0.011 spider assy
No flaking
0 Replace four shafts
B Wear in #2 planetary shaft 29 -0.009 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
C Gears
Condition of replaced in a set of
There should be no cracks four.)
tooth flank
D Thickness of thrust washer 0 1.3 Replace

1,6-0.2
E Thickness of thrust washer 0

2.0-0.2 1.6 Replace
Wear in shaft (diameter of

F part coming in contact with 0 94.9 Replace
95-0.087
oil seal)
W2-4-19
NOTE:
W2-4-20
REMOVAL AND INSTALLATION OF RIGHT AND LEFT PILOT VALVE
WARNING
Preparation
1. Park the machine on a firm, level surface. Releasing the hydraulic pressure at page. T2-
1-47.
2. To drain the hydraulic pressure from the the hydraulic oil cap to release any residual
Hydraulic System, refer to procedure pressure present in the tank itself.
Removal
1. Free and lift rubber cap (5) complete with plate
(4) unlocking its hooks using a screwdriver.
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
Installation
1. Install pilot valve (9) on the frame tightening

7 7
securing screws (20) M6x25 complete with
washers.

: 5 mm

: 11.8 Nm (8.7 lbfft)

3
2. Connect hoses to pilot valve body (9).
3
: 19 mm (Port: P) 60
: 29.4 Nm (22 lbfft)
: 22 mm (Port: 1 to 8, T)
LEFT SIDE RIGHT SIDE
: 49 Nm (36 lbfft)
BUCKET
5 SWING (L) GRAY 1 RED
(H)
3. Tighten the handgrip on the pilot valve (9), BUCKET
tighten lock-nut (6) and reconnect the electric 6 SWING (R) RED 2 BLUE
(R)
connector. 7 ARM (H) BLUE 3 BOOM (H) GREEN
: 22 mm
8 ARM (R) GREEN 4 BOOM (R) GRAY
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).

60
W2-5-2
REMOVAL AND INSTALLATION OF TRAVEL PILOT VALVE
WARNING
Preparation
1. Park the machine on a firm, level surface. Releasing the hydraulic pressure at page. T2-
1-47.
2. To drain the hydraulic pressure from the the hydraulic oil cap to release any residual
Hydraulic System, refer to procedure pressure present in the tank itself.
.
Removal
1. Remove the cover under the cab
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. 60
6. Remove body (8) removing securing screws (9)

complete with washers.
: 17 mm
W2-5-3
Installation
1. Install body (8) on the frame tightening securing

screws (9) complete with washers.
: 17 mm
: 37 Nm (27.4 lbfft)
2. Connect pipes (from 3 through 6) to body (8).

: 19 mm
: 16.7 Nm (12.3 lbfft)
: 22 mm
: 30 Nm (22.0 lbfft)
3. Connect pressure sensors (7) to body (8).

: 24 mm
: 16.7 Nm (12.3 lbfft)
4. Install the levers tightening securing screws (2)

and the pedals tightening securing screws (1).
: 17 mm
: 46.1 Nm (34.1 lbfft)

: 13 mm

: 23.5 Nm (17.4 lbfft)

5. Install the cover under the cab 60
: 19 mm
: 108 Nm (80.0 lbfft)
W2-5-4
DISASSEMBLY RIGHT AND LEFT PILOT VALVE
60
1- Adjusting nut M14 7- Plug (Q.ty 4) 17- Spring (Q.ty 2)

2- Boots 8- O-Ring (Q.ty 4) 18- Spring (Q.ty 2)
3- Circular plate 9- Push rod (Q.ty 4) 19- Washer 2 (shim) (Q.ty 4)
4- Joint M14 12- Spring seat 1 (Q.ty 2) 20- Spool (Q.ty 2)
5- Plate 14- Spring seat 1 (Q.ty 2) 21- Spool (Q.ty 2)
6- Seal (Q.ty 4) 15- Spring (Q.ty 4) 22- Casing
W2-5-5
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 every disassembly

operations, as a rule.
1. Plug each port of pilot valve, and clean it.

P Port : PF 1/4
14 Port and T: PF 3/8
2. Fix pilot valve with vise, via a protective plate

(Alminum plate etc.), and remove boot (2).
60
3. Remove adjusting nut (1) applying spanners to
circular plate (3).
: 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
6. Remove plate (5).

NOTE: When the force of return spring (15) is
high, press plate to let it come up slowly.
When the force of return spring (15) is low, plug (7)
is left in casing (22) due to sliding resistance of O-
Ring (8).
60

60
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

60
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
W2-5-7
9. 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.
60
W2-5-8
ASSEMBLY RIGHT AND LEFT PILOT VALVE

60
1- Adjusting nut M14 9- Push rod (Q.ty 4) 18- Spring (Q.ty 2)

2- Boots 10- Spring (Q.ty 4) 19- Washer 2 (shim) (Q.ty 4)
3- Circular plate 11- Spring seat 2 (Q.ty 2) 20- Spool (Q.ty 2)
4- Joint M14 12- Spring seat 1 (Q.ty 2) 21- Spool (Q.ty 2)
5- Plate 13- Spring seat 2 (Q.ty 2) 22- Casing
6- Seal (Q.ty 4) 14- Spring seat 1 (Q.ty 2) 23- 2E4 Port
7- Plug (Q.ty 4) 15- Spring (Q.ty 2) 24- 1E3 Port
8- O-Ring (Q.ty 4) 17- Spring (Q.ty 2)
W2-5-9
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
4. 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).

60
6. Fit plug (7) assy to casing (22).

60
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
W2-5-11
7. nstall joint (4) on casing (22) with special tool

(E) (380001055) securely.
: 22 mm
: 47.12.9 Nm (34.82.1 lbfft)

(
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
: 68.64.9 Nm (503.6 lbfft)
: 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 (FOR TRAVEL)

CONSTRUCTION
R
R
K
R
\
\
[ [

I
G
/RFWLWH
J
7
J
O
T
7 U
X
W 7
L 7

N 7
K X
W 7
M W
X
U
T
7
/RFWLWH

]
U
Z
7 aa
60
NOTE: T=tightening torque Nm (lbfft)

5 Rubber boots 2 12-x Seal 14203 6
6 Foot pedal (Switch plate) (2) 12-y Wiper ring 6
6-d Switch plate 2 13 Damper spring 4
6-f Regulation screw M828 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 (1) 15 Orifice (4)
7-h Plate 1 15-u Plug M6 4
7-i Capscrew M1020 2 15-t Orifice M6, 0.6 4
7-j Shaft 2 17 Shuttle valve kit (2)
7-k Set screw M410 2 17-w Shuttle valve & orifice 2
8 Flange kit 4 17-r Ball M6, 35 2
10 Control spool 4 17-z Orifice M5, 0.8 2
11 Return spring 4 21 Plug 4
12 Damper flange kit (4) 22 Valve body 1
12-o Damper plunger 14 4
W2-5-13
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: K
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.
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. N
Torque: 1.2 Nm (0.89 lbfft) &
I
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 M
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. 60
6) Reassemble parts in reverse order.
W2-5-14
3. 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 (lbfft)
2) Set the switch plate (6) horizontally
3) Screw on simultaneously both regulation J
screws (6-g) using a flat screw driver
(5.5x150) until feeling some resistance.
NOTE: do not misadjust the two damping screws

(6-l).
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.
I O
4. Retaining plate removal (7-h)
1) Remove
Both rubber boots
Both switch plates (6)
2) Unscrew simultaneously both screws (7-i)
holding the retaining plate using a 8 mm
socket wrench.
* Reassembly : 60
screw thread.
Torque: 30 Nm (22 lbfft)
L
K
60
W2-5-15
3) Lift the retaining plate (7-h) to remove it.

K
* Reassembly:
Use the retaining plate (7-h) to insert the 4
guides into the body simultaneously and
perpendicularly (22).
5) Drain the pilot control unit.
5. 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: R
Replace with a new wiper ring (12-y). \
$ %
60
CAUTION
Always place the damping plunger (12-o) prior to
the wiper ring (12-y), and make sure the wiper ring K
(12-y) is correctly positioned.
\
3) Remove the damping plunger (12-o).
4) Using a needle, remove the seal (12-x) [
placed inside the body (22)
* Reassembly: R
Replace with a new seal and grease it.

60
[
$ %
60
W2-5-16
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.
$ %
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 & ' 60
are detected, replace the 4 springs.
6. 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 sub-
assemblies.

5) Visually check that the guides / plungers are
in good condition. If defects are present,
replace the 4 sub-assemblies.
60
W2-5-17
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.

60
7. Throttle kit replacement

1) Remove X
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:
screw thread

Screw on until it sets just above the body 60
(22).
W2-5-18
3) Unscrew the throttle (15-t) using a 3 mm

socket wrench.
* Reassembly:
4) Repeat the operation for the other 3
assemblies.
5) Replace with new screws (15-u) and new
throttles (15-t).
X
W
60
8. Shuttle valve kit removal (17)

1) Remove the pilot control unit from the
machine

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.
shuttle valve thread (17-w).
60
IMPORTANT: wait for 8 hours before using the

machine to let the Loctite #242 dry completely.
Z
60
W2-5-19
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.
60
W
Z ]
60
9. Check valve kit removal (14)

T
1) Remove the pilot control unit from the
machine

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 lbfft) 60
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), O-
rings and balls (14-r). If defects are
detected, replace all the assemblies.

T
U 60
W2-5-20
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. T
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 lbfft)
60
8. Repeat the operation for the other check valve
plug.
W2-5-21
NOTE:
W2-5-22
UNDERCARRIAGE
CONTENTS
Group 1 - Swing bearing Tool table ............................................... W3-5-4
Removal and installation of swing Group 6 - Upper and lower roller

bearing .................................................. W3-1-1
Removal and installation of upper
Group 2 - Travel device roller ...................................................... W3-6-1
Removal and installation of travel Removal and installation of lower

device (E215B) ..................................... W3-2-1 roller ...................................................... W3-6-4
Disassembly travel device .................... W3-2-2 Upper roller disassembly........................ W3-6-7
Disassembly and assembly of travel Upper roller assembly ............................ W3-6-7

device (E215B) .................................... W3-2-3 Lower roller disassembly........................ W3-6-11
Maintenance standard ...................... W3-2-61
Lower roller assembly ............................ W3-6-13
Sprocket............................................ W3-2-61
Maintenance standard............................ W3-6-15
Removal and installation of travel
device (E245B) ..................................... W3-2-63 Tool table ............................................... W3-6-16
Disassembly procedure of travel device
Group 7 - Tracks
(E245B)................................................. W3-2-67
Removal and installation of tracks ......... W3-7-1
Assembling procedure of travel device
(E245B)................................................. W3-2-80 Maintenance standard............................ W3-7-5
Motor...................................................... W3-2-88 Tool table ............................................... W3-7-7
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
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
SWING BEARING E215B-E245B
REMOVAL AND INSTALLATION OF SWING

BEARING
WARNING
Wear close-fitting clothing and safety equipment ap-
propriate to the job. Use tools appropriate for the job
to be performed. Always ensure that slings and
chains used for lifting are adequate to the load and
in good condition.
Before removing the swing bearing, the upperstruc-

ture must be removed first. For removal and instal-
lation of the upperstructure, refer to Remove and
Install Main Frame section. In this section, the pro-
cedure 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 rele-

vant 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 sur-
faces 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). 6
2. 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 rele-

vant washers (Q.ty 36) and tighten them to the
prescribed torque.
: 30 mm
: 563 56 Nm (415 41 lbfft)
NOTE - Fill in greasebath with 8.6 0.86 kg of IP BI-

MOL 481 or equivalent grease.

60
TOOL TABLE
TOOL NO. DESCRIPTION

380001026 Lifting tools slewing ring
W3-1-2
REMOVAL AND INSTALLATION OF TRAVEL DEVICE (E215B)
WARNING
Preparation
1. Park the machine on a firm, level surface. 3. Cut-off the engine. Press the valve located on
2. To drain the hydraulic pressure from the Hy- the hydraulic oil cap to release any residual
draulic System, refer to procedure "Releasing pressure present in the tank itself. Remove hy-
the hydraulic pressure" at page. T2-1-47. draulic oil tank cap. Connect a vacuum pump to
maintain negative pressure in the hydraulic oil
tank.
NOTE: be sure to run the vacuum pump continu-

ously while working.
Removal
The procedure starts on the premise that the track 2. Attach the travel device to a crane using a wire
link has already been removed. rope. Remove any slack from the wire rope so
1. Loosen bolts M12 (7) to remove cover (6). Dis- as to secure the travel device when the mount-
connect hoses (2), (3), (4) and (5). ing bolts are removed.
: 19 mm
NOTE: Travel device weight:
: 29.4 5 Nm (21.7 3.7 lbfft)
Approx. 300 kg (661.5 lbs).
: 27 mm
: 78.5 5 Nm (57.9 3.7 lbfft)
: 36 mm 3. Remove bolts M16 (1). Remove the travel de-
: 177 18 Nm (130.5 13 lbfft) vice using the crane.
: 24 mm
: 279 29 Nm (206 21 lbfft)
NOTE: Install caps on all disconnected hose and
line ends.
W3-2-1
Installation DISASSEMBLY TRAVEL DEVICE

1. Install the travel device using bolts (1).
Preliminary operations
2. Connect hoses (2), (3), (4) and (5).
3. Install cover (6) and fix it with screws (7) and In the case that it was necessary to undergo a (par-
washers (8) and (9). tial or total) revision, it will be necessary to dismount
: 19 mm the gearmotor from the machine. As this is known as
: 83.4 8.4 Nm (61.5 6.2 lbfft) an out of the ordinary maintenance procedure, it is
important that only personnel with specific skills and
IMPORTANT - After completing travel motor instal- experience undertake it.
lation, be sure to fill the travel motor with hydraulic It is also important that this procedure is undertaken
oil. After completing installation of the travel motor in a workshop that is adequately tooled. As well as
or the travel device, be sure to perform test driving normal workshop tools it will be necessary to use
to prevent motor seizure. Test drive as follows: special tools.
1. Run the engine with the engine control dial in In the following pages all the procedures for disas-
the slow idle position. sembling and reassembling the gearmotor are giv-
2. Turn the travel speed mode switch to the slow en, it is important to strictly adhere to them.
speed position. Proceed with these operations using all the neces-
3. Test drive the machine back-and-forth for 0.5 m sary safety measures, like for example:
to 1 m in each direction five times or more.
1. Cutting off all the hydraulic system connections
on the gearmotor to avoid the introduction of
4 5 any foreign parts in the circuit and the gearmo-
tor.
2. Making sure that the coupling surfaces are not
3 damaged.
3. Following the handling so as to be sure that
2 there are no risks for human safety and to guar-
antee the reliability of the gearmotor.
4. Making available a work area that is in line with
work and health safety in the workplace guide-
lines.
8
1
NOTE: Initial inspection of hydraulic motor and
7 6
gears, can be made without disassembling the track
drive from the machine.
9 SM0300
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

1. By using a tackle place the gearbox unit (1) on
a spacer (2).

60
2. 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 TRAVEL DEVICE
4. 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 E215B
8. Remove the 2nd reduction assembly (9).

60
9. By using pliers remove the circlips (10) from

their seats placed in the hydraulic motors 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 disas-

sembly, it is now necessary to remove it from the
machine and bring it to a properly equipped work-
shop.
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 us-
ing 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 gear-
box 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 gear-

box 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 mo-

tor 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

second plug (4).

60
W3-2-9
E215B TRAVEL DEVICE
5. 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

third plug (7).

60
W3-2-10
TRAVEL DEVICE E215B
9. Remove the 1st spring (8) from the plunger assy

(9).
60
10. Unscrew the fourth plug (10) from the flushing

valve (2).
60
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 flush-
ing 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

60
W3-2-14
TRAVEL DEVICE E215B
plug (21).

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

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

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 E215B
41. Take out the spring seat (30) from the second
flanged plug (29).

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

60
W3-2-20
TRAVEL DEVICE E215B
49. Remove the O-ring seals (38) from the plugs

(39).

60

60
51. Unscrew the nos. 4 orifices M5 (41) from the

base plate (17).

60
52. Remove the caulking with a M5 tap before un-

screwing the orifices.
60
W3-2-21
E215B TRAVEL DEVICE
53. Unscrew the nos. 2 orifices M5 (42) from the

base plate (17).

60

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
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 shift-

ing 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 pis-
ton (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 E215B
72. Remove the swash plate (60) from the flanged

hub (44).

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

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 re-

placement, because this will damage it.
NOTE - The disassembly ends with the above oper-

ation.
All items are now available for the necessary in-
spections.
60
W3-2-28
TRAVEL DEVICE E215B
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 proper-
ly 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 individ-
ual 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 TRAVEL DEVICE
Hydraulic motor reassembling method

Reassembly of motor shaft and cylinder block
1. Assemble the back-up ring (66) inside its seat
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
4. By using a plastic hammer and a metal stopper,

completely assemble together the bearing (65)
and the motor shaft (64).

60
W3-2-30
TRAVEL DEVICE E215B
5. Place the bearing-motor shaft sub-assembly

(65-64) in the seat inside the flanged hub (44).

IMPORTANT - Be careful when inserting the shaft
inside the motor seal (52).
60

completely assemble together the bearing-mo-
tor 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 TRAVEL DEVICE
9. Assemble the nos. 2 pistons (62) into their

seats inside the flanged hub (44).
NOTE - Be sure that the pistons (62) can move free-

ly 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

60
12. Assemble the spherical retainer holder (57) on

NOTE - The two splines must be aligned together.

60
W3-2-32
TRAVEL DEVICE E215B
13. The orifice of the piston (58) must be open and

free of dust or dirt.
60
14. Assemble correctly the nos. 9 pistons (58) in

the retainer plate (59).

60
15. Assemble the pistons-retainer plate sub as-

sembly (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 assem-
bled.
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

push the bearing into the base plate (17) shoul-
der until assembly is complete.

60
26. Place the valve plate (46) on the base plate

(17).
IMPORTANT - Bronze layer surface must be up-

wards.
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 lbfft)

60
30. By using the tool (C) (XXXXXXXXX), fit the O-

ring 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 lbfft)
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 lbfft)

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 lbfft)

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 lbfft)
60
W3-2-38
TRAVEL DEVICE E215B
36. By using a punch and a hammer deform the

thread hole (69).
60
Reassembly of the flanged plug assy

37. By using the stopper (D) (XXXXXXXXX), as-
semble the O-ring in its seat in the plug (35).
'

60
38. Tighten the plugs (35) by a torque wrench at

20.6 1 Nm torque.
: 20.6 1 Nm (15.2 0.7 lbfft)
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 E215B
44. Insert the first spring seat (32) on the counter-

balance valve spool (33).

60
45. Insert the first spring (31) on the counterbal-

ance 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 lbfft)
60
49. Insert the second spring seat (32) on the coun-

terbalance valve spool (33).
60
50. Insert the second spring (31) on the counterbal-

ance 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 lbfft)
60
Reassembly of the relief valve assy

54. By using the stopper (E) (XXXXXXXXX), as- (
semble 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 lbfft)
60
W3-2-44
TRAVEL DEVICE E215B
Reassembly of the two speed control

60. By using the tool (F) (XXXXXXXXX), fit the O-
ring 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 lbfft)

60
62. Insert correctly the two speed spool kit (22) in

the base plate (17).
NOTE: Two speed spool (22) have to move smooth-

ly inside its seat in the base plate (17).

60
63. Insert the spring (20) in the second speed spool

(22).
60
W3-2-45
E215B TRAVEL DEVICE
64. Insert the spring seat (19) in the spring (20).
60
65. By using the tool (F) (XXXXXXXXX) fit the O-

ring 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 lbfft)
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 lbfft)

60
69. Assemble the O-ring seals (14) into its seat in

the flushing valve (2).
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 lbfft)

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 O-

ring seal in its seat in the plug (10).

60
W3-2-48
TRAVEL DEVICE E215B
76. Insert the first plug (10) in the flushing valve (2)

and tighten by a torque wrench at 67 5 Nm
torque.
: 67 5 Nm (49.4 3.7 lbfft)
60
77. Insert the second spring seat (12) in the oppo-

site side of the plunger assy.
60
78. Insert the second spring (8) on the plunger as-

sy.
60


60
W3-2-49
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 lbfft)
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


60
W3-2-50
TRAVEL DEVICE E215B
84. Insert the third plug (4) in the flushing valve (2)
torque.
: 67 5 Nm (49.4 3.7 lbfft)
60


60
86. Insert the fourth plug (1) in the flushing valve (2)

torque.
: 67 5 Nm (49.4 3.7 lbfft)
NOTE - it is suggested to operate like that when mo-

tor 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).

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 (surfac-
es 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 for-
eign substances; metallic ring surfaces (F)
must be perfectly clean and dry. We suggest to
dip the metallic rings in volatile solvent or indus-
trial degreasing alcohol.
3. Carefully clean the lapped surface (D) of met-
al rings (E) and remove dust or fingerprints.
Then lubrificate them with a thin oil film, taking 60
care not to oil the other components.
W3-2-53
E215B TRAVEL DEVICE
5. 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 hydrau- +
lic 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 me-
tallic 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 lbfft) corre-
sponding to an output multiplier torque of
7250 250 Nm (5347 184 lbfft).

60
W3-2-56
TRAVEL DEVICE E215B
12. Stake the ring nut (8) near 2 seats of the hy-
draulic motor.

60
NOTE - Stake 45 mm (depth 11,5 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 E215B
18. Insert the 1st reduction assembly (15).

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 hous-

ing (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 lbfft)

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 lbfft)
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 indica-
tions 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 regula-
tions.
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) Remedy

A 68 (2.67) 60 (2.36)
B 584.7 (22.80) 575 (22.42)
Build up and
C PCD644.6 (25.14) -
finishing
D 659 (25.70) 648 (25.27)
E 190 (7.41) -
W3-2-61
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
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 at-
tachment, and put it on square timbers to float
and stabilize.
Removing cover
2. Remove sems bolt (6) M12x25 and also re-
move covers (1). 6
: 19 mm 1
60
3. Preparation of oil pan.
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 en-
try 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
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
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 start-
ing operation, operate motor in low idling and at
low speed for several minutes, and check it for
possible oil leakage and noise.
TIGHTENING TORQUE
NAME SIZE TOOLS No. REMARKS
(N/m)
Bolts M12 19 6 83.4 (61.5 lbfft)
Apply Loctite #262
Capscrew M16 24 3 279 (206 lbfft)
10X1.5 19 - 49 (36.1 lbfft)
Flareless nut for pipes,
18X2.5 32 - 147 (108 lbfft)
sleeve
28 41 - 275 (203 lbfft)
PF1/4 19 - 29.4 (21.7 lbfft)
Hose cap
PF1/2 27 - 78.5 (57.9 lbfft)
PF1/4 19 - 36.3 (26.8 lbfft)
Connector PF1/2 27 - 108 (79.7 lbfft)
PF1 41 - 255 (188 lbfft)
W3-2-66
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).
14,15,33,34
3. Then separate plug (15), O-ring (14), spring
(34) and ball (33).
: 10 mm 8 17
: 14 mm. 9
10
12
NOTE: cap (11) is pressed out by spring (9). 11
Therefore, do the work, taking care of the following 13 60
- Loosen socket bolts (13) evenly all round
- Loosen socket bolts (13), holding down cap (11).
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 turn-
ing it by hand.
IMPORTANT: plunger (3) and base plate (2) have a

very tight fit. Therefore, do the work, paying atten-
tion 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 2
by force, the bore surface of base plate (2) and the
outer surface of plunger (3) are scored. 3
- In case the plunger gets stuck halfway, do as fol- 60
lows:
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 neces-
sary; the outer surface of it may be scored at dis-
assembly.
W3-2-67
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) re-
mains 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 17-6 2
screw (17-15). If the set screw is turned, the set 17-16
17-15
pressure of the relief valve changes, making the
motor unable to attain required performances. 17
- Do not disassemble the relief valve assy. 60
Otherwise, the set pressure changes and the mo-

tor is unable to attain required performances.
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.
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 turn- 25
21
ing it.
IMPORTANT: Spool (19) and base plate (2) are

combined to a very small fit. For this reason, exe- 2
cute the work, paying attention to the following:
- Do not disassemble spool (19) unless necessary. 19
- In case the spool gets stuck halfway, do not force
it out. If the spool is forced out, the bore surface of 22
base plate (2) and the outer surface of spool (19) 60
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 neces-

sary.
5. Orifices (28), (29), (30) are caulked so they do
not get loose.
Do not disassemble them.
W3-2-69
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 2
it is wrenched, bring knock pin (60) back in place
by lightly tapping base plate (2) with a plastic mal-
let and remove the knock pin. 60
- When removing base plate (2), valve plate (62)
comes with base plate (2). Since the moving sur- 60
face of valve plate (62) tends to be scored, use

care so valve plate (62) does not fall.
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, de-
sired 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 56
may be injured as brake piston (56) pops out.
For this reason, keep the air pressure less than 57
58
0.29 MPa (43 psi) and do the work, holding down 54
55
brake piston (56) so brake piston (56) does not 54
jump off. 54 55
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 sur-
face of cylinder block (37) in contact with valve
plate (62). If the surface is scored, desired per- 37
formances will not be attained.
- Exercise care so as not to score the moving sur- 1
face of the shoe of piston assy (38). Desired per-
formances will not be attained if the surface is
scored.
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
60
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).
39
38 60
W3-2-72
TRAVEL DEVICE E245B
5. Separate retainer holder (40) from cylinder

block (37). Then take off pin (45) from cylinder
block (37).
45
37
40 60
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 41
jig, bend spring (43) and take off snap ring (41),
using snap ring pliers.
%
37
60
IMPORTANT: When removing snap ring (41), take 44

care as below, so as not to injure yourself:
- If snap ring (41) is tight to remove with snap ring 43
pliers, you may injure yourself when the snap ring
comes off from the pliers; 42
- 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 37

seat (42) from cylinder block (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 re-

moving 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.
46
- Swash plate (46) comes off with piston assy (38)
and steel ball (47) in some cases. On that occa-
sion, use care so piston assy (38) and steel ball
(47) do not fall. 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). 61
3. Separate steel balls (47) from flange (1).
NOTE: Since steel balls (47) are hard to come off, 48

do it as below:
- Degrease steel balls (47) fixed in flange (1), using 47
kerosene or thinner;
- Separate steel balls (47) from flange (1), using a
magnet. 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 36
oil seal (53) in shaft (36) is not scored. If it is scored,
oil leakage occurs. 49
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 reduc-
tion unit by crane. 1
2. Remove two plugs (97) and drain lube oil from
the reduction unit.
: 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 96
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 mal-
let.
Put a flat-blade screwdriver between cover (95) and 72
housing (72) and take off cover (95).
95 60
W3-2-75
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 bear-
ing (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 87
88
care of the following: 89
Screw (92) is coated with Loctite and hard to get 90
slack. If you loosen it by force, it is scored and can 91
not be reused. Heat the screw with a hair dryer be- 60
fore loosening it.
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.
1
2. Next, separate thrust plate (81), planetary gear
C (80), needle bearing (79), inner race (78) and
thrust plate (77), in that order.
: 17 mm 79
WARNING
Bolt (82) is coated with adhesive Loctite to prevent
it from loosening. Fix flange (1) securely for that rea-
son. 78
80 77
When loosening bolt (82), use a tool with a suffi- 81
ciently long extension such as iron pipe. If you do 82
60
not use it and try to loosen by force, you may injure
your waist or other parts.
Removing holder C
1. Fix flange (1) and loosen and remove bolt (76).
2. Holder C (74) is fixed to flange (1) with pin (99).
3. Attach the removing jig from the motor side and
separate holder C (74) by the use of a press.
74
: 17 mm
WARNING 76
99
When loosening bolt (76), use care of the followin:
Coat bolt (76) with screw locking agent to prevent it 60
from loosening. For that purpose, fix flange (1) se-
curely.
To loosen bolt (76), use a tool with a sufficiently long
extension such as an iron pipe. If you loosen it by
force, you may injure your waist or yourself in some
cases.
W3-2-78
TRAVEL DEVICE E245B
Separating flange from housing

1. Attach a jig to the end face on the outer flange
of housing and separate flange (1) from hous-
ing (72) by pressing flange (1) by press. &
1
99
72
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 disassem-
bled parts thoroughly, coat them with a thick film of
rust preventive oil, put them in plastic bags and
store them in a cool, dark, dry place.
NOTE: If the parts are stored in a hot humid place,

they may be rusted even if rust preventive oil is ap-
plied. 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 sur-

face 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 for-

eign matter on the surface on which floating seal 72 60
(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
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 hy-
draulic oil to all sliding surface of seal ring located 1
in floating seal (70).
- When assembling housing (72) into flange (1),
make sure that the shaft centers are aligned with
each other. 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), us- 74
ing the shim thickness (F) adjusting jig.
2. In that case, measure the step H between the h
end face of the inner race of angular bearing
(71) and the end face of flange (1).
Press load: 3000 kgf
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). H
71
IMPORTANT: Do not reuse shims (73) that were
once used.
- Do this work without fail. If pre-load adjustment is
1
not done well, the reduction unit may be broken
during operation.
- Clean the measuring surface thoroughly. 60
W3-2-81
E245B TRAVEL DEVICE
Assembling holder C
1. Fix flange (1) and erect pins (99) [four places]
upright on flange (1).
2. Bring the shims selected under (5) in contact 74
with holder C (74), using grease, match the pin
holes in holder C (74) to the pins and press it in 73
by press.
3. Fit washer (75) to holder C (74), coat bolts (76)
with Loctite and tighten the bolts to a specified 99
torque.
: 17 mm
: 539 Nm (397.5 lbfft) 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 hold-
er C (74).
- Thoroughly clean the threads of bolt (76), de-
99
grease it and coat it with adhesive Loctite. 75
- Thoroughly clean and degrease the inside of the
screw threads of flange (1). 75
76
60
Assembling planetary gear C

1. Assemble thrust plate (77) to planetary gear C 72
(80).
74
2. Next, fit needle bearing (79) to planetary gear C
(80).
77
3. Finally, attach inner race (78). 78
4. Then install planetary gear C (80) by engaging 80 79
the bore diameter of inner race (78) with trun-
nions (four) of holder C (74).
80 77 79 78
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 fi-
nally 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 74
gear C (80).
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 lbfft)
82 81
NOTE: Use care of the attaching direction of thrust 82
plate (81). If the neck of the bolt is damaged, it
breaks down.
Clean the screw threads of bolt (82) thoroughly, de-
grease it and coat it with Loctite.
Clean the screw threads in the tapped hole of holder
&
C (74) thoroughly and degrease it thoroughly.
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 80
those of sun gear C (83) and assemble them to-
gether.
84 83
60
Assembling holder B
1. Engage the inner gear teeth of holder B (85)
with the teeth of sun gear C (83) and assemble
holder B (85) into sun gear C (83).
83
85
60
W3-2-84
TRAVEL DEVICE E245B
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), 86
and assemble planetary gear B (89) into holder
B (85). 89
NOTE: Attach thrust plate (86) to planetary gear B 85

(89) so the draft side (by press) of thrust plate (86) 87
is located on the holder B side (85). 88
89 86 88 87
- 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 85
gear B (89).
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 89
tighten it to a specified torque. 90
91
: 8 mm
: 58.8 Nm (43.4 lbfft)
93
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) 92
with the teeth of drive gear (93).
60
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
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 72
thrust plate (94) according to the table below. 91
94
72
91
94
60
Unit: mm (in)
Step dimension (T) Thrust plate code Shim thickness (t)
1.20 ~ 0.67
20941-62306 2.3
(0.0472 ~ 0.0264)
0.66 ~ 0.04
20941 - 62307 2.8
(0.0260 ~ 0.0016)
0.03 ~ -0.16
20941 - 62308 3.0
(0.00122 ~ -0.0063)
-0.174 ~ -0.41
20941 - 62309 3.2
(-0.00685 ~ -0.0161)
-0.42 ~ -0.80
B0841 - 23017 3.6
(-0.0165 ~ -0.0315)
NOTE: Align the hole in the center of thrust plate

(94) with the convex part of drive gear (93) and as-
semble them together.
W3-2-86
TRAVEL DEVICE E245B
Attaching cover
1. Remove foreign matter completely from the
matching surface between the end face of 72
housing (72) and cover (95).
2. Next, thoroughly degrease the matching sur- 95
face between the end face of housing (72) and 96
cover (95).
3. Further, apply liquid packing to the corner of the
spigot joint on the matching surface side of
housing (72) of cover (95).
4. Match the tapped holes in housing (72) with the
bolt holes in cover (95) and place cover (95) in
housing (72).
5. Finally, attach bolts (96) and tighten them to 60
specified torque.
: 8 mm
: 73.4 Nm (54.1 lbfft)
Fitting plugs
1. Take off O-ring (98) from plug (97), replace it
with a new one and place it in plug (97).
2. Then, attach plugs (97) to the oil inlet / outlet 95
and the level ports (3 in all) of cover (95), and
tighten them to specified torque.
: 12 mm
98
: 157 Nm (115.8 lbfft) 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 di-
ameter of oil seal (53) will be scored. 1
- 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
60
leakage may occur and break the inside of the re-
duction gear while the motor is running.
Assembling piston 3
1. Place spring (61) in the hole where piston assy
(48) of flange (1) is located. 48
2. Then, mount piston assy (48) to flange (1). 61
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
60
Installing shaft
1. Press ball bearing (49) into shaft (36), using the
bearing fixing jig.
Then mount shaft (36) into the center of flange 36
(1).
49
60
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 44
bench so the sliding surface of valve plate (62)
faces up.
2. Assemble cylinder block (37) so the slope of 43
spring seat (42) faces downward.
3. Then mount spring (43) and collar (44) on 42
spring seat (42), in that order.
4. Press in the top face of collar (44), using a jig, 37
and fix snap ring.
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 pli- 60
ers is engaged in the hole of the snap ring.

If it is difficult to narrow the snap ring, use snap ring
pliers one size larger. 41
To press in collar (44), align the center of the cylin-
der block with that of the press.
60
5. Place cylinder block (37) on a work bench so

the sliding surface of cylinder block (37) in con- 45
tact with valve plate (62) faces downward.
6. 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 37
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. 60
Before fixing pins (45), coat the pin holes with

grease.
W3-2-90
TRAVEL DEVICE E245B
7. 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 hold-
er (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 37
(1).
NOTE: At assy, use care so piston assy (38), retain-

er plate (39) and retainer holder (40) do not come off 1
from cylinder block (37).
Before assy, coat the surface of swash plate (46)
and the sliding surface of piston assy (38) with hy-
draulic oil. 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 cir-
cumference of friction plate (55) with the con-
cavity of flange (1) and install them to flange 54
(1). 55
54
3. In this way attach disk plate (54) and friction 55
54
plate (55) to the flange, in that order.
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 fac-
es upward.
56
IMPORTANT: Coat O-rings (57), (58) with sufficient .
grease, before fixing them. 57
Align the knock pin hole in flange (1) in contact with
base plate with the knock pin hole in brake piston 58
(56), using the positioning jig (K). Then install brake
piston (56).
Before fitting brake piston (56), coat the outer sur-
56
face of the brake piston and the bore of flange (1)
with grease. 1
Assemble brake piston (56) by pressing it so it does
not tilt. If the brake piston is assembled inclined, it 60
develops trouble and tears off O-rings in some cas-
es.
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), us- 62
ing 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). 50
NOTE: Place valve plate (62) with the copper alloy

side facing upward. 2
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 60
of valve plate (62).
W3-2-94
TRAVEL DEVICE E245B
Attaching base plate

1. Fit O-rings (64) and O-rings (63) [4 places] to
60 2
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 sur-
face of valve plate (62) in contact with base
plate (2) faces downward. 52
4. Then tighten them with socket bolts (52). 60
: 12 mm 63
: 205 Nm (151.2 lbfft) 64
NOTE: Coat O-ring (64) with grease. 60
Do not coat O-ring (63) with grease.

Fix knock pin (60) with its taper part upward.
Coat the surface of valve plate (62) and the cylinder
block (37) with hydraulic oil and install them to base
plate (2).
Since the surface of the base plate (2) in contact
with base plate (2) faces downward, take care so
the valve plate does not fall.
When installing base plate (2) to flange (1), make
sure of the location of O-ring (63) and the location of
the oil passage hole in base plate (2).
Before assmble, make sure of the knock pin (60)
fixed in base plate (2), the hole in the base plate (2)
into which spring (59) enters, the knock pin hole on
the flange side (1), and the position of spring (59).
Tighten socket bolts (52) evenly all round on the cir-
cumference.
W3-2-95
E245B TRAVEL DEVICE
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 O-
25
ring (23) is set in plug (22), fit plug (22) to base
plate (2) and tighten it to a specified torque. 21 23
4. 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 2
to a specified torque.
: 10 mm 19
: 118 Nm (87 lbfft) 23
22
60
NOTE: Assemble spool A (19) into base plate (2) so

that the pipe port surface of base plate (2) comes to-
ward 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 lbfft)
17-17,18 2
NOTE: Replace O-ring (17-7) with a new one, be- 17-3
fore assembly. 17-7
Make sure that O-ring (17-7) and backup ring (17-
18) are fitted to poppet seat (17-3). 17 60
Coat O-ring (17-17) and backup ring (17-18) with
grease, before assy.
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 or-
der, to plunger (3).
2. Fit ball (33) and spring (34), O-ring (14), plug
(15), in that order, into the hole beside the hole
in base plate (2) in which cap (11) is placed.
33,34,14,15
3. Finally, fasten capscrew (13) to a specified
torque.
: 10 mm 17
8
: 108 Nm (79.7 lbfft)
9
10
NOTE: Coat O-ring (12) with grease. 11,12

Cap (11) is pushed up by the action of spring (9).
When tightening up socket bolts (13), hold them 13
down by hand.
Tighten four socket bolts (13) evenly all round. If cap
(11) is tightened up tilted, O-ring (12) is damaged, 60
resulting in oil leakage.
This completes assy of the hydraulic motor.
TOOL TABLE
REF. TOOL NO. DESCRIPTION

A XXXXXXXXX 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
Sprocket
%
&
'
(
$
60
IMPORTANT: Consult NEW HOLLAND KOBELCO S.p.A. for any inqueries concerning welding procedures.
Standard mm (in) Allowable Limit mm (in) Remedy

A 66 (2.57) 58 (2.26)
B 586 (22.85) 575 (22.42)
Build up and
C PCD644.6 (25.14) -
finishing
D 659 (25.70) 649 (25.31)
E 190 (7.41) -
W3-2-99
E245B TRAVEL DEVICE
NOTES
W3-2-100
REMOVAL AND INSTALLATION OF SWIVEL JOINT
WARNING
Preparation
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, 3. Remove tubes (2 and 8) (PF1).
to aid in assembly.
: 36 mm
: 177 18 Nm (130.5 13 lbfft)
1. Remove tube (5 and 6) (PF1/2).
: 27 mm 4. Remove tubes (3 and 4) (PF1/4).
: 78.5 5 Nm (57.9 3.7 lbfft) : 19 mm
: 29.4 5 Nm (21.7 3.7 lbfft)
2. Remove tubes (1 and 7) (PF1).
: 36 mm
: 177 18 Nm (130.5 13 lbfft)
60
W3-3-1
5. Remove drain hose (2).

: 27 mm
: 78.5 5 Nm (57.9 3.7 lbfft)
6. Remove hoses (4 and 6).
: 36 mm

: 177 18 Nm (130.5 13 lbfft)
7. Remove hoses (1 and 3).

: 36 mm
: 177 18 Nm (130.5 13 lbfft)
8. Remove hose (5).

: 19 mm
: 29.4 5 Nm (21.7 3.7 lbfft)
60
9. Loosen the stop nut (7) M20 of swivel joint and

remove the screw (8) M20x120.
: 36 mm
: 157 Nm (115.8 lbfft)
60
10. Remove two adapters (9 and 10).

: 19 mm
: 36 Nm (26.6 lbfft)
60
W3-3-2
11. Remove six screws (2) M10x25.

: 19 mm
: 14.7 Nm (10.8 lbfft)

12. Remove clip (1).
: 6.8 Nm (5.0 lbfft)
13. Remove seal (4).

60
14. Attach eye bolt (5), lift it up temporarily, and re-

move three screws (6) M12x35.
: 19 mm
: 108 Nm (79.7 lbfft)

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
SWIVEL JOINT DISASSEMBLY AND

ASSEMBLY
View from X
Section G-G
60
1 - Body 7 - O-Ring
2 - Stem 8 - Socket Bolt (M8 x 20)
3 - Thrust plate 9 - Socket Bolt (M8 x 30)
4 - Cover 12 - Plug
5 - Seal assy 13 - O-ring
6 - Seal assy
W3-3-4
Disassembly
The part numbers used in this disassembly proce-
dure correspond to those of a construction drawing
in the figure on page W3-3-4.
1. Mark cover (4) and body (1) with matching
marks for convenient reassembly.
2. Place a 'V' (A) block on a work bench, place a
swivel joint set on the side, fix it and loosen
socket bolt (9) by means of a pipe and wrench.
Alternately, the swivel joint may be fixed by
holding stem (2) in a vise.
$
: 6 mm
60
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
5. 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.
$ 60
6. Remove the back-up ring of the seals assem-

blies (5 and 6) by means of a spatula (E). (
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 assem-

blies (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 screw-
driver 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
Assembly
Prior to assembly, clean each parts (excluding the %
O- Ring and slipper ring), and arrange in the se-
quence of assembly.
1. Make sure that oil and grease remains have
been completely removed.
2. Apply grease on the groove where are seated
the O- Ring (6).
3. Apply hydraulic oil to O-ring (13) thinly and in-
sert it into O-ring groove. Check the twist of O-
ring.
4. Slipper ring (B) is assembled, after first insert-
ing the backup ring, by slightly-distorting the
shape as shown in figure. Also after inserting all 60
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, hy-
draulic 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).
NOTE: If stem (2) is pressed in too fast, the seal

may be damaged. Do it slowly. The clearance be-
tween 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
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 tight-
en to stem (2).
: 6 mm
: 30.4 Nm (22.4 lbfft)
60
9. After installing O-Ring (7) to cover (4) and align-

$
ing the matching marks of the cover (4) and
body (1), coat socket bolt (9) with Loctite 242
and tighten it which will then complete assem-
bly.

: 6 mm
: 30.4 Nm (22.4 lbfft)
60
W3-3-8
Allowable Limit
Item Remedy
(basis of judgment)
Sliding surface and sealed
Scored or something hurt it. Replace
parts
Sliding surface exception 1. Scored more than 0.1 mm. Replace
sealed parts 2. Scored less than 0.1 mm. Repair with oil stone
Body, Stem
1. Wear more than 0.5 mm deep. Replace
2. Wear less than 0.5 mm deep. Repair
Sliding surface ring
3. Scored less than 0.5 mm and able to
Repair
repair.
1. Wear more than 0.5 mm. Replace
2. Wear less than 0.5 mm. Repair
Cover Sliding surface ring
3. Scored less than 0.5 mm and able to
Repair
repair.
1. Protruded excessively from seal groove.
Replace
(with back-up ring)
60
2. Slipper ring narrower than 1.5 mm of

seal groove, or narrower than back-up
ring.
Slipper ring Replace (with

back-up ring)
PPPD[
60
3. Worn unevenly more than 0.5 mm.
PPPD[
Replace (with
back-up ring)
60
W3-3-9
Inspection after assembly

After completion of assembly, inspection for oil le-
akage, 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 pres-
sure 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 pres-
sure relief valve side closed for, at least, 3 min-
utes 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 direc-
tional 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 60
side and also by regulating low pressure relief
valve (5), gradually increase the pressure and
1- Pressure Gauge
check for outside leakage with a color check at
2- Swivel Joint
a pressure of 0.49 MPa.
3- Stop Valve
4- Hydraulic source
5- Relief Valve for low pressure
6- Stop Valve
7- Relief Valve for high pressure
8- Directional Valve
9- Piping, etc.
W3-3-10
TRACK ADJUSTER E215B-E245B

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 ap-
plicable 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 ac-
cess to track components, remove the front
60
idler and track adjuster assembly from track
frame by prying it out, using a pry bar shown in
figure.
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 Disas-
sembly and Assembly" on page W1-1-1 before
starting the disassembly work.
$
Be sure to use special tool (A) (380001029) for as-
sembly / 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 as-
sembly 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 lift-

ing strap.
Put the track adjuster in the track spring holder
assembly (380001029).
Remove the lifting strap.

9
60
W3-4-2
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.

60
7. Fit retainer plate (A) to bracket (2), tighten hold-

ing-down nuts alternately, and secure idler ad-
juster 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
9. 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
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 adjust-
er 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).
60
: 46 mm
: 75 mm
W3-4-5
5. 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). ; 60
: 19 mm
: 59 Nm (43.5 lbfft)
TOOL TABLE

380001029 Jig stand track adjuster
W3-4-6
FRONT IDLER E215B-E245B

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
3. Put idler on repair stand. Apply push-out jig on

shaft (B) (380001052), push out shaft (6) with

collar (3), then remove collar (3).
%

60
* : Push with press
W3-5-1
E215B-E245B FRONT IDLER
4. If removal of collar (3) on the opposite side is re-

quired, turn over front idler and proceed with

the procedure described in the previous step.
%

60
* : Push with press
5. With idler (1) mounted on the stand, tap bu-

shing (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 se-
aling faces.
7. Separate O-Ring from shaft.
60
W3-5-2
FRONT IDLER E215B-E245B
Assembly
1. Align inner hole of idler (1) and bushing (2) and
press fit it vertically with press so that jig (D)
'

(380001054) for bushing press-fitting is inser-
ted into bushing.
60
* : 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. Install idler (1) on the shaft (6) with the floating

seal (4) fitted into shaft (6) with the toward collar
(3).
6. Fit floating seal (4) on the other side of idler (1).

60
7. 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.

8. Fill in 265 cm 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
Front Idler
& '
$
%
60
Unit: mm
Standard Allowable Remedy
A 84 66
B 159 -
C 500 482 Buildup weld and finishing
D 540 -
E 20 -
IMPORTANT: Consult NEW HOLLAND KOBELCO for any inqueries concerning welding procedures.
Axle and Bushing

Unit: mm
Standard Allowable Remedy
Axle Outside Dia 75 74.2
Bushing Inside Dia 75 76 Replace
Bushing Flange thickness 2 1.2
TOOL TABLE

380001051 Pin push bar
380001052 Push-out jig
380001053 Punch for upper roller bushes
380001054 Bushing press-fitting jig
W3-5-4
UPPER AND LOWER ROLLER E215B-E245B

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 be-

tween sprockets and tracks, remove it before loos-
ening.
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).
60
W3-6-1
E215B-E245B UPPER AND LOWER ROLLER
4. 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 lbfft)
2. Remove the wooden blocks and the hydraulic

jack.
60
W3-6-2
3. 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 lbfft)
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 lbfft)

60
W3-6-3
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).
60
3. Loosen valve (3) to drain grease enough to per-

mit the roller removal.
: 19 mm

60
W3-6-4
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 lbfft)
60
W3-6-5
4. 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 lbfft)

60
NOTE: Check track sag after thoroughly removing

soil stuck on the track area by washing.
60
W3-6-6
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 col-
lar (8) to floating seals (6, 7) using a press or a
hammer.

$
60
W3-6-7
7. 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 circumfer-
ence of bushings and extrude them perpendicularly
little by little.

60
W3-6-8
UPPER ROLLER ASSEMBLY

1. Assembly of the upper roller is done in the re- &
verse 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 in-

serting side of the bushing, with molybdenum
disulfide grease.
4. 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.
IMPORTANT: If you fail in this operation by press-

ing 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 engi-
ne oil lightly to seal surface.

60

60
W3-6-9
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 lbfft)

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 60
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 lbfft)
- After assembling the upper roller, confirm that

oil is not leaking from it and that it rotates
smoothly by.
W3-6-10
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
Disassembly Lower Roller

Be sure to thoroughly read Precautions for Disas-
sembly and Assembly on page W1-1-1 before star-
ting the disassembly work.
1. Remove plug (1) and elastic pins (3) from col-

lars (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 col-
lar (2).
5. Press out axle (8), and remove collar (2) and O-
Ring (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
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
Assembly Lower Roller

1. Install bushings (6) (Q.ty 2) onto roller (7) using
a press. Take care not to dent the flange sur-
face of bushings. Apply a coat of grease to O-
Ring (4) and install onto axle (8).
2. 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 han-
dling 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). Ap-
ply sealant (Loctite 503 or equivalent) to plug (1).
Tighten plug (1).
Engine oil quantity: 211 cm3

: 6 mm
: 9.8 Nm (7.2 lbfft)

60
W3-6-14
Upper Roller
&
$
% 60
Unit: mm
Standard Allowable Limit Remedy
A 84 -
B 150 - Replace
C 140 130
Lower Roller
'
& $ &
%
60
Unit: mm
A 172 181.5
B 218 - Buildup
weld and
C 23 11.5 finishing
D 150 132
W3-6-15
Upper roller axle and bushing

Unit: mm
Axle Outside Dia. 45 44.7
Replace
Bushing Inside Dia. 45 45.3
Lower roller axle and bushing

Unit: mm
Axle Outside Dia. 65 64.2
Bushing Inside Dia. 65 66 Replace
Bushing Flange Thickness 2 1.2
TOOL TABLE

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
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).
60
1. Move the tracks so that master pin (3) is posi-

tioned 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 es-
cape from grease outlet.
: 19 mm

60
W3-7-1
E215B-E245B TRACKS
WARNING
The front idler may jump out of position due to
strong spring force when the tracks is disconnected.
Especially, the strong spring force is always applied
to the bolt part of the rod. If the rod and/or the bolt
are damaged, metal fragments may fly off when the
tracks is disconnected.
60
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. Jack up the machine and put the track under

the lower roller.
Be sure to position the track in correct direction,
as illustrated.
O : Sprocket side
OO : 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 coun-

terbore surfaces, bushing ends, shall be free from
dust and rust.
5. Install master pin (5), using a hammer and spe-

cial tool.
A: 380001008
B: 380001009
C: 380001013 (E215B); 380001010 (E245B)
D: 380001012 (E215B); 380001011 (E245B)
E: 380001015 (E215B); 380001016 (E245B)
G: 380001019
60
5: MASTER PIN
IMPORTANT: inject rust preventive protective ' & (

(ex. TECTYL165 G) between pin and bushing clear-
ance.
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 re- * % $
connecting the links. Also, apply a coat of grease 60
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. Supply grease to the cylinder through the

grease fitting to adjust the track tension.
: 19 mm
When proper track sag is obtained, turn value clock-

wise and tighten. 60
Track sag specifications (A):

320 to 350 mm
: 19 mm
: 59 Nm (43.5 lbfft)
IMPORTANT: check track sag after thoroughly re-

moving soil stuck on the track area by washing.
60
W3-7-4
TRACKS E215B-E245B
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 Allowable Limit
Remedy
E215B E245B E215B E245B
A 761 760 774 778 Replace
Master Pin
(% (%
%
60 60
Unit: mm
Remedy
E215B E245B E215B E245B
A 207 220 200 -
Replace
B 38 39.7 36.5 37
W3-7-5
E215B-E245B TRACKS
Master Bushing
% &
$
60
Unit: mm
Remedy
E215B E245B E215B E245B
A 129.2 135 - -
B 38 40 ++00.87 39.5 42.8 Replace
C 58.7 60 54.1 57
Grouser Shoe
&
$
60
Unit: mm
Remedy
E215B E245B E215B E245B
A 220 222.5 - -
B 9.5 12.5 - - Replace
C 25.5 28 15 14
W3-7-6
TRACKS E215B-E245B
TOOL TABLE

380001008 Tool fitting/pushing-out master pin
380001010 Tool fitting/pushing-out master pin (E245B)
W3-7-7
E215B-E245B TRACKS
NOTES
W3-7-8
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
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 SM0200
boom cylinder.
: 24 mm
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) 4

using a hammer and bar.
2
SM0201
5 4 2
4 3 SM0202
W4-1-1
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.
SM0203
7. Disconnect hoses (7) and (8) of bucket cylinder
and arm cylinder.
9 9 10
10
NOTE: if the machine is equipped with the hammer/
7 7
crusher, bucket rotation or anti-drop valves variants,
disconnect the relevant hoses (9), (10) and (11).
8 8
Bucket (7) and arm (8) cylinder hoses:
11 11
: 41 mm
: 36 mm
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)

SM0205
located between the boom cylinders.
: 17 mm
14
13
9. Remove panel (13) by removing securing
screws (14).
: 19 mm
SM0206
W4-1-2
10. Remove work light and bracket by removing

securing screws (15).
: 17 mm
16
18
11. Disconnect fuel transfer pump hose (16).
: 41 mm
17
15
12. Loosen lock nuts (17) and remove bolt (18).
: 30 mm
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.
SM0209
W4-1-3
Installation
1. Lift the front attachment.
3450 kg
16
Install dust seals to boom foot. Align the boom
foot boss with the main frame boss. Insert a
18
thrust plate to both right and left sides of the
boom foot boss to take out clearance between
the boom foot boss and the main frame boss.
2. Install boom foot pin (20) using a hammer and 15 20

bar. 17
3. Install bolt (18) and tighten lock nuts (17).

SM0210
: 30 mm
: 200 Nm
14
4. Install fuel transfer pump hose (16). 13
: 41 mm
: 30 Nm
5. Install work light and bracket by removing

: 17 mm
: 15 Nm
6. Install panel (13) by tightening securing screws

(14).
SM0206
: 19 mm
: 80 Nm
9 9 10
10
7. Connect hoses (7) and (8) of bucket cylinder
and arm cylinder. 7 7
8 8
connect the relevant hoses (9), (10) and (11).
11 11
: 41 mm
: 206 21 Nm
: 36 mm
SM0204
: 177 18 Nm
: 27 mm
: 41 mm
: 78 5 Nm
: 206 21 Nm
: 12 mm Anti-drop valves hoses (11):
: 150 10 Nm : 22 mm
: 49 5 Nm
W4-1-4
8. Attach the boom cylinder to a crane.

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)
: 17 mm 4 3 SM0202
: 20 Nm
Using a grease gun, inject grease via nipples
(21) (boom) and (22) (boom cylinders). 5
1
NOTE: fill the hydraulic oil tank with hydraulic oil to 3
the specified level. Run the engine at idle. Check
hose connections for any oil leakage.
4
IMPORTANT: bleed air from hydraulic circuit.
2
SM0201
12
22 21 22
SM0212
W4-1-5
Maintenance: monoblock version
F E G H
A B C J K
D I
SM0213
Unit di misura: mm
Allowable
Parts name Standard Remedy
limit
Pin 90 89
A
Bushing 90 91.5
Pin 85 84
B Boss (Main Frame) 85 86.5
Bushing (Boom Cylinder) 85 86.5
Pin 85 84
C Bushing (Boom Cylinder) 85 86.5
Foro (Boom) 85 86.5
Pin 90 89
D
Bushing 90 91.5
Pin 85 84
E Boss (Arm) 85 86.5
Bushing (Arm Cylinder) 85 86.5
Pin 85 84
Replace
F Boss (Boom) 85 86.5
Pin 80 79
G Boss (Arm) 80 81.5
Bushing (Bucket Cylinder) 80 81.5
Pin 80 79
H Bushing 80 81.5
Pin 70 69
I
Bushing 70 71.5
Pin 80 79
J
Bushing 80 81.5
Pin 80 79
K
Bushing 80 81.5
IMPORTANT: be sure to install front attachment bushings using a press.
W4-1-6
WARNING
Removal
2. Disconnect lubrication pipes (1) from boom

cylinder rod end.
: 17 mm
3. Loosen lock nuts (2), remove bolt (3) and

Carry out the same procedure for the other
SM0215
boom cylinder.
: 24 mm
3
4. Attach each boom cylinder to a crane. 1
5
Remove cylinder rod end pin (5) and shims (6)

using a hammer and bar.
4 2
SM0216
5 4 2
4 3 SM0217
W4-1-7

onto the wooden block.

itself.
7. Disconnect hoses (12), (7) and (8) of positioner

cylinder, bucket cylinder and arm cylinder. SM0218

disconnect the relevant hoses (9), (10) and (11). 10
9 9
Positioner cylinder hoses (12) (from the control 7 7

valve):
: 30 mm
8 8

11 11
: 41 mm 12
: 36 mm 12 SM0219

: 41 mm
: 12 mm 13

: 27 mm

: 22 mm
Close all openings with plugs to keep clean.

SM0220

15
: 17 mm
14
9. Remove panel (14) by removing securing

screws (15).
: 19 mm
SM0221
W4-1-8
10. Remove work light and bracket by removing

: 17 mm
17
19
11. Disconnect fuel transfer pump hose (17).
: 41 mm
18
16
: 30 mm
SM0222
13. Sling the boom to a hoist. Slightly lift the boom.

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.
SM0224
W4-1-9
Installation
1. Lift the front attachment.
4100 kg
Install dust seals to boom foot. Align the boom 16
foot boss with the main frame boss. Insert a
thrust plate to both right and left sides of the 18
boom foot boss to take out clearance between
the boom foot boss and the main frame boss.
2. Install boom foot pin (20) using a hammer and
bar. 15 20
17
3. Install bolt (18) and tighten lock nuts (17).
: 30 mm
SM0210
: 200 Nm
4. Install fuel transfer pump hose (16).
14
: 41 mm
: 30 Nm 13
5. Install work light and bracket by removing

: 17 mm
: 15 Nm
6. Install panel (13) by tightening securing screws
(14).
: 19 mm
: 80 Nm
SM0206
7. Connect bucket cylinder hoses (7), positioner
cylinder hoses (12) and arm cylinder hoses (8).

crusher, bucket rotation or anti-drop valves variants, 10
connect the relevant hoses (9), (10) and (11). 9 9
Positioner cylinder hoses (12) (from the control
7 7
valve):
: 30 mm
8 8
: 83 5 Nm

11 11
: 41 mm 12
: 206 21 Nm 12 SM0219
: 36 mm
: 177 18 Nm
: 27 mm
Hammer/crusher hoses (9): : 78 5 Nm
: 41 mm
: 206 21 Nm
: 22 mm
: 12 mm
: 49 5 Nm
: 150 15 Nm
W4-1-10
8. Attach the boom cylinder to a crane.

Lift the boom cylinder and align the boom
cylinder rod with the pin hole on the boom.
the boom control lever.

nuts (2):
: 24 mm
: 147 Nm
3
11. Connect lubrication hoses (1) to boom cylinder 5 4 2

rod.
: 17 mm
: 20 Nm 2
6
: 17 mm 4 3 SM0217
: 20 Nm
Using a grease gun, inject grease via nipples
(21) (boom) and (22) (boom cylinders). 3
1
5
NOTE: fill the hydraulic oil tank with hydraulic oil to
the specified level. Run the engine at idle.
Check hose connections for any oil leakage.
IMPORTANT: bleed air from hydraulic circuit. 4 2
SM0216
12
22 21 22
SM0212
W4-1-11
Maintenance: triple articulation version
F E L M G
A B C D H J K
N I
SM0238
Unit di misura: mm
Allowable
Parts name Standard Remedy
limit
Pin 90 89
A-D-N
Bushing 90 91.5
Pin 90 89
B Boss (Main Frame) 90 91.5
Bushing (Boom Cylinder) 90 91.5
Pin 85 84
C Bushing (Boom Cylinder) 85 86.5
Boss (Boom) 85 86.5
Pin 90 89
E Boss (Positioner) 90 91.5
Bushing (Positioner Cylinder) 90 91.5
Pin 90 89
F Boss (Boom) 90 91.5
Bushing (Positioner Cylinder) 90 91.5
Pin 80 79
Replace
G Boss (Arm) 80 81.5
Pin 80 79
H Bushing 80 81.5
Pin 70 69
I
Bushing 70 71.5
Pin 80 79
J-K
Bushing 80 81.5
Pin 85 84
L Boss (Positioner) 85 86.5
Pin 85 84
M Boss (Arm) 85 86.5
IMPORTANT: be sure to install front attachment bushings using a press.
W4-1-12
STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION
o p q
g
h
k
j
Section A
d
l
B
m
c
n
e
a b
Section B
f
A SM0214
E215B-E245B E215-E245
a (*) 419
b (*) 31 23
c 630
d 610
e 430
f 1464
g 433
h 326
i 80
j 428.7
k 33
l 433
m 307
n 80
o 20
p 3.73
q 449
(*) Arm: 2940 mm Unit: mm
W4-1-13
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).
IMPORTANT: during the removal of the bucket, take
Use the bucket cylinder control to align the care that the pin are not contaminated by dirt, sand
connecting rod (C) to hole (D)and insert pivot pin etc. After the reinstallation of the bucket, provide
(E). grease to the pins through the appropriate fittings.
Secure pivot pins using lock pins and retaining rings
and reposition the O rings into their seats.
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
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
CYLINDERS REMOVAL AND INSTALLATION
WARNING
Bucket Cylinder removal


itself.
3. Insert wooden block (3) between bucket

cylinder (1) and arm (2).
SM0200
4. Complete the bleeding of the residual pressure 1

IMPORTANT: Pin (6) end of the link will drop when

pin is removed, possibly resulting in personal injury.
2
Be sure to secure the link using a wire before
removing pin (6).
SM0226

6
Pull-out pin (6) with the help of a mallet and a 7 4
bar so that the end of the cylinder is free, then
remove adjusting shims (7).
: 24 mm
5
SM0227
W4-1-16
6. Disconnected hoses (8) from bucket cylinder

(1). 9
: 10 mm 12
: 36 mm 11
Put plugs on cylinder pipes and hoses.
10
NOTE: bucket cylinder weight: 153 kg 1
7. Using a hoist, slightly lift bucket cylinder (1). 8

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
: 24 mm
8. Remove bucket cylinder (1).
SM0228
W4-1-17
Bucket Cylinder installation
NOTE: bucket cylinder weight: 153 kg 9

12
1. Connect bucket cylinder (1) to a crane using a 11
sling belt.
Align the hole of the bucket cylinder with the pin 10
hole on the arm-tip bracket.
1
2. Install adjusting shims (12) and insert pin (11).
Install screw (10) and tighten lock-nuts (1).
: 24 mm
8
: 147 Nm
3. Connect two hoses (8) to bucket cylinder (1).

: 10 mm 8
: 83 5 Nm
: 36 mm
: 177 Nm

SM0228
4. Align the bucket cylinder rod with bucket links
(13) and (14).
Install shims (7) and pin (6).

the arm control lever.
6
7 4
5. Install bolt (5) onto pin (6) then tighten lock nuts
(4).
: 24 mm
5
: 147 Nm
14
13
IMPORTANT: if link (13) has been disconnected
from the arm, be sure to insert shims (7) when
connecting it. Bleed air from hydraulic circuit.
SM0229
W4-1-18
Arm cylinder removal
1. Insert a wooden block (3) between arm cylinder

(1) and boom (2).
1

itself.
Complete the bleeding of the residual pressure 3
from the hydraulic system" at page T2-1-47. 2
SM0230
3. Loosen lock nuts (4), remove bolt (5) and pull-
out pin (6) with the help of a mallet and a bar so 6
that the end of the cylinder is free, then remove 7 4
adjusting shims (7).
: 24 mm
5
4. Disconnected hoses (8) and (9) from arm
cylinder.
: 10 mm
: 36 mm
SM0231
5. Disconnect lubrication hose (10).

: 17 mm
8
NOTE: arm cylinder weight: 255 kg
10
6. Using a hoist, slightly lift arm cylinder (1).
Loosen locking nuts (11) remove screw (12)
and pull-out pin (13) with the help of a mallet 9
and a bar so that the end of the cylinder is free,
then remove adjusting shims (14).
: 24 mm SM0232
13
14 11
7. Remove arm cylinder (1).
12
SM0233
W4-1-19
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). 13
14 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

hose connections for any oil leakage. 8
4. Slightly lift arm cylinder and align the arm

cylinder rod with the pin hole on the arm.
10

the arm control lever. 9
5. Install adjusting shims (7), pin (6), install screw

SM0232
(5) onto pin (6) and tighten lock-nuts (4).
: 24 mm
: 147 Nm 6
7 4
SM0231
W4-1-20
Boom cylinders removal
1. 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 5
retracted.
1
3
2. Disconnect lubrication hoses (1).
: 17 mm
3. Loosen lock nuts (2), remove bolt (3) and 4

2
: 24 mm
SM0201
4. Attach boom cylinder to a crane. 3

onto the wooden block. 5 4 2
6. Press the valve located on the hydraulic oil tank 2

itself.
Complete the bleeding of the residual pressure 6
from the hydraulic system" at page T2-1-47. 4 3 SM0202
7. Disconnect hoses (7) of boom cylinder. Put

plugs on cylinder pipes and hoses.
: XX mm : 30 mm
7

: 17 mm 9
8
9. Remove securing screws (8) complete with
washers, then remove pin (9) and adjusting
SM0234
shims (10).
: 24 mm
10 10
10. Using a hoist, lift boom cylinder. Remove the
other boom cylinder following the same
procedure.
SM0235
W4-1-21
Boom cylinders installation
1. Using a crane, install the boom cylinders to the

main frame.
7
2. Install adjusting shims and pin (9), then tighten
securing screws (8) complete with washers.
: 24 mm
: 540 Nm
9
3. Connect lubrication hose (7) to boom cylinder. 8
: 30 mm : 36 mm
SM0234
: 137 Nm : 206 Nm

10 10
: 17 mm
: 20 Nm

nuts (2):
: 24 mm
: 147 Nm
SM0235
7. 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. 6
NOTE: fill the hydraulic oil tank with hydraulic oil to 4 3 SM0202
5
1
3
4
2
SM0201
W4-1-22
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 1

itself.
"Procedure for the bleeding of the pressure 3
2
SM0236
3. Loosen lock nuts (4), remove bolt (5) and pull-
out pin (6) with the help of a mallet and a bar so 6
that the end of the cylinder is free, then remove 7 4
adjusting shims (7).
: 24 mm
5
4. Disconnected hoses (8) and (9) from arm
cylinder.
: 10 mm
: 36 mm
SM0237
5. Disconnect lubrication hose (10).

: 17 mm
8
NOTE: positioner cylinder weight: 220 kg
10
6. Using a hoist, slightly lift positioner cylinder (1).
Loosen locking nuts (11) remove screw (12)
and pull-out pin (13) with the help of a mallet 9
and a bar so that the end of the cylinder is free,
then remove adjusting shims (14).
: 24 mm SM0232
13
14 11
7. Remove positioner cylinder (1).
12
SM0233
W4-1-23
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 13
14 11
(11).
: 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

the specified level. Run the engine at idle. Check 8
4. Slightly lift positioner cylinder and align the

positioner cylinder rod with the pin hole on the 10
arm.
9
the arm control lever.
SM0232
5. Install adjusting shims (7), pin (6), install screw

(5) onto pin (6) and tighten lock-nuts (4). 6
: 24 mm 7 4
: 147 Nm
IMPORTANT: bleed air from hydraulic circuit. 5
SM0237
W4-1-24
CYLINDERS ASSEMBLY AND DISASSEMBLY

Bucket cylinder
13
19
20
15
16
17
18
16
19
20
21
24
23 22
11
12
1
2
3
8 4
5
6
9
10
SM0240
1- Wiper Ring 9 - Backup Ring 18 - O-Ring

2- Backup Ring 10 - O-Ring 19 - Slide Ring
3- Seal 11 - Cylinder Rod (q.ty 2)
4- Seal 12 - Cylinder Tube 20 - Slide Ring
5- Bushing 13 - Cushion Bearing (q.ty 2)
6- Snap Ring 15 - Piston 21 - Shim
7- Cylinder Head 16 - Backup Ring 22 - Set Screw
8- Socket Bolt (q.ty 2) 23 - Steel Ball
(q.ty 12) 17 - Seal Ring 24 - Nut
W4-1-25
Bucket cylinder disassembly 6. Loosen nut (24) using special tool (xxxxxxxxx).
Remove piston (15), shim (21) cushion bearing.
Socket to loosen nut (24):
Be sure to thoroughly read all the precautions for
- bucket cylinder: 90 mm (XXXXXXXX)
disassembly/assembly work on page W1-1-1 before
starting the disassembly procedure.
The disassembly procedure below starts on the

7. Remove seal ring (17), slide rings (19) and (20),
premise that the hydraulic lines and the line
O-ring (18) and backup rings (16) from piston
securing bands have been removed.
(15).
NOTE: bucket cylinder mass: 153 kg

8. Remove cylinder head (7) from cylinder rod
1. Lift and securely place the cylinder on a (11).
workbench using a crane.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder. 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
2. Fully extend cylinder rod (11). Secure the rod bushing (5).
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
Bucket cylinder assembly 9. Align the holes on cylinder rod (11) and nut
(24).
Insert steel ball (23) into the hole, and tighten
1. Install bushing (5) to cylinder head (7) using a set screw (22) into the hole.
press. Mushroom the head of set screw (22) at two
Special tools for bushing installation (5): places using a punch and hammer.
- Bucket cylinder: 80 mm (XXXXXXXX)
: 10 mm
: 56.9 10.7 Nm
IMPORTANT: be sure that the rings are installed
correctly.
IMPORTANT: be sure to align cylinder rod (11) with
the center of cylinder tube (12) when inserting, in
order to avoid damaging the rings.
2. Install seal (3), back-up ring (2), elastic ring (6)
and seal (4) on the cylinder front sleeve (7).
10. Secure cylinder tube (12) horizontally using a

work bench.
3. Install wiper ring (1) to cylinder head (7) using a Insert cylinder rod (11) into cylinder tube (12).
plastic hammer.
11. Install cylinder head (7) to cylinder tube (12).

4. Install O-Rings (10) and backup ring (9) to Tighten socket bolts (8).
cylinder head (7).
: 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:
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
Arm cylinder
14
13
19
20
15
23 22
16
17
18
16
20 11
19 25
26
27
28
12
1
2
3
8 4
5
6
9
10
SM0241
1- Wiper Ring 10 - O -Ring 19 - Slide Ring

2- Backup Ring 11 - Cylinder Rod (q.ty 2)
4- Seal 13 - Cushion Bearing (q.ty 2)
5- Bushing 14 - Cushion Seal 22 - Set Screw
6- Snap Ring 15 - Piston 23 - Steel Ball
7- Cylinder Head 16 - Backup Ring 25 - Snap Ring
8- Socket Bolt (q.ty 2) 26 - Cushion Seal
(q.ty 12) 17 - Seal Ring 27 - Cushion Bearing
9 - Backup Ring 18 - O -Ring 28 - Stopper
W4-1-28
Arm cylinder disassembly 7. Remove seal ring (17), slide rings (19) and (20),
(15).
(11).
9. Remove O-Rings (10), backup rings (9) and (2)

NOTE: arm cylinder mass: 251 kg
1. Lift and securely place the cylinder on a bushing (5).
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).
2. Fully extend cylinder rod (11). Secure the rod
: 14 mm



cylinder rod (11) and piston nut (15).

: 10 mm

screwed in.
6. 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
Arm cylinder assembly 9. Align the holes on cylinder rod (11) and piston
nut (15). Insert steel ball (23) into the hole, and
tighten set screw (22) into the hole.
1. Install bushing (5) to cylinder head (7) using a Mushroom the head of set screw (22) at two
press. places using a punch and hammer.
Special tools for bushing installation (5):
(XXXXXXXX) : 10 mm
: 56.9 10.7 Nm
correctly.
10. Install snap ring (25) and cushion seal (26) to
cylinder rod (11). Install cushion bearing (27)
and stopper (28) to cylinder rod (11).
3. Install wiper ring (1) to cylinder head (7) using a
plastic hammer.
IMPORTANT: be sure to keep cylinder rod (11)
aligned with the center of cylinder tube (12) when
4. Install O-Rings (10) and backup ring (9) to inserting, in order to avoid damaging the rings.
cylinder head (7).

5. Install O-Ring (18), backup ring (16) (Q.ty 2), vise.
seal ring (17), slide ring (19) (Q.ty 2) and (20) Insert cylinder rod (11) into cylinder tube (12).
(Q.ty 2) to piston (15).
Special tools for seals assembly: (XXXXXXXX)
Tighten socket bolts (8).
6. Install cylinder head (7) to cylinder rod (11). : 14 mm
Special tools for cylinder head installation:
(XXXXXXXX) : 367 Nm

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).
Nut Turning Special Tools (24):
-110 mm (XXXXXXXX)
: 10280 Nm
W4-1-30
Positioner cylinder (triple articulation version)
19
20
15
16
17
18
16
19
20
21
24
23 22
11
12
1
2
3
8 4
5
6
9
10
SM0242
1- Wiper Ring 9 - Backup Ring 19 - Slide Ring

2- Backup Ring 10 - O -Ring (q.ty 2)
3- Seal 11 - Cylinder Rod 20 - Slide Ring
4- Seal 12 - Cylinder Tube (q.ty 2)
5- Bushing 15 - Piston 21 - Shim
6- Snap Ring 16 - Backup Ring 22 - Set Screw
7- Cylinder Head (q.ty 2) 23 - Steel Ball
8- Socket Bolt 17 - Seal Ring 24 - Nut
(q.ty 12) 18 - O -Ring
W4-1-31
Positioner cylinder disassembly 8. Remove cylinder head (7) from cylinder rod
(11).
starting the disassembly procedure. 9. Remove O-Rings (10), backup rings (9) and (2)
bushing (5).
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.

: 17 mm




: 12 mm

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),

(15).
W4-1-32
Positioner cylinder assembly

1. Install bushing (5) to cylinder head (7) using a order to avoid damaging the rings.
press.
Special tools for bushing installation (5):
(XXXXXXXX)
IMPORTANT: be sure that the rings are installed work bench.
correctly. Insert cylinder rod (11) into 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).

2) to piston (15).
Special tools for seals assembly: (XXXXXXXX)

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).
Nut Turning Special Tools (24):
- 110 mm (XXXXXXXX)
: 9900 Nm
9. lign the holes on cylinder rod (11) and nut (24).

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
Boom cylinders
13
19
20
15
16
17
18
16
19
20
21
24
23 22
11
12
1
2
3
8 4
5
6
9
10
SM0240
1- Wiper Ring 9 - Backup Ring 18 - O-Ring

2- Backup Ring 10 - O-Ring 19 - Slide Ring
3- Seal 11 - Cylinder Rod (q.ty 2)
5- Bushing 13 - Cushion Bearing (q.ty 2)
6- Snap Ring 15 - Piston 21 - Shim
7- Cylinder Head 16 - Backup Ring 22 - Set Screw
8- Socket Bolt (q.ty 2) 23 - Steel Ball
(q.ty 12) 17 - Seal Ring 24 - Nut
W4-1-34
Boom cylinders disassembly 7. Remove seal ring (17), slide rings (19) and (20),
(15).
(11).
9. Remove O-Rings (10), backup rings (9) and (2)

NOTE: boom cylinder mass: 176 kg
1. Lift and securely place the cylinder on a bushing (5).
workbench using a crane.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.

: 14 mm




: 10 mm

screwed in.
6. 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
Boom cylinders assembly 9. Align the holes on cylinder rod (11) and nut
(24).
1. Install bushing (5) to cylinder head (7) using a set screw (22) into the hole.
press. Mushroom the head of set screw (22) at two
Special tools for bushing installation (5): places using a punch and hammer.
- Boom cylinders: 85 mm (XXXXXXXX)
: 10 mm
: 56.9 10.7 Nm
correctly.
order to avoid damaging the rings.

work bench.
3. Install wiper ring (1) to cylinder head (7) using a Insert cylinder rod (11) into cylinder tube (12).
plastic hammer (7).

4. Install O-Rings (10) and backup ring (9) to Tighten socket bolts (8).
cylinder head (7).
: 14 mm
: 267 Nm

2) to piston (15).
Special tools for seals assembly:

Special tools:
- Boom cylinders: (XXXXXXXX)

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).
Socket to tighten nut (24):
- Boom cylinder: 90 mm (XXXXXXXX)
: 5470 Nm
W4-1-36
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)

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

Tool for the installation and removal of the rod guide bushing:
XXXXXXXXX for boom cylinders ( 85 mm)
XXXXXXXXX for bucket cylinder ( 80 mm)
XXXXXXXXX for arm cylinder ( 95 mm)
XXXXXXXXX for positioner arm cylinder ( 90 mm)

Head installation tool:
XXXXXXXXX for boom cylinders
XXXXXXXXX for bucket cylinder
XXXXXXXXX for arm cylinder
XXXXXXXXX for positioner arm cylinder

W4-1-37
Maintenance standard: rod
SM0243
Cylinders STANDARD (A) Remedy
Boom 85 0.03
Arm 95 0.03
Replace
or plate with chromium
Bucket 80 0.03
Positioning (*) 90 0.03
(*) Triple articulation version Unit: mm
W4-1-38

New Holland KOBELCO E215B E245B Workshop Manual

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E215B

Print No. 87677762A

NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. - Product Support

- Be sure to thoroughly read this manual for NEW HOLLAND KOBELCO

Please refer to the materials listed below in

- Operation and Maintenance Instruction

WORKSHOP MANUAL COMPOSITION

Consecutive page number for each group

Group number (if exist))

This is the safety alert symbol.

SI Units (International System of Units) are used in this manual.

Example: 24.5 MPa (250 kgf/cm2)

mm ft 0.003281 MPa psi 145.0

Volume L US gal 0.2642 Power kW CV-PS 1.360

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 Flow rate L/min US gpm 0.2642

Torque N.m kgf.m 0.10197 mL/rev cc/rev 1.0

N.m lbf.ft 0.7375

SAFETY PRECAUTIONS Page

Section 1 GENERALITIES ..................................................................... S1

Section 3 COMPONENT OPERATION

OPERATIONAL PERFORMANCE TEST

Section 1 GENERAL INFORMATION

Section 4 FRONT ATTACHMENT

Section 2 SAFETY PRECAUTIONS

Section 3 SAFETY PLATES

Always keep head, body, limbs, feet, hands, and

RECOGNISE SAFETY INFORMATION

This is your SAFETY ALERT SYMBOL

- When you see this symbol on your machine or

UNDERSTAND SIGNAL WORDS

In this Manual you will find the following words

DANGER: indicates an imminent hazardous

WARNING: indicated a potential hazardous

CAUTION: indicates a potential hazardous situation IMPORTANT

NOTE: indicates an additional explanation for

This Manual also contains this symbol

FOLLOW SAFETY PRECAUTIONS

Carefully read and observe all safety signs on the

PREPARE FOR EMERGENCIES

Be prepared if a fire starts or an accident occurs.

WEAR PROTECTIVE CLOTHING

Wear close-fitting clothing and safety equipment

PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause

INSPECT THE MACHINE

Inspect the machine carefully every day or work-

USE HAND HOLDS AND STEPS

Falling is one of the major causes of personal

- When you get on and off the machine, always

ADJUST THE OPERATOR'S SEAT

A seat poorly adjusted for operator or work

- The seat should be adjusted whenever machine

FASTEN SEAT BELT

Should the machine overturn, the operator may

- Prior to operating the machine, thoroughly

MOVE AND OPERATE MACHINE SAFELY

Bystanders can be run over.

- Pay the utmost attention not to run over

OPERATE ONLY FROM THE DRIVER'S SEAT

Inappropriate engine starting procedures may

DO NOT CARRY PERSON ON THE MACHINE