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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
GENERALITIES E215B-E245B

the attachment if necessary, only after assessing that The load must always be properly arranged in the
ground conditions allow the traverse safely and bucket; move with extreme care when transporting
without risks. oversize loads.
The gradient you may attempt to overcome is limited Do not lift and move the bucket overhead where
by factors such as ground conditions, load being persons are standing or working, nor downhill when
handled, machine type and speed, and visibility. working on a slope as this would decrease machine
There is no substitute for good judgement and stability. Load the bucket from the uphill side.
experience when working on slopes. Loads to be raised using the machine should be
Avoid operating the attachment too close to an exclusively hooked to the hitch specially provided.
overhang or high wall, either above or below the The excavator is no lifting and transportation means,
machine. Beware of caving edges, falling objects therefore it should not be used to position loads
and landslides. Remember that such hazards are accurately. Should it be exceptionally used to lift and
likely to be concealed by bushes, undergrowth and lay building components, special caution must be
such. taken as follows:
Avoid faggots, bushes, logs and rocks. Never drive
over them, nor over any other surface irregularities
- The machine must be equipped compulsorily with
that discontinue adherence or traction with the
the appropriate variant provided upon request.
ground, especially near slopes or drop-offs.
- Secure the loads to be raised using cables or
Be alert to avoid changes in adherence conditions
chains fastened with appropriate hooking
that could cause loss of control. Work with extreme
mechanisms.
care on ice or frozen ground and on stepped slopes
or near drop-offs. - Nobody should be allowed to remain under the
raised load or within the excavator operating range
The word bulldozing generally refers to work in
for any reason whatever.
virgin rough terrain, characterised by the presence of
all the perils and risks listed above. We emphasise
the danger represented in these conditions by large Never exceed specified loading capacity. Incorrect
tree limbs (possibly falling on the machine) and large fastening of slings or chains may cause boom/arm
roots (which may act as a leverage under the failure or failure of the lifting means with consequent
machine when up-rooted and cause the unit to bodily injuries and even death.
overturn). Always ensure that slings and chains used for lifting
Position the machine dependent upon the loading are adequate to the load and in good condition.
and unloading areas in order to swing leftwards to All loading capacities are referred to the machine
load to obtain best visibility. on a level surface and should be disregarded
Never use the bucket or attachment as a man lift when working on a slope.
or carry riders. Never use the machine as a work Avoid travelling across slopes. Proceed from uphill
platform or scaffolding. The machine must not be downhill and vice-versa. If machine starts slipping
improperly used for works not consistent with its sideways when on a slope, lower the bucket and
features (such as pushing railway cars, trucks or thrust bucket teeth into the ground.
other machines).
Working on slopes is dangerous. Grade the working
Always pay attention to people within the machine area if possible. Reduce work cycle time if it is not
operating range. possible to grade the working area.
Never move or stop the bucket, other loads or the Do not move full bucket or a load from uphill downhill
attachment above ground personnel or truck cabs. as this would reduce machine stability. Do not work
Ensure the truck driver is in a safe place before with the bucket turned to the uphill side.
loading the truck. Do not work with the bucket turned uphill as
Load trucks from side or rear. counterweights protruding downhill would reduce
Use only the type of bucket recommended machine stability on the slope and increase risk of
considering machine type, materials to be handled, overturning.
material piling up and loading characteristics, ground We recommend to work on slopes with the bucket
type and other typical conditions of the work to be downhill, after checking machine stability with the
performed. bucket empty and attachment retracted, by slowly
When transporting a loaded bucket, keep it as swinging the upper structure by 360.
rolled-back as possible. Keep boom and arm as low Position the carriage at a right angle relative to
as possible. slopes, hanging walls, etc. to exit the working area
Ground speed should be adequate to the load and easily.
ground conditions. Standard use, provides for the travel controls at the
front and travel motors at the back. Should travel

S1 - 3
E215B-E245B GENERALITIES

motors be positioned at the front with regard to the - Look up the in the telephone directory.
actual travel direction. Remind relative to travel - Define together with the Company representative
direction that controls are reversed. which precautions should be taken to guarantee
Always check travel motor position before moving off. work safety.
Properly judge ground conditions with particular - All electric lines should be considered as operative
attention to consistency of the area you are going to live lines even though it might be well known that
work on. the line in question is out of work and visibly
Keep the machine sufficiently far from the ditch connected to the ground.
edge. - The Electric Power Company, if previously advised
Never dig under the machine. and involved in the work, as well as machine
Operator, Owner and/or any natural person or legal
Should it be necessary to dig under the machine,
entity having rent orleased the machine or being
always ensure that digging walls are opportunely
responsible at the time by contract or by law, are
propped up against landslide to prevent the machine
liable for the adoption of the necessary
from falling into the trench.
precautions.
Do not swing the upperstructure, raise the load or
- Decrease work speed. Reaction time could be too
brake abruptly if not required. This may cause
slow and distance evaluation wrong.
accidents.
- Warn all ground personnel to keep clear of the
Prior to beginning the work near gas distribution
machine and/or load at all times. If the load has to
mains or other public utilities:
be guided down for laying, consult the Electric
- Contact the company owner of the gas mains or its Power Company to know which precautions should
nearest branch before starting the work. Look up be taken.
the number in the telephone directory.
- Appoint a person in charge of signalling duties.
- Define together which precautions should be taken This person will have the responsibility of observing
to guarantee work safety. the machine, any part of it and/or the load
- Decrease work speed. Reaction time could be too approaching the electric lines from a standpoint
slow and distance evaluation wrong. more favourable than the 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
GENERALITIES E215B-E245B

Never leave the machine unattended with the engine Read all safety plates mounted on the machine and
running. observe instructions they contain before starting,
Prior to leaving the 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
E215B-E245B GENERALITIES

Never lubricate, repair or adjust the machine with the flammable fluids to clean parts. Use proprietary
engine running, except when this is specifically certified non-flammable, non-toxic solvents only.
required by the Operation and Maintenance When using compressed air to clean parts, wear
Instruction Manual. safety glasses with side shields. Limit pressure to
Do not wear loose clothing, jewellery near rotating max. 2 bars, in accordance with local and national
parts. safety regulations in force.
When service or maintenance require access to Do not run the engine of this machine in closed
areas that cannot be reached from the ground, use a buildings without proper forced ventilation capable to
ladder or step platform conforming to local or national remove toxic exhaust gases concentrating in the air.
regulations to reach the working area. If such means Do not smoke, nor allow open flames or sparks
are not available, use machine grab rails and steps. nearby while refuelling the unit or handling highly
Always perform all service or maintenance work with flammable materials.
the greatest care and attention.
Do not use open flames as light sources to look for
Shop and/or field service platforms or ladders should leaks or inspect anywhere on the machine.
be manufactured and maintained in accordance with
Make sure that all mechanical tools provided are in
local or national safety regulations in force.
good condition at all times. Never use tools with
Disconnect batteries and label all controls to warn mushroomed or damaged heads. Always wear eye
that service work is in progress, according to local protections with side shields.
and national safety regulation requirements.
Move with extreme care when working under, on or
Block the machine and all attachments to be raised near the machine or its attachments.
according to local and national safety regulation
In case of attachment tests during which the engine
requirements.
should be kept running, a qualified operator must sit
Do not check or fill fuel tanks or install batteries near in the 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
GENERALITIES E215B-E245B

operating range before starting or operating the injuries are most likely to occur. Pay attention to
machine and/or its attachments. prevent possible part movements by means of
Sound the horn. blocks or by keeping clear of such zones when
motion may take place during maintenance or repair.
Rust inhibitors are volatile and flammable.
Move the hydraulic system lock safety lever to the
Prepare parts in well ventilated areas. Keep open
lock position when stopping the machine for
flames away.
whatever reason.
Do not smoke.
Always install the safety stays for the hood and other
Store containers in a cool well ventilated place where hinged covers before performing any maintenance or
they could not be reached by unauthorised people. repair work in the engine compartment.
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
TRANSFERS AND TRANSPORTATION
safety shoes and gloves, safety glasses when
splinters or other particles may be ejected.
Wear the appropriate 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
E215B-E245B GENERALITIES

Tow the machine following the instructions contained Before any maintenance or repair, make sure that
in the Operation and Maintenance Instruction there are no fuel or electrolyte leaks from the
Manual. batteries. If any, correct prior to proceeding with
further work. Do not recharge batteries in confined
spaces. Ensure proper ventilation is provided to
avoid accidental explosions due to build-up of
ENGINE explosive gas released during charging.
Disconnect batteries before working on the electrical
Do not run the engine in closed buildings without system or carrying out any other type of work.
proper ventilation capable to remove harmful exhaust
fumes.
Do not place head, body, limbs, feet, hands or fingers
HYDRAULIC SYSTEM
near rotating fans or belts. Be especially careful near
blower fans.
Loosen the radiator cap very slowly to relieve system Pressure fluid escaping from a very small hole can be
pressure before removing it. Always top-up coolant almost invisible and still have sufficient force to
level with the engine off or idling if hot. See the penetrate the skin. Always check any suspected
Operation and Maintenance Instruction Manual. pressure leaks using a piece of cardboard or wood.
Keep the exhaust manifold and tube free from Do not use hands. If injured by escaping fluid, obtain
combustible matters. Fit the machine with shields medical attention immediately or serious infection or
and guards when working in the presence of reaction may develop.
combustible matter free in the air. Stop the engine and ensure pressure is relieved from
Do not refuel with the engine running, especially if all systems before removing side panels, housings,
hot, as this increases fire hazard in case of fuel guards and covers. See the Operation and
spillage. Maintenance Instruction Manual.
Never attempt to check or adjust fan belt tensions Always use gauges of adequate capacity for
when the engine is running. pressure testing. Refer to the Operation and
Maintenance Instruction Manual or Repair Manual.
Do not adjust the fuel injection pump when the
machine is operating.
Do not lubricate the machine with the engine running.
Do not run the engine with the air intakes open and
not protected. If this cannot be avoided for service
reasons, place protection meshes on all intakes TOOLS
before servicing the engine.

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
SAFETY PRECAUTIONS E215B-E245B

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
SAFETY PRECAUTIONS E215B-E245B

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
E215B-E245B SAFETY PRECAUTIONS

USE HAND HOLDS AND STEPS

Falling is one of the major causes of personal


injury.

- When you get on and off the machine, always


face the machine and maintain a three-point
contact with the steps and handrails.
- Prior to climbing or leaving the machine, check
that the fasteners of stepping points and the
handrails are tightened and are undamaged.
Repair them as required.
- Keep the access to the machine clear of foreign
objects and clean. Remove grease or mud from
stepping points and rails to minimise the danger
of slipping or stumbling.
- Do not use the controls or the safety lever as
hand holds when climbing on or off the machine.
- Do not climb or leave the machine running. Do
not jump on or off the machine.
- Do not climb or leave the machine while holding
tools or other objects in your hands.
- Do not climb or leave the machine while it is
moving.

ADJUST THE OPERATOR'S SEAT

A seat poorly adjusted for operator or work


requirements may quickly fatigue the operator
leading to improper operations.

- The seat should be adjusted whenever machine


operator changes.
- The operator should be able to fully press the
pedals and correctly move the control levers
with his back resting against the seat back.
- If not, move the seat fore and aft, and check
again.

S2 - 4
SAFETY PRECAUTIONS E215B-E245B

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
E215B-E245B SAFETY PRECAUTIONS

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
SAFETY PRECAUTIONS E215B-E245B

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
E215B-E245B SAFETY PRECAUTIONS

DRIVE MACHINE SAFELY

Before moving the machine, confirm which way to


move travel pedals/levers for the corresponding
direction you wish to go.

- Pushing down on the front of the travel pedals or


pushing the levers forward moves the machine
towards the idlers.

Traveling on a grade may cause the machine to


slip or to overturn, possibly resulting in serious
injury or death.

- When traveling up or down a grade, keep the


bucket in the direction of travel, approximately
20 to 30 cm (A) above the ground.

- If machine starts to skid or becomes unstable,


lower the bucket immediately.

- Traveling across the face of a slope may cause


the machine to skid or to overturn. When
travelling (ascending/descending) on a slope,
be sure to point the tracks uphill/downhill.

- Turning on an incline may cause the machine to


tip over. If turning on an incline is absolutely
unavoidable, do so at a place where the slope is
gentle and the surface is firm.

- Do not travel on slopes with an angle exceeding


30. Do not travel across hill on slopes
exceeding an angle of 15.

S2 - 8
SAFETY PRECAUTIONS E215B-E245B

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
E215B-E245B SAFETY PRECAUTIONS

INVESTIGATE JOB SITE BEFORE


OPERATING THE MACHINE

Explore the working area to identify potential risks


before starting and operating the machine. Make
sure that the structure and the conditions of the
ground are safe before starting operations.
- Make sure that the digging area is sufficiently
stable and firm to support the weight of the
machine during the work operations.
- Working near edges and ditches presents a risk
for the stability of the machine. Check first that
edges and the walls of the digging are
sufficiently strong. If necessary, prop the edges
appropriately to prevent caving-ins.
- DO NOT dig too near the machine.
- Always position the tracks perpendicular to the
edge of the digging with the travel motors on the
rear side.
- When working on a slope or near the edge of the
road, have a flagman available.

PROTECTING AGAINST THE FALL OF


ROCKS AND LANDSLIDES
When operating in zones where the possibility of
falling rocks or landslides exists or when there is
the risk for front impacts with objects that could
penetrate the cab, make sure that protection
structures are installed: F.O.P.S. (Falling Object
Protection Structure) and FRONT GUARD.
- DO NOT install any cab lifting device to the
protection structures.
- DO NOT weld, drill or modify protective
structures. Any type of modification could
weaken the structural integrity of the safety
system, with serious consequences for the
operator, in case of collision, falling objects or
landslides.
- After an accident, DO NOT try to straighten or
repair protective structures. Contact a Dealer to
verify the functionality, to repair or to completely
or partially replace the protective structures.

S2 - 10
SAFETY PRECAUTIONS E215B-E245B

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
E215B-E245B SAFETY PRECAUTIONS

KEEP PERSONNEL CLEAR FROM


WORKING AREA

A person may be hit severely by the swinging front


attachment or counterweight and/or may be
crushed against an other object, resulting in
serious injury or death.

- Keep all persons clear from the area of


operation and machine movement.
- Before operating the machine, set up barriers to
the sides and rear area of the bucket swing
radius to prevent anyone from entering the work
area.

NEVER MOVE THE BUCKET OVER


ANY ONE

Never lift, move, or swing bucket above anyone or


a truck cab. Serious injury or machine damage
may result due to bucket load spill or due to
collision with the bucket.

SP0030

DO NOT OPERATE IN TUNNELS

DO NOT operate the machine in enclosed spaces


or, in any case, without appropriate ventilation.
Operations in tunnels or underground sites where
potential explosive conditions exist are not
allowed. There is a danger for explosions and
potentially deadly injuries. Please comply with the
ATEX regulation relative to devices to be used in
a potentially explosive environment.

S2 - 12
SAFETY PRECAUTIONS E215B-E245B

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
E215B-E245B SAFETY PRECAUTIONS

AVOID EXCESSIVE DIGGING EFFORTS

Operate the machine complying with the load


limits in accordance with the "table of lifting loads"
located inside the cab.
- Do not exceed the prescribed load limits.
- Do not use the strength of the attachment to
travel or move the machine.
- Do not try digging exploiting the mass of the
machine.

PAY ATTENTION WHEN DIGGING DEEPLY

When digging deeply, pay special attention to


prevent contacts of the attachment and the
relevant hydraulic hoses with the ground.
DO NOT swing the turret or the undercarriage
when the attachment boom is fully lowered. Under
these conditions there is the danger that the boom
collides with the track chains.

DO NOT USE THE TRACTION FORCE OF


THE MACHINE FOR DIGGING

Do not travel the machine to dig. In doing this, an


excessive stress on the front attachment could
results in damages to the structure. Use the
undercarriage for travelling only.

DO NOT USE THE TURRET SWING FOR


DIGGING

Do not use the turret swing for digging or moving


rocks. An excessive stress on the front
attachment could results in damages to the
structure reducing the operating life of the swing
system. Also, this inappropriate use of the
machine could cause serious injuries or fatalities.

S2 - 14
SAFETY PRECAUTIONS E215B-E245B

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
E215B-E245B SAFETY PRECAUTIONS

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

S2 - 16
SAFETY PRECAUTIONS E215B-E245B

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
E215B-E245B SAFETY PRECAUTIONS

DISPOSE OF WASTE IN THE APPROPRIATE


MANNER

Waste improperly disposed of represents a


danger for the envinronment. Potentially
dangerous waste used on the excavators
includes lubricants, fuel, coolant, brake fluid,
filters and batteries.

- Used sealed containers when discharging


fluids. Do not use containers for food or
beverages which may induce drinking.

- Do not spill waste over the ground, into drains,


or water beds.

- Obtain information about the correct methods to


recycle or dispose of waste from local
Authorities, collection centres or your Dealer.

WORK IN A CLEAN AREA

- Before starting an operation, clean the working


area. Clear the area from all the objects that can
be dangerous for mechanics or people in the
working area.

PROPERLY LIGHT THE WORKING AREA

Properly and safely light the working area.


- Use safe portable lamps in order to work inside
and under the machine.
- Make sure that the lamp is shielded by a cage;
the incandescent filament of a lamp,
accidentally broken, can cause fuel or oil fire.

S2 - 18
SAFETY PRECAUTIONS E215B-E245B

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
E215B-E245B SAFETY PRECAUTIONS

STARTING THE ENGINE WITH BOOSTER


BATTERIES

If the engine is to be started using booster


batteries, ensure to comply with all procedures
detailed in the chapter OPERATING
INSTRUCTIONS.
- The operator should be sitting in the 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
SAFETY PRECAUTIONS E215B-E245B

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
E215B-E245B SAFETY PRECAUTIONS

AVOID HIGH-PRESSURE FLUIDS

Fluids such as diesel fuel or hydraulic oil under


pressure can penetrate the skin or eyes causing
serious injury, blindness or death.

- Avoid this hazard by relieving pressure before


disconnecting hydraulic or other lines.

- Tighten all 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
SAFETY PRECAUTIONS E215B-E245B

PROTECT AGAINST FLYING DEBRIS

If flying debris hit eyes or any other part of the


body, serious injury may result.

- Guard against injury from flying pieces of metal


or debris; wear goggles or safety glasses.
- Keep bystanderds away from the working area
before striking any object.

HANDLE FLUIDS SAFELY - AVOID FIRES

Handle fuel with care: it is highly flammable. If fuel


ignites, an explosion and/or a fire may occur,
possibly resulting in serious injuty or death.

- Do not refuel the machine while smoking or


when near open flame or sparks.

- Always stop the engine before refuelling the


machine.

- Fill the tank outdoors.

All fuels, most lubrificants, and some antifreeze


fluids are flammable.

- Store flammable fluids well away from fire


hazards.

- Do not burn or puncture pressurized containers.

- Do not store oily rags; they can ignite and burn


spontaneously.

S2 - 23
E215B-E245B SAFETY PRECAUTIONS

PREVENT FIRES
Check for Oil Leaks:
- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts
which may cause oil leaks.
- Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil-
cooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts:
- Short circuits can cause fires.
- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10)
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
Check Key-start Switch:
- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF
position to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.
Check Heat Shields:
- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.

S2 - 24
SAFETY PRECAUTIONS E215B-E245B

EVACUATING IN CASE OF FIRE

If a fire breaks out, evacuate the machine in the


following way:

- Stop the engine by turning the key-start switch


to the OFF position if there is time.

- Use a fire extinguisher if there is time.

- Exit the machine.

BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can


cause sickness or death.

- If you must operate in a building, be sure there


is adequate ventilation. Either use an exhaust
pipe extension to remove the exhaust fumes or
open doors and windows to bring enough
outside air into the area.

SP0062

USE APPROPRIATE TOOLS

Use tools appropriate for the job to be performed.

- Inappropriate tools, parts and procedures might


generate dangerous conditions.

- Use tools of correct size to tighten or loosening


securing elements, in order to avoid injuries
caused by a wrench getting out of control.

- Do not use U.S. Standard or British Standard


tools on metric fasteners and vice versa.

Use only genuine spare parts (please refer to the


Spare Parts Catalogue).

S2 - 25
E215B-E245B SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED


FLUID LINES

Flammable spray can be generated by heating near


pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable
materials.

Pressurized lines can be accidentally cut when heat


goes beyond the immediate flame area. Install
temporary fire resistant guards to protect hoses or
other materials when welding, soldering, etc.

AVOID APPLYING HEAT TO LINES


CONTAINING FLAMMABLE FLUIDS

- Do not weld or flame cut pipes or tubes that


contain flammable fluids.
- Clean them thoroughly with non-flammable
solvent before welding or flame cutting them.

REMOVE PAINT BEFORE WELDING OR


HEATING

Hazardous fumes can be generated when paints


is heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
- Avoid breathing potentially toxic fumes and
dust.
- Do all such work outside or in a well-ventilated
area.
- Dispose of paint and solvents properly.
- Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing
the dust. Wear an approved respirator.
2. If you use solvent or paint stripper, remove
stripper with soap and water before
welding. Remove solvent or paint stripper
containers and other flammable material
from area. Allow fumes to disperse at
least 15 minutes before welding or
heating.

S2 - 26
SAFETY PRECAUTIONS E215B-E245B

WELDING REPAIR INTERVENTIONS

Welding repair interventions must be performed


only by a certified welder with sufficient
experience. Also, appropriate safety rules must be
implemented by all the personnel involved in the
operations. The duration through time of the
welding depends upon the quality and the
accuracy with which the operation is performed.
- Identify first all the fracture points and the zones
in which welding is required.
- Clean accurately the zones involved.
- Remove all paint and inspect the parts with
penetrating liquid or a magnetic particle tester.
- Move the starter switch into position "OFF" and
wait for 4 seconds to cut-off electricity from the
system.
- Disconnect the negative terminal (-) from the
battery.
- Connect the ground cable of the welder at least
1 m from the component to be welded.
- Make sure that the ground cable is NOT
connected to a seal or bearing and that there
are noo seals or bearings between the ground
cable and the part to be welded.
- Avoid welding pieces at low temperature i. e.
below 16 C. If necessary, warm-up the part
involved prior to welding it.
- Remove paints from all surfaces prior to
warming-up or welding. Painted surfaces, when
warmed-up or when welded, can generate toxic
fumes.
- Use appropriate masks or protective glasses.
- Wear gloves and adequate clothing to protect
the skin.

S2 - 27
E215B-E245B SAFETY PRECAUTIONS

NOTE:

S2 - 28
SAFETY PLATES E215B-E245B

SAFETY PLATES

Triple articulation version

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
SAFETY PLATES E215B-E245B

1 - Attachment operating range safety plate

Ensure that any person near the working site is


outside the machine operating range before
starting the machine or operating the
attachments. Sound the horn.
Background: yellow
Border and icons: black

2 - Track adjuster plate

It shows that obligation is made to consult the


Operation and Maintenance Instruction Manual
prior to acting on the track adjust valve.
Danger of severe injuries.
Background: yellow
Border and icons: black

3 - Counterweight operating range safety plate

Ensure that any person near the working site is


outside the machine operating range before
starting the machine or operating the
attachments. Sound the horn.
Background: yellow
Border and icons: black

S3 - 3
E215B-E245B SAFETY PLATES

4 - Read-your-manual plate

It is positioned in the cab to recommend to


carefully read the Operation and Maintenance
Instruction Manual prior to starting, operating,
servicing, refuelling or carrying out any other
work on the machine.
Background: yellow
Border and icons: black

5 - Boom and arm movement warning plate


(triple articulation version)

It shows the danger represented by the bucket


hitting the cab.
Pay special attention as no stops are provided to
prevent this problem.
Background: yellow
Border and icons: black

SP0073

6 - Open windscreen warning plate

It indicates the risk of injuries deriving from the


windscreen not being locked or being
improperly locked in the open position.
Background: yellow
Border and icons: black

S3 - 4
SAFETY PLATES E215B-E245B

7 - Tag indicating maintenance in progress

Maintenance staff is obliged to apply the tag that


indicates that the machine is not fully efficient
and warns about maintenance staff being
located in not visible positions. This tag should
be applied to the left-hand control lever, safety
lever or cab door.
Background: yellow
Border and icons: black

8 - Engine hood warning plate

It highlights the obligation to stop the engine


before opening engine hood.
Danger of severe injuries following the presence
of rotating parts such as fan, pulleys, and belts.
Background: yellow
Border and icons: black

9 - Controls lock/unlock plate

It shows the position that the safety lever can


assume when the engine is running.
When the operator is about to leave the cab with
the engine running, even if for a short time, he
must move the safety lever to the LOCK
position. Controls are disabled and therefore no
accidental machine or attachment movement is
possible.
Background: white
Border and icons: black

S3 - 5
E215B-E245B SAFETY PLATES

10 - Hydraulic oil pressurised tank


warning plate

It indicates that the hydraulic oil is pressurised.


Consult the Operation and Maintenance
Instruction Manual. Prior to intervening on the
hydraulic oil tank, bleed the pressure by
actuating the appropriate bleeding button
located on the cap. The hydraulic oil, at
operating temperature, can cause burns in
case of contact with the skin.
Background: yellow
Border and icons: black

11 - Burns danger plate

It indicates that a burns danger exists, since


the zone is characterised by high temperature.
Background: yellow
Border and icons: black

12 - Safety distance plate

It instructs to keep at a safe distance from a


zone dangerous for personal safety.
Background: yellow
Border and icons: black

S3 - 6
SAFETY PLATES E215B-E245B

13 - No-stepping warning plate

It instructs not to step on the zone where this


decal is attached.
Background: yellow
Cross: red
Border and icons: black

14 - Special equipment movement warning plate


It shows the danger represented by the special
equipment hitting the cab.
Pay special attention as no stops are provided
to prevent this problem.
Background: yellow
Border and icons: black

S3 - 7
E215B-E245B SAFETY PLATES

NOTE:

S3 - 8
OPERATIONAL PRINCIPLE

M0103
OPERATIONAL PRINCIPLE E215B-E245B

SECTION AND GROUP CONTENTS

Section 1 GENERAL
Group 1 Specifications

Section 2 SYSTEM
Group 1 Mechatro Control System
Group 2 Hydraulic System
Group 3 Electrical System

Section 3 COMPONENT OPERATION


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
(Monoblock Version) .......................... T1-1-11
Transporting dimensions E215B
(Triple Articulation Version) ............... T1-1-12
Bucket applications as a function
of the arms E215B ............................. T1-1-13
Digging data E245B
(Monoblock Version) .......................... T1-1-14
Digging data E245B
(Triple Articulation Version) ............... T1-1-15
Transporting dimensions E245B
(Monoblock Version) .......................... T1-1-16
Transporting dimensions E245B
(Triple Articulation Version) ............... T1-1-17
Bucket applications as a function
of the arms E245B ............................. T1-1-18
SPECIFICATIONS E215B-E245B

MAIN COMPONENTS

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
SPECIFICATIONS E215B-E245B

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
E215B-E245B SPECIFICATIONS

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
SPECIFICATIONS E215B-E245B

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
E215B-E245B SPECIFICATIONS

PILOT VALVE
ATTACHMENT TRAVEL
Model PV48K2004 6TH6NRZ
Primary pressure 5.0 MPa 4.9 MPa
Secondary pressure 0.6 ~ 3.2 MPa 0.54 ~ 2.35 MPa
Rated flow 20 L/min 25 L/min
Mass Approx. 2 kg Approx. 8 kg

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
SPECIFICATIONS E215B-E245B

TRAVEL DEVICE
Item E215B E245B
Reduction gear unit Epicycloidal, three-stage planetary type
Model 710 C3 K
Gearbox ratio 1 : 55.2 1 : 43.2
Travel motor Two speed, axial piston swash plate type
Model MAG 170 VP MAG 170 VP
high speed 81.2 cm3/rev 112.6 cm3/rev
Displacement
low speed 129.3 cm3/rev 181.3 cm3/rev
Max. flow 220 L/min 246 L/min

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
E215B-E245B SPECIFICATIONS

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
SPECIFICATIONS E215B

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
E215B SPECIFICATIONS

TRANSPORTING DIMENSIONS E215B


(Triple Articulation Version)

G E
D

H
F

I C
L

M A
N B NH0148

VERSIONS A B C D E F G H I L
(1) 9683 (1) 3062
(2) 9665 (2) 3014
E215BEL 3656 4451 1035 2800 2503 3027 948 471
(3) 9643 (3) 2954
(4) 9631 (4) 3237
(1) 9683 (1) 3062
(2) 9665 (2) 3014
E215BL 3656 4451 1035 2800 2503 3027 948 471
(3) 9643 (3) 2954
(4) 9631 (4) 3237
(1) 9683 (1) 3062
(2) 9665 (2) 3014
E215BLC 3656 4451 1035 2800 2503 3027 948 471
(3) 9643 (3) 2954
(4) 9631 (4) 3237
Arm: (dimensions in mm)
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 mm

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
SPECIFICATIONS E215B

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
E245B SPECIFICATIONS

DIGGING DATA E245B


(Monoblock Version)

(Dimensions in mm)

Arm 2080 2400 2940 3500


A 9185 9446 9929 10366
A 8991 9258 9750 10195
B 5822 6142 6682 7242
B 5602 5936 6501 7064
C 9458 9537 9751 9767
D 6755 6811 7055 7167
E 3679 3559 3544 3478
F 4286 3973 3521 2960
G 5005 5346 5879 6588

T1-1-14
SPECIFICATIONS E245B

DIGGING DATA E245B


(Triple Articulation Version)

(Dimensions in mm)

Arm 2080 2400 2940 3500


A 9322 9598 10098 10555
A 9131 9413 9922 10387
B 5572 5873 6399 6914
B 5449 5757 6292 6814
C 10700 10900 11298 11562
D 7773 7970 8369 8650
E 2929 2742 2524 2695
F 5034 4593 3742 3214
G 2470 2749 3151 3818

T1-1-15
E245B SPECIFICATIONS

TRANSPORTING DIMENSIONS E245B


(Monoblock Version)

VERSIONS A B C D E F G H I L
(1) 9617 (1) 3141
(2) 9577 (2) 3050
E245B 3840 4645 1053 2800 2503 3045 970 486
(3) 9487 (3) 2886
(4) 9564 (4) 3044
Arm: (dimensions in mm)
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 mm

E245B

M Track shoe width (mm) 550(*) 700 800(*)

N Gauge (mm) 2490 2690 2890

(**) Working weight (kg) 22000 22500 22850

Spec. ground pres. (bar) 0.51 0.41 0.37

(**) With arm 2940 mm and bucket 1.3 m3


(*) Asymmetric type shoes

T1-1-16
SPECIFICATIONS E245B

TRANSPORTING DIMENSIONS E245B


(Triple Articulation Version)

G E
D

H
F

I C
L

M A
N B NH0148

VERSIONS A B C D E F G H I L
(1) 9684 (1) 3067
(2) 9665 (2) 3014
E245B 3840 4645 1053 2800 2503 3045 970 486
(3) 9641 (3) 2957
(4) 9634 (4) 3235
Arm: (dimensions in mm)
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 mm

E245B

M Track shoe width (mm) 550(*) 700 800(*)

N Gauge (mm) 2490 2690 2890

(**) Working weight (kg) 22600 23100 23450

Spec. ground pres. (bar) 0.53 0.42 0.38

(**) With arm 2940 mm and bucket 1.3 m3


(*) Asymmetric type shoes

T1-1-17
E245B SPECIFICATIONS

BUCKET APPLICATIONS AS A FUNCTION


OF THE ARMS E245B
E245B Monoblock

BUCKETS E245B

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
SECTION 2 E215B-E245B

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
MECHATRO CONTROL SYSTEM E215B-E245B

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
E215B-E245B MECHATRO CONTROL SYSTEM

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
MECHATRO CONTROL SYSTEM E215B-E245B

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

PILOT SECONDARY PRESSURE

pi

pi

P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

SM0119

T2-1-5
E215B-E245B MECHATRO CONTROL SYSTEM

1. Positive control
1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each
low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator,
and consequently the working speed according to the lever manipulated movement will be obtained.
2. P-Q control
1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller
and the mechatro controller processes pilot signal and operates the command according to the input
voltage (load pressure).
2) The lower value between command values calculated by positive control and operated value found by
P-Q control {operated value found in item 1)} is selected and is output to each pump proportional valve
as command value.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator and
consequently working speed will be obtained according to lever movement.

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
MECHATRO CONTROL SYSTEM E215B-E245B

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

BOOM UP PILOT SECONDARY PRESSURE


pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

BOOM UP PILOT SECONDARY PRESSURE


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.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control
valve.
4. With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and
also with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are
switched and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during
boom up operation.

T2-1-7
E215B-E245B MECHATRO CONTROL SYSTEM

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 SECONDARY PRESSURE


PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM IN PILOT SECONDARY PRESSURE

P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D

PILOT SECONDARY PRESSURE

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
MECHATRO CONTROL SYSTEM E215B-E245B

1. Recirculation and conflux (Low loading)


1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2
spool and low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional
valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool.
In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure
sensor and the output voltage is input to mechatro controller. And the mechatro controller processes
pilot signal according to the combined operation and outputs command, which is different from the 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
E215B-E245B MECHATRO CONTROL SYSTEM

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

ARM IN PILOT SECONDARY PRESSURE


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

ARM IN PILOT SECONDARY PRESSURE


pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
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
MECHATRO CONTROL SYSTEM E215B-E245B

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

ARM OUT PILOT SECONDARY PRESSURE


pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM OUT PILOT SECONDARY PRESSURE


pi
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
ARM OUT PILOT SECONDARY PRESSURE
SECONDARY PRESSURE SM0124

1. On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and
is input to low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control
valves.
4. With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the
command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and
consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out
operation.

T2-1-11
E215B-E245B MECHATRO CONTROL SYSTEM

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

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE


pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE


pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE


pi
PILOT SIGNAL
PROCESS TRAVELSTRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE 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.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload proportional valves and travel straight proportional valve.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel
straight valve of the control valve.
4. The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump
delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.

T2-1-12
MECHATRO CONTROL SYSTEM E215B-E245B

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

BUCKET DIGGING PILOT SECONDARY PRESSURE


pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
ACCEL VALVE PSV-B
POTENTIO
BUCKET DIGGING PILOT SECONDARY PRESSURE
pi PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

BUCKET DIGGING PILOT SECONDARY PRESSURE


pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C

BUCKET DIGGING PILOT SECONDARY PRESSURE


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
SECONDARY PRESSURE SM0126

T2-1-13
E215B-E245B MECHATRO CONTROL SYSTEM

1. On starting bucket digging operation, bucket digging operating pilot pressure switches bucket spool and is
input to low pressure sensor.
2. The engine speed command output by accel potentiometer is input to mechatro controller.
3. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload proportional valves and travel straight proportional valve.
4. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel
straight valve of control valve.
5. The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump
delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
6. ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary
pressure, and actuate stroke limiter and then controls the stroke of bucket spool.
The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and
pump delivery rate is low.
7. When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to
the pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control
the stroke limit of bucket spool.

T2-1-14
MECHATRO CONTROL SYSTEM E215B-E245B

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
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
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.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve
for arm 2 spool.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel straight
spool, arm 2 spool.
4. With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the
command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are
switched enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently
the return oil on arm cylinder rod side is recirculated into arm cylinder head side.
5. Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery
rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with
minimum speed drop possible.

T2-1-15
E215B-E245B MECHATRO CONTROL SYSTEM

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

PILOT SECONDARY PRESSURE



pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

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

PILOT SECONDARY PRESSURE


pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

PILOT
SECONDARY PRESSURE SM0128

T2-1-16
MECHATRO CONTROL SYSTEM E215B-E245B

1. Judgment travel straight


1) During travel operation (right and left), pilot pressure switches each travel spool and is input to low
pressure sensor on carrying out attachment system operation.
2) Mechatro controller decides as travel straight on receiving the input according to the combination
shown in the table from the low pressure sensor and turns travel straight signal on.
3) On turning travel straight signal on, the following commands are output to each proportional valve.
2. Operation of each proportional valve
(Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump in
travel straight condition.)
1) Travel straight proportional valve outputs switching pressure according to the high priority select
pressure in the attachment system operating (Boom, arm, bucket, swing, option) pilot pressure during
operation.
2) Short-circuit proportional valve outputs pressure according to the high priority select pressure in the
both attachment and travel system operating pilot pressure during operation.
3) P1 unload proportional valve outputs switching pressure according to the high priority select pressure
in the attachment system operating pilot pressure during operation.
4) P2 unload proportional valve outputs switching pressure according to the high priority select in the
travel operating pilot pressure during operation.
5) P1 pump proportional valve outputs switching pressure according to the high priority select pressure in
the attachment system operating pilot pressure during operation.
6) P2 pump proportional valve outputs switching pressure according to the high priority select in the travel
operating pilot pressure during operation.

ATT operation Boom Arm Bucket Swing Option


Right travel operation (P1)
Left travel operation (P2)

T2-1-17
E215B-E245B MECHATRO CONTROL SYSTEM

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
PROCESS PROPORTIONAL
VALVE PSV-D
MECHATRO
pi : PROPORTIONAL VALVE SM0130
CONTROLLER SECONDARY PRESSURE

1. Change mechatro controller to PRESSURE DRAING MODE by operating switch on gauge cluster.
For detail of changing mode method, refer to Pressure draining (releasing) circuit on GROUP 2 -
HYDRAULIC CIRCUIT.
2. Once mechatro controller decides it as pressure release control, regardless of each input signal (operating
pilot, accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to
minimum tilt angle.
2) Outputs command of pressure release to control step-by step motor (M2) and fixes engine speed to
pressure release control speed.
3) Outputs maximum command to P1 and P2 unload proportional valves and each pilot secondary
pressure fixes P1 and P2 unload valves to the maximum opening.
3. Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump
pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
4. Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure)
to be released by operating each control lever and switching spool with the unload valve opened.

T2-1-18
MECHATRO CONTROL SYSTEM E215B-E245B

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
E215B-E245B MECHATRO CONTROL SYSTEM

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

OPTION PILOT SECONDARY PRESSURE


pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

OPTION PILOT SECONDARY PRESSURE


pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D

OPTION PILOT SECONDARY PRESSURE


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.
3. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload pressure proportional valves and travel straight proportional valve.
4. Each proportional valves output pilot proportional valve secondary pressure according to the command
output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload
valves and travel straight valve of the control valve.
5. The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and
P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.

T2-1-20
MECHATRO CONTROL SYSTEM E215B-E245B

3. MECHATRO CONTROLLER
3.1 SUMMARY OF MULTI DISPLAY
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
1. Controls

SWING PARKING
BRAKE RELEASE
GAUGE SWITCH
CLUSTER

SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.

FUSE &
STARTER SWITCH RELAY BOX

ACCEL DIAL
DETAIL A

SM0133
A

2. Gauge cluster

11
No. Name
22:00 1 Engine coolant temperature gauge
2 Fuel level gauge
H 3 Screen change switch
4 Buzzer stop switch
1 5 Work mode select switch
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 Select switch
10
6 11 Multi display (LCD)
4 9 8 5 7
SM0134

T2-1-21
E215B-E245B MECHATRO CONTROL SYSTEM

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
MECHATRO CONTROL SYSTEM E215B-E245B

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


No. Switches
1 Screen change switch
2 Buzzer stop switch
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 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
E215B-E245B MECHATRO CONTROL SYSTEM

4. MAINTENANCE SCREEN DISPLAYS


This screen displays the remaining time to the end of recommended replacement/change interval specified
for filter/oil.
For the initial set value of recommenced replacement/change time, see the following table.

Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
Hydraulic oil 5,000 Hr

This menu is available for confirmation of the following items.


The maintenance screen changes each time the screen change switch is pressed.

1) Remaining time display to the engine oil change


This display shows the remaining time to the coming engine oil change.
492Hr
ENGINE OIL
H

2) Remaining time display to the coming fuel filter replacement


This display shows the remaining time to the coming engine fuel filter
replacement.
492Hr
FUEL FILTER
H

3) Remaining time display to the coming hydraulic oil filter replacement


This display shows the remaining time to the coming hydraulic oil filter
replacement.
992Hr
HYD. FILTER
H

4) Remaining time display to the coming hydraulic oil change


This display shows the remaining time to the coming hydraulic oil
change.
4992Hr
HYD. OIL
H

NOTE:
The display automatically changes to the main screen, if switch is not operated for 30 seconds.
For the setting procedure of maintenance time to be performed to the coming oil change in each type and
filter replacement, see the paragraph 3.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.

T2-1-24
MECHATRO CONTROL SYSTEM E215B-E245B

5. Gauge cluster display


After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen.
The display functions of multi display are explained below.

CLOCK DISPLAY

SELF DIAGNOSIS / WARNING

MACHINE CONDITION

H
MULTI DISPLAY INDICATIONS
SM0146

1) Display function for operator .........................Screen usually displayed during operation


1.1 Clock display function ............................Current time is displayed.
1.2 Self-diagnosis display ............................When abnormality is detected on mechatro system like
sensor, proportional valve, etc., this displays error code.
1.3 Warning display .....................................When machine was thrown into dangerous state, or was
failed, displays warning symbol. (For warning contents, see items shown on the next page.)
1.4 Machine condition display ......................Displays machine operating condition.
2) Display function for maintenance...................Displays remaining time up to replacement/change of
following items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil
3) Failure history display function.......................Stores abnormality occurred on mechatro system in the past
and displays in order of recent occurrence.
4) Mechatro adjustment display .........................Displays procedure for adjustment of mechatro system like
output adjustment and unload adjustment, etc.
5) Service diagnosis display...............................Displays information like pressure sensor sensed value,
proportional valve command, etc. output by mechatro controller
6) Failure diagnosis mode display function .......Specifies failed section automatically for failures which are not
detected by self diagnosis and displays the results.

T2-1-25
E215B-E245B MECHATRO CONTROL SYSTEM

Warning table

These descriptions indicate error codes stored as trouble history code

W009 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
MECHATRO CONTROL SYSTEM E215B-E245B

Warning Condition
Trouble
Level Buzzer sounds
Priority Screen Condition Only Engine History
(*) Type Auto Manual Code
Key ON Run
(**) Stop Stop
Data from Mechatro controller
1 DATA COMMUCATION ERROR O O 3 x O
is not received
The swing parking brake
1 SWING BRAKE DISENGAGED O O 2 O O W001
switch is turned ON
Engine is stopped after engine
A 1 ENGINE STOP O 1 O x
oil pressare low warning
Impossible to drain hyd.
2 FAIL DRAIN HYD. PRESSURE O O 1 x O
Pressure
2 DRAINING HYD. PRESS. Possible to drain hyd. Pressure O 4 x O

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
E215B-E245B MECHATRO CONTROL SYSTEM

3. Self diagnosis display items


As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure
type with the aid of error code.
Alphabet: Decide system failure occurred.
10:25 B 01 3 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
MECHATRO CONTROL SYSTEM E215B-E245B

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
E215B-E245B MECHATRO CONTROL SYSTEM

2. Service diagnosis display screen (Example)


The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low
speed and lever to neutral position.)
1) Service diagnosis Mode No.1

No. 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
MECHATRO CONTROL SYSTEM E215B-E245B

No. Displays Contents No. Displays Contents


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
MEAS. 750 mA 3.0 M Measured value / Converted value from pressure DI6 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 --- ON/OFF indication
Mechatro
COMP. 350 mA 0.6 M Set value in computer / Converted value from pressure DI8 OFF ON/OFF indication
controller
MEAS. 350 mA 0.6 M Measured value / Converted value from pressure DI9 OFF ON/OFF indication
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
COMP. 750 mA 0.0 M Set value in computer / Converted value from pressure DI11 --- ON/OFF indication
MEAS. 750 mA 0.0 M Measured value / Converted value from pressure DI12 --- ON/OFF indication
DI13 ON ON/OFF indication
DI14 --- ON/OFF indication
9 19
NO.9 PROPO-VALVE NO.19 DIGITAL INPUT
E-1 P1 PUMP DI15 --- ON/OFF indication
COMP. 417 mA 1.0 M Set value in computer / Converted value from pressure DI16 ON ON/OFF indication
MEAS. 417 mA 1.0 M Measured value / Converted value from pressure DI17 ON ON/OFF indication
POWER SHIFT 0 mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 30 L Flow rate of pump P1 DI19 --- ON/OFF indication
E-2 P2 PUMP DI20 OFF ON/OFF indication
COMP. 417 mA 1.0 M Set value in computer / Converted value from pressure DI21 --- ON/OFF indication
MEAS. 417 mA 1.0 M Measured value / Converted value from pressure DI22 --- ON/OFF indication
POWER SHIFT 0 mA Power shift DI23 ON ON/OFF indication
FLOW RATE 30 L Flow rate of pump P2 DI24 OFF ON/OFF indication
DI25 ON ON/OFF indication
DI26 --- ON/OFF indication
DI27 OFF ON/OFF indication
DI28 --- ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
1.2 V 77% Fuel level DI30 --- ON/OFF indication
H-10 HYD.OIL TEMP DI31 --- ON/OFF indication
0.0 V 0 Hydraulic oil temperature DI32 --- ON/OFF indication
GLOW --- Glow switch DI33 ON ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 --- ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 --- ON/OFF indication
ENG OIL FILTER --- Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 --- ON/OFF indication
DOUBLE FLOW ON Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW --- Command from grid heater DI39 --- ON/OFF indication
HEATER OFF Engine oil level DI40 OFF ON/OFF indication
ENG OIL LEVEL OK Coolant level DI41 --- ON/OFF indication
COOLANT LEVEL OK DI42 ---
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH NIB Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. --- Set value in computer MEAS. OFF Measured value
MEAS. --- Measured value DO5 COMP. --- Set value in computer
F-6 MEAS. --- Measured value
COMP. --- Set value in computer DO6 COMP. --- Set value in computer
MEAS. --- Measured value MEAS. --- Measured value
DO7 COMP. OFF Set value in computer
MEAS. OFF Measured value
15 22
NO.15 PROPO-VALVE NO.22 DIGITAL OUTPUT
D-11 P1 I-TRAVEL DO8 COMP. ON Set value in computer
COMP. 0 mA 0.0 M Set value in computer / Converted value from pressure MEAS. ON Measured value
MEAS. 0 Ma 0.0 M Measured value / Converted value from pressure DO9 COMP. OFF Set value in computer
D-12 P2 I-TRAVEL MEAS. OFF Measured value
COMP. 0 mA 0.0 M Set value in computer / Converted value from pressure DO10 COMP. --- Set value in computer
MEAS. 0 mA 0.0 M Measured value / Converted value from pressure MEAS. --- Measured value
D-15 P1 BY PASS VALVE DO11 COMP. OFF Set value in computer
COMP. 347 mA 0.6 M Set value in computer / Converted value from pressure MEAS. OFF Measured value
MEAS. 347 mA 0.6M Measured value / Converted value from pressure DO12 COMP. --- Set value in computer
D-16 P2 BY PASS VALVE MEAS. --- Measured value
COMP. 0 mA 0.0 M Set value in computer / Converted value from pressure DO13 COMP. --- Set value in computer
MEAS. 0 mA 0.0 M Measured value / Converted value from pressure MEAS. --- Measured value
DO14 COMP. --- Set value in computer
MEAS. --- Measured value

SM0150

T2-1-31
E215B-E245B MECHATRO CONTROL SYSTEM

No. Displays Contents


23
NO.23 DIGITAL OUTPUT
DO15 COMP. --- Set value in computer
MEAS. --- Measured value
DO16 COMP. ON Set value in computer
MEAS. ON Measured value
DO17 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO18 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO19 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO20 COMP. --- Set value in computer
MEAS. --- Measured value
DO21 COMP. ON Set value in computer
MEAS. ON Measured value
24
NO.24 DIGITAL OUTPUT
DO22 COMP. --- Set value in computer
MEAS. --- Measured value
DO23 COMP. OFF Set value in computer
MEAS. ON Measured value
DO24 COMP. --- Set value in computer
MEAS. --- Measured value
DO25 COMP. --- Set value in computer
MEAS. --- Measured value
DO26 COMP. --- Set value in computer
MEAS. --- Measured value
DO27 COMP. --- Set value in computer
MEAS. --- Measured value
DO28 COMP. --- Set value in computer
MEAS. --- Measured value
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
MECHATRO CONTROL SYSTEM E215B-E245B

2) Service diagnosis Mode No.2

No. Displays Contents No. Displays Contents


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
C-2 P2 PUMP 0.0 M Pump pressure sensor C-2 P2 PUMP 0.0 M Pump pressure sensor
E-1 P1-PSV 417 mA Command current E-1 P1-PSV 417 mA Command current
E-2 P2-PSV 417 mA Command current E-2 P2-PSV 417 mA Command current
D-1 P1-UL(BPC) 750 mA Command current D-1 P1-UL(BPC) 750 mA Command current
D-2 P2-UL(BPC) 750 mA Command current D-2 P2-UL(BPC) 750 mA Command current
B-1 BOOM RAISE 0.0 M Boom up pressure sensor D-3 S-TRAVEL 350 mA Command current
B-2 BOOM LOWER 0.0M Boom down pressure sensor B-9 TRAVEL(R) 0.0 M Travel right pressure sensor
G-3 ENG SPEED 1000 Engine actual speed B-10 TRAVEL(L) 0.0 M Travel left pressure sensor
POWER SHIFT 0 mA Power shift current Pi-P1 0.0 M Pilot pressure at travel straight (P1 side)
Pi-P2 0.0 M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0 mA Power shift current

32 35
NO.32 ARM,SWING NO.35 OPT
C-1 P1 PUMP 0.2 M Pump pressure sensor C-1 P1 PUMP 0.2 M Pump pressure sensor
C-2 P2 PUMP 0.0 M Pump pressure sensor C-2 P2 PUMP 0.0 M Pump pressure sensor
E-1 P1-PSV 417 mA Command current E-1 P1-PSV 417 mA Command current
E-2 P2-PSV 417 mA Command current E-2 P2-PSV 417 mA Command current
D-1 P1-UL(BPC) 750 mA Command current D-1 P1-UL(BPC) 750 mA Command current
D-2 P2-UL(BPC) 750 mA Command current D-2 P2-UL(BPC) 750 mA Command current
D-3 S-TRAVEL 350 mA Command current D-3 S-TRAVEL 350 mA Command current
D-6 ARM-IN-2 750 mA Command current E-3 OPT RELIEF 110 mA Command current
B-3 ARM OUT 0.0 M Arm out pressure sensor B-16 P1 OPT 0.0 M P1 side option pressure sensor
B-4 ARM IN 0.0 M Arm in pressure sensor B-17 P2 OPT 0.0 M P2 side option pressure sensor
B-1 BOOM RAISE 0.0 M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 0.0 M Swing pressure sensor DOUBLE FLOW SW OFF Conflux/ Single selector switch
G-3 ENG SPEED 1000 Engine actual speed G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0 mA Power shift current POWER SHIFT 0 mA Power shift current

SM0152

3) Service diagnosis Mode No.3

No. Displays Contents No. Displays Contents


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
E215B-E245B MECHATRO CONTROL SYSTEM

3. Service diagnosis data list


Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use these
data to decide normal/abnormal status.
The values in following display are reference values with standard attachment attached machine.
The value of pressure sensor is calculated taking variation into accounts. When compared to performance
check reference criteria, measure it with the aid of calibrated measuring instrument.
The current of proportional valve is not the measured value, but command value. The measured value
should be confirmed by the value in the displayed value for each proportional valve.
The current value of pump proportional valve is reference value because it varies according to pump
pressure and adjusted torque value.
The value in display during operation shows the value in steady state, rather than, at start of operation.
Check on machine after sufficiently warming up machine.
The value in display may differ according to software version. Contact our dealer/distributor.

Operation No.1 : No operation 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
E-2 P2-PSV 350 mA E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 750 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 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
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
B-1 BOOM RAISE 3.0 M B-1 BOOM RAISE 3.0 M
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 mA

T2-1-34
MECHATRO CONTROL SYSTEM E215B-E245B

Operation No.5 : Boom down in full lever operation & in


operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 12.5~16.0 M
C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 600~617 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427~477 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 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
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 12.5~16.5 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 12.5~16.5 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 550~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 550~750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 200 mA D-6 ARM-IN-2 400 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 3.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 mA

T2-1-35
E215B-E245B MECHATRO CONTROL SYSTEM

Operation No.8 : Operation No.9 :


Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 15.0~22.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~22.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 488~677 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 488~677 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 3.0 M B-3 ARM OUT 3.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 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

Operation No.10 : Operation No.11 :


Swing in full lever operation & relief Swing in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 10.0~15.0 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 528~750 mA E-2 P2-PSV 750 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 3.0 M B-7 SWING 3.0 M
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 mA

T2-1-36
MECHATRO CONTROL SYSTEM E215B-E245B

Operation No.12 : Operation No.13 :


Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 4.0~8.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 4.0~8.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 650~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 540~563 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 720 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 mA

Operation No.14 : Operation No.15 :


Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
H mode Hi idle H mode Hi idle
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
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 720 mA
B-5 BUCKET DIG 0.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 3.0 M B-6 BUCKET DUMP 3.0 M
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 mA

T2-1-37
E215B-E245B MECHATRO CONTROL SYSTEM

Operation No.16 : Operation No.17 :


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
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 350 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 mA
* Conflux switch is ON. Relief set pressure is value * Conflux switch is OFF. Relief set pressure is value
of shipping. of shipping.

Operation No.18 : Operation No.19 :


Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
H mode Hi idle H mode Hi idle
No.34 TRAVEL No.34 TRAVEL
C-1 P1-PRES 5.0~12.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 5.0~12.0 M
E-1 P1-PSV 750 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
B-9 TRAVEL (R) 2.0~2.5 M B-9 TRAVEL (R) 0.0 M
B-10 TRAVEL (L) 0.0 M B-10 TRAVEL (L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 mA

T2-1-38
MECHATRO CONTROL SYSTEM E215B-E245B

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
E215B-E245B MECHATRO CONTROL SYSTEM

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
MECHATRO CONTROL SYSTEM E215B-E245B

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
E215B-E245B MECHATRO CONTROL SYSTEM

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
MECHATRO CONTROL SYSTEM E215B-E245B

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
E215B-E245B MECHATRO CONTROL SYSTEM

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
MECHATRO CONTROL SYSTEM E215B-E245B

2.1 Setting the language

To modify the language, proceed as follows:


1. Keep BUZZER CUT-OFF button (1) pressed
and, at the same time, move the STARTER
SWITCH onto ON; the screen shows display
(A). 10:25
2. Keep BUZZER CUT-OFF button (1) pressed,
then press SELECT button (2) three times; the 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
E215B-E245B MECHATRO CONTROL SYSTEM

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
MECHATRO CONTROL SYSTEM E215B-E245B

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
E215B-E245B MECHATRO CONTROL SYSTEM

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
4 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
24 RXD3 Reception RS232C communication
25 DL EARTH / OPEN(5V
26 GP 0V
27 CANH1 CAN communication
Spare
28 CANL1 CAN communication
29 DO 20 Spare Output EARTH/OPEN
30 DO 21 Safety relay Output EARTH/OPEN
31 DO 22 Spare Output EARTH/OPEN
32 DO 23 Extra pressure release Output EARTH/OPEN
33 DO 24 Spare Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN
SM0160

T2-1-48
MECHATRO CONTROL SYSTEM E215B-E245B

Connector No. Pin No. Port name Function Input/putput Signal level
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A28 Spare Input 0.5~4.5V
21 +5VA Power output 5V
22 D1 37 Spare Input GND / OPEN

Connector No. Pin No. Port name Function Input/putput Signal level
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
15 +5VA Power output 5V
16 Reserved
SM0161

T2-1-49
E215B-E245B MECHATRO CONTROL SYSTEM

Connector No. Pin No. Port name Function Input/putput Signal level
CN104 1 GA 0V
2 A17 Boom head (Over load) Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A18 Spare Input 0.54.5V
6 GA 0V
7 GA 0V
8 A19 Extra pressure source Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A20 Spare Input 0.5~4.5V
12 GA 0V
13 A21 Engine coolant
Input Resistor
14 GA temperature
15 A22
Fuel level Input Resistor
16 GP
17 A23 Resistor
Spare Input
18 GA
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
21 +5VA Power output 5V
22 +5VA Power output 5V
23 A25 Extra pressure source Input 0.5~4.5V
24 GA 0V
25 GA 0V
26 A26 Spare Input 0.5~4.5V
27 +5VA Power output 5V
28 DI 1 Starting point of accel motor Input GND / OPEN

Connector No. Pin No. Port name Function Input/putput Signal level
CN105 1 +24V 20~32V
Battery relay output side
2 +24V 20~32V

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
9 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
21 GND Battery (-) 0V
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
27 D8+ Spare Output +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
MECHATRO CONTROL SYSTEM E215B-E245B

Connector No. Pin No. Port name Function Input/putput Signal level
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ Accel motor A phase Output 1.5A
4 F1- Accel motor A phase Output 1.5A
5 F2+ Accel motor B phase Output 1.5A
6 F2- Accel motor B phase Output 1.5A
7 OIL Oil level (spare) 0
8 OILG
9 D11+ OPT changeable relief 2 Output +0~800mA
10 D11- -0~800mA
11 D12+ Spare Output +0~800mA
12 D12- -0~800mA
13 D13+ Bypass valve Output +0~800mA
14 D13- -0~800mA
15 D14+ Spare Output +0~800mA
16 D14- -0~800mA
17 GND Battery (-) 0V
18 D12+ Spare Output +0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shiled GND
23 CANH2 Proportional vlave expand unit CAN communication
24 CANL2 CAN communication

Connector No. Pin No. Port name Function Input/putput Signal level
CN107 1 DI 3 Grid heater feedback Input +24V/OPEN
2 DI 8 Engine coolant temperature Input EARTH / OPEN
3 DI 9 E/G oil pressure Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
5 DI 11 Spare Input EARTH / OPEN
6 DI 12 Spare Input EARTH / OPEN
7 DI 13 E/G coolant level Input EARTH / OPEN
8 DI 14 Spare Input EARTH / OPEN
9 DI 15 Spare Input EARTH / OPEN
10 DI 20 Heater temperature of fuel filter Input EARTH / OPEN
11 DI 28 Spare Input EARTH / OPEN
12 DI 32 Hand control nibbler Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
14 DI 39 Spare Input EARTH / OPEN
15 DI 40 Heater temperature Input EARTH / OPEN
16 DI 41 Spare Input EARTH / OPEN
17 Reserved
SM0163

T2-1-51
E215B-E245B MECHATRO CONTROL SYSTEM

Connector No. Pin No. Port name Function Input/putput Signal level
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Water separator Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 Spare Input GND / OPEN
6 DI 16 Wiper rise up Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
8 DI 18 ATT boost Input GND / OPEN
9 DI 19 Spare Input GND / OPEN
10 DI 21 Spare Input +24V / OPEN
11 DI 22 Spare Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation Input GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
15 DI 26 Spare Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 Spare Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
22 DI 34 Spare Input +24V / OPEN
23 DI 35 Spare Input +24V / OPEN
24 Reserved
25 H1+ Spare 0~5V
26 H2- 0V
27 H2+ Spare 0~5V
28 H2- 0V

Connector No. Pin No. Port name Function Input/putput Signal level
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Spare Output GND / OPEN
6 DO 6 Reserved Output GND / OPEN
7 DO 12 Spare Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Grid heater Output GND / OPEN
15 Reserved
16 GP 0V
17 TXD2 Tranmission RS232C communication
18 RXD2 Reception RS232C communication
Spare
19 RTS RS232C communication
20 CTS RS232C communication
21 SHG2 Shiled GND
22 DO 10 Spare SV 24V/OPEN
SM0164

T2-1-52
MECHATRO CONTROL SYSTEM E215B-E245B

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
6 Buzzer stop switch
7 Work mode select switch

T2-1-53
E215B-E245B MECHATRO CONTROL SYSTEM

3. Relay & fuse box (symbol E-1)


1) General view

(Overhead view of box)


LABEL INSIDE

Note) These circles indicate the parts


which are used in standard specification

1 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
MECHATRO CONTROL SYSTEM E215B-E245B

2) Circuit diagram

SM0167

T2-1-55
E215B-E245B MECHATRO CONTROL SYSTEM

SM0168

T2-1-56
MECHATRO CONTROL SYSTEM E215B-E245B

SM0169

T2-1-57
E215B-E245B MECHATRO CONTROL SYSTEM

4) High pressure sensor : YN52S00048P1

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 SYSTEM E215B-E245B

HYDRAULIC CIRCUIT (MONOBLOCK VERSION)

SM0077

T2-2-3
E215B-E245B HYDRAULIC SYSTEM

3. N&B HYDRAULIC CIRCUIT (OPTION)


N&B HYDRAULIC CIRCUIT READING KEY

Item Component name

50 Selector valve

51 Stop valve

52 Pilot valve

53 Overload relief valve

The hydraulic circuit for N&B is used to add to


standard circuit

Selection condition and proportional valve


command when any of nibbler single & conflux flow
or breaker in service.

Command signal of solenoid proportional valve


SELECTION
(W:O, W/O: -)

Electromagnetic
Conflux/single flow command signal of P1 P2 Travel P1 P2
changeover switch selector valve (50) Pump Pump Straight Unload Unload
(W:O, W/O: -)

Conflux flow of
Conflux ON - O O O O O
nibbler

Single flow of
Conflux OFF - - O - - O
nibbler

Breaker Conflux OFF O - O - - O

When using nibbler, according to specification of


nibbler installed.

Adjust overload relief valve (53) of optional port to


customize specification ordinary set pressure.

T2-2-4
HYDRAULIC SYSTEM E215B-E245B

N&B HYDRAULIC CIRCUIT

51

53

52

53

50

SM0078

T2-2-5
E215B-E245B HYDRAULIC SYSTEM

4. 4. HOLDING VALVE FOR BOOM & ARM


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

HOLDING VALVE FOR ARM


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

HYDRAULIC CIRCUIT READING KEY


Item Component name

54 Holding valve for boom cylinders

55 Holding valve for arm cylinder

T2-2-6
HYDRAULIC SYSTEM E215B-E245B

HOLDING VALVE FOR BOOM & ARM HYDRAULIC CIRCUIT

54 55

SM0079
54

T2-2-7
E215B-E245B HYDRAULIC SYSTEM

5. POSITIONING CIRCUIT
(TRIPLE ARTICULATION VERSION)

HYDRAULIC POSITIONING CIRCUIT READING


KEY
Item Component name

56 P1 OPT valve

57 Holding valve for positioner cylinder

58 Positioner cylinder

59 Positioning pilot valve

OPERATION

When the operation for positioning is performed, the


pilot proportional secondary pressure is delivered
through port A of the positioning pilot valve (59) and
flows to PAo1 port of the P1 OPT valve (56) then,
the spool of P1 OPT valve (56) is switched. The
pressure oil by P1 pump is supplied to (R) side of
positioner cylinder (58) through Ao1 port of P1 OPT
valve (56). On the other hand, the return oil from (H)
side of positioner cylinder returns to the tank circuit
thorough Bo1 port of P1 OPT valve (56).
The holding valve (57) prevents the positioning
falling in case of rod side cylinder piping breaks.

T2-2-8
HYDRAULIC SYSTEM E215B-E245B

POSITIONING CIRCUIT (TRIPLE ARTICULATION VERSION)

57

R
POSITIONING
CYLINDER

H 58

59

56

SM0080

T2-2-9
E215B-E245B HYDRAULIC SYSTEM

6. COLOR CODING STANDARD FOR 7. NEUTRAL CIRCUIT 7.3 PUMP POSITIVE FLOW CONTROL
HYDRAULIC CIRCUITS This section describes the following. (1) Type: The operation is maintained until the
Blue 7.1 Bypass cut valve and unload valve control Electric flow controlled variable displacement opening of spool sleeve is closed.
Feed, drain circuit pump.
7.2 Safety lock lever and pilot circuit
less than 0.44 MPa (64 psi) 7.3 Pump positive flow control (2) Principle:
Green The current command I to the 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
HYDRAULIC SYSTEM E215B-E245B

NEUTRAL CIRCUIT: Positive control function at safety lock lever down (unloked position)

651 652

611
643 646
532

SM0081

T2-2-11
E215B-E245B HYDRAULIC SYSTEM

8. TRAVEL CIRCUIT 8.2 2-SPEED TRAVEL SOLENOID COMMAND


CIRCUIT AND AUTO 1st SPEED RETURN
This section describes the following.
FUNCTION
8.1 Travel forward pilot simultaneous operation
1) Purpose:
circuit
Change travel motor speed with switch.
8.2 2 speed travel solenoid command circuit and
auto 1-speed return function (2) Principle:
If the switch is turned, an electric signal is
8.3 Travel main circuit
issued. It excites the 2-speed travel solenoid
8.4 Travel motor function which in turn converts the primary pilot pressure
and the self pressure to a tilting angle of the
8.1 TRAVEL FORWARD PILOT variable displacement motor.
SIMULTANEOUS OPERATION CIRCUIT (3) Operation:
(1) Purpose: If the rabbit marked switch on the gauge cluster
Light operating force and shockless operation is pressed, the solenoid (SV-3) of the
(2) Mechatronics : proportional valve block (13) is excited and
changes the proportional valve. Then the
1) If the travel lever with damping mechanism
solenoid command pressure is issued from port
is operated for travel right, left and forward
A3, enters the Ps port of the travel motor (4),
motions, the secondary pilot proportional
opens the oil passage to the 2nd speed select
pressure comes out of the 3, 1 ports of P/V
piston, and causes the motor to run in the 2nd
(10). The higher of the pressures is
speed tilting mode by its self pressure.
selected, comes out of the 6, 5 ports and
However, when the main circuit pressure rises
acts upon the low pressure sensors (SE-9)
above 27.3 MPa (3960 psi) (E245B) and 28 MPa
(SE-10).
(4060 psi) (E215B), the 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.
The secondary pressure from proportional
valve which has exerted on PCb and PCa
ports switches the unloading spool in
CLOSE side.

T2-2-12
HYDRAULIC SYSTEM E215B-E245B

TRAVEL CIRCUIT: Travel 2nd speed, RH & LH simultaneous operation.

SM0082

T2-2-13
E215B-E245B HYDRAULIC SYSTEM

9. BUCKET CIRCUIT 5) The secondary pressure delivered in travel bucket spool and returns to tank circuit from
priority proportional valve (PSV-C) is led to Bc port of C/V (2).
This section describes the following.
PTb port provided in control valve (2) and References:
9.1 Bucket digging pilot circuit shifts the travel priority valve one stage. In bucket dumping operation, the travel
9.2 Auto accel operation priority valve also switches like digging
9.3 Flow control in the work mode 9.2 AUTO ACCELERATION OPERATION operation, resulting in confluence with travel
9.4 Bucket digging travel priority main circuit straight.
(1) Principle:
9.5 Bucket spool stroke limiter Auto acceleration actuates according to signals When the bucket operation and other
from low pressure sensor. operation are simultaneously performed, the
travel priority valve does not actuate,
(2) Operation:
resulting in single flow of bucket circuit.
9.1 PILOT CIRCUIT FOR BUCKET DIGGING <When lever is set to neutral position>
(1) Mechatronics : In the event where the sensor does not receive
signal for 4 seconds or more even though the 9.5 BUCKET SPOOL STROKE LIMITER
1) When the operation for bucket digging is
acceleration dial is set to MAX position, the (1) Purpose:
performed, the pilot proportional secondary
engine speed should be raised to 1050 rpm. To secure simultaneous operability of boom and
pressure is delivered through port 1 of the
<When lever is operated> arm on boosting up attachment pressure (Pump
right pilot V (9), flows to PAc port, and acts
When the pressure 0.6MPa (87psi) is input to flow rate decreases.) and to prevent cavitations
on the low pressure sensor (SE-1), and at
low pressure sensor in STD specification (travel, at low engine speed
the same time the bucket spool is switched.
bucket, swing, arm), proportional voltage from
2) The voltage output by low pressure sensor (2) Operation:
low pressure sensor inputs in mechatro
(SE-1) inputs in mechatro controller. The On boosting up attachment pressure, pilot
controller, and then the engine speed returns to
mechatro controller performs signal primary pressure exerts on PCc port of C/V(2)
the dial set position corresponding to the lever
processing and outputs current through attachment booster solenoid valve,
operation.
corresponding to the increase of pump flow operates stroke limiter of bucket spool, and
rate to pump proportional valves (PSV-P1) throttle oil path of spool. As a result, P1 pump
and (PSV-P2) on the P1 and P2 pump sides, 9.3 FLOW CONTROL IN THE WORK MODE pressure increases, making the simultaneous
and at the same time the command current operation of boom up and bucket digging
(1) Principle:
is output to P1 unloading valve (PSV-D), P2 possible.
When the engine speed is intermediate speed
unloading valve (PSV-B) and travel priority Even though the engine speed is low, similarly
or lower, command current value to have the
proportional valve (PSV-C). the cavitations can be prevented by actuating
pump delivery rate constant is output.
In the following pages, the relation of the stroke limiter.
operation of low pressure sensor to both the (2) Operation:
increase of pump flow rate and unloading Even if the engine speed specified by
proportional valve is the same. Therefore acceleration potentiometer is low speed, as the
the explanation is omitted. delivery rate corresponds to the intermediate
speed, the actuator moves earlier than the
3) The secondary pressure output by P1 pump
movement equivalent to the control lever angle
proportional valve (PSV-P1) and P2 pump
rate in light load operation.
proportional valve (PSV-P2) exerts on pump
regulator, actuating the pump onto the
delivery flow increase side. 9.4 BUCKET DIGGING AND TRAVEL PRIORITY
4) The secondary pressure delivered in P1 CONFLUENCE (CONFLUX) MAIN CIRCUIT
unloading valve (PSV-D) and P2 unloading (1) Operation:
valve (PSV-B) is led to PBp1, PCb, PBp2
1) The oil delivered through A1 port of P1
and PCa ports provided in control valve (2).
pump goes into P1 port of C/V (2), opens
The secondary pressure from proportional
load check valve LCc through parallel circuit
valve which has exerted on PBp1 and PBp2
and enters in bucket spool.
ports holds the by-pass cut spool on CLOSE
side, like the operation in the lever neutral 2) On the other hand, the oil delivered through
position. A2 port of P2 pump goes into P2 port of C/V
The secondary pressure from proportional (2), confluences with oil from P1 pump
valve which has exerted on PCb and PCa through travel priority valve, and goes into
ports switches the unloading spool in bucket spool. (Confluence of oil from 2
CLOSE side. pumps)
3) 3)With the function of pilot circuit, the oil flow
is switched from bucket spool, and is fed into
bucket cylinder head side through Ac port of
C/V (2). On the other hand, the return oil
from cylinder rod (R) side is throttled by

T2-2-14
HYDRAULIC SYSTEM E215B-E245B

BUCKET CIRCUIT: Bucket digging (Travel priority conflux), Auto-accelation and Standby flow rate constant control

SM0083

T2-2-15
E215B-E245B HYDRAULIC SYSTEM

10. BOOM CIRCUIT


This section describes the boom raise conflux
operation.
10.1 Boom up pilot circuit
10.2 Boom up 2 pumps conflux main circuit in C/V

10.1 BOOM RAISE PILOT CIRCUIT


(1) Operation:
1) If boom up operation is performed, the
secondary pilot proportional pressure from
the right pilot valve (9) gets out of port 4 and
acts upon the low pressure sensor (SE3). At
the same time, the pressure acts upon the
PAb and PB1 ports.
2) The secondary pressure which enters the
PAb port of C/V (2) shifts the boom spool.
The secondary pressure which enters the
PB1 port shifts the boom conflux spool.

10.2 BOOM UP 2 PUMPS CONFLUX MAIN


CIRCUIT IN C/V
(1) Purpose:
Boom up speed up
(2) Principle:
Confluxing oil from 2 pumps
(3) Operation:
1) The oil delivered through A1 port of P1
pump flows into C/V (2) P1 port, and
branches into bypass circuit and parallel
circuit. Since P1 unloading valve is closed,
the boom spool is moved and bypass circuit
is closed, the oil opens load check valve
LCb through parallel circuit and flows into
boom spool.
2) Then the oil passes through boom spool,
opens lock valve of boom lock valve CRb,
and is led into (H) side of boom cylinder
through C/V (2) Ab port.
3) Meanwhile, the oil delivered from the A2
port of the P2 pump enters the P2 port of C/
V (2) and due to shut off the P2 unloading
valve, the oil then passes through the
parallel circuit and via the restrictor on the
circumference of the boom conflux spool,
pushes the load check valve CCb open from
the boom conflux circuit, and combines the
oil delivered by the P1 pump internally.
4) The return oil from boom cylinder (R) side
flows into tank circuit through boom spool
from C/V (2) Bb port.

T2-2-16
HYDRAULIC SYSTEM E215B-E245B

BOOM CIRCUIT : Boom up operation, Confluence function.

SM0084

T2-2-17
E215B-E245B HYDRAULIC SYSTEM

This section describes boom lower operation. 10.5 CONSTANT RECIRCULATION FUNCTION
10.3 Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
10.4 Prevention of natural fall by lock valve and (1) Purpose:
actuation at lowering Prevention of cavitation during boom lowering
10.5 Constant recirculation function of boom down motion.
main circuit (2) Principle:
The oil returning from the boom cylinder head
(H) is recirculated to the rod (R).
10.3 BOOM DOWN PILOT CIRCUIT
(1) Operation: (3) Operation:
When the oil is supplied to the boom cylinder rod
1) If the boom down operation is performed, (R) side during boom down operation, the boom
the secondary pilot proportional pressure moves faster than it should do in some cases by
comes out of port 2 of the right pilot valve (9) the self weight of the attachment.
and acts upon the low pressure sensor (SE- On that occasion, the circuit pressure on the rod
4). (R) side is on the negative side.
At the same time, the pressure acts upon The oil supplied to the boom cylinder rod (R)
the PBb port of C/V (2). flows into the A1 port of the P1 pump and the P1
2) The voltage output of the low pressure port of C/V. The oil then passes through the
sensor (SE-4) enters the mechatro boom spool and goes out of the Bb port.
controller and processed in it. On that occasion, the oil returning from the head
3) Then, the proportionl secondary pressure (H) goes through the recirculation path in the
fed into C/V (2) PBb port and branches off in boom spool, pushes the check valve in the spool
two lines and switches boom spool and open, is recirculated to the Bb port and is
releases boom lock valve. supplied to the rod (R). When the (R) pressure
is larger than the head (H) pressure, the check
valve in spool closes.
10.4 PREVENTION OF NATURAL FALL BY LOCK
Thereupon, the recirculation is stopped.
VALVE AND ACTUATION AT LOWERING
(1) Purpose:
Prevention of natural fall when the lever is
neutral
(2) Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation:
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line
on the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from
making a natural fall.

T2-2-18
HYDRAULIC SYSTEM E215B-E245B

BOOM CIRCUIT: Boom down operation & Prevention of natural boom falling.

SM0085

T2-2-19
E215B-E245B HYDRAULIC SYSTEM

11. SWING CIRCUIT as the swing spool is shifted, the oil pushes the
load check valve LCs open through the parallel
This section describes the following operations.
circuit, enters the B port of the swing motor via
11.1 Swing left pilot circuit the Bs port of C/V (2), and rotates the swing
11.2 Swing auto parking brake motor counterclockwise.
11.3 Swing main circuit
11.4 Swing motor circuit
11.4 SWING MOTOR CIRCUIT
(1) Anti cavitation circuit at swing deceleration
11.1 PILOT CIRCUIT FOR LEFT SWING
(2) Shockless relief valve that prevents the swing
(1) Operation: motor from being reversed.
1) When the left swing operation is performed,
the pilot proportional secondary pressure is
delivered through port (1) of left pilot V (9),
and the secondary pressure acts on PBs
port of C/V (2), and simultaneously flows out
from Pss port of C/V and acts on low
pressure sensor (SE-5).
2) The voltage output by the low pressure
sensor is input in the mechatro controller,
and is signal-processed.
3) Then, the secondary pressure led into PBs
port of C/V (2) switches the swing spool.

11.2 SWING AUTO PARKING BRAKE


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

11.3 SWING MAIN CIRCUIT


(1) Operation:
The oil delivered from the A2 port of the P2
pump enters the P2 port of C/V (2) and is
branched off into the bypass line and the parallel
circuit. However, since the bypass line is closed

T2-2-20
HYDRAULIC SYSTEM E215B-E245B

SWING CIRCUIT: Swing operation (LH)

SM0086

T2-2-21
E215B-E245B HYDRAULIC SYSTEM

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

12.2 ARM-IN, LIGHT-LOAD VARIABLE NORMAL Reference:


RECIRCULATION, INTERNAL CONFLUX In light-load arm-in operation (normal
MAIN CIRCUIT recirculation, conflux), when the attachment
(1) Operation: to which the circuit in P1 pump side is
applied is operated, the meter-in path of arm
1) The P2 pump delivery oil flows in travel left
2 spool is closed, resulting in single flow
section through P2 port of C/V (2) and is
operation.
branched off in by-pass circuit and parallel
circuit, but because arm 1 spool is switched,
Spool position at arm in,
the delivery oil which goes through parallel light load and combined operation
circuit opens load check valve LCa and is (This position is not shown in hydraulic diagram)
flowed into arm 1 spool. Meter-in passage
Neutral position
2) On the other hand, P1 pump delivery oil (Close)
flows in P1 port of C/V (2), and the flows in
travel straight section and travel right
tandem path. Then because arm 2 spool
was switched, the delivery oil opens load Normal recirculation opsition
check valve LCAT2, goes through arm 2 Arm 2 spool
SM0196
spool, and confluences with P2 pump
delivery oil in the valve section, and then is
flowed into arm cylinder head (H) side
through Aa port of C/V (2).

T2-2-22
HYDRAULIC SYSTEM E215B-E245B

ARM CIRCUIT: Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function

SM0087

T2-2-23
E215B-E245B HYDRAULIC SYSTEM

This section describes the following operations. 4) The return oil returns directly into tank circuit
12.3 Arm in, heavy load operating pilot circuit because arm 2 spool is switched to
(recirculation cut) recirculation cut position.
12.4 Arm in, heavy load operating sequence
confluxed main circuit Position of arm 2 spool

Neutral position Recirculation cut position

12.3 ARM IN, HEAVY LOAD OPERATING PILOT


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

voltage output by P2 pump pressure sensor


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

12.4 ARM IN, HEAVY LOAD OPERATING


RECIRCULATION CUT MAIN CIRCUIT
(1) Purpose:
Speed up for arm in operation
(2) Principle:
Cut the recirculation and reduce rod pressure.
(3) Operation:
1) P2 pump delivery oil flows in the travel left
section through P2 port of C/V (2) and
branched off in by-pass circuit and parallel
circuit. Consequently the arm spool is
switched and pushes and opens load check
valve LCa through parallel circuit, and flows
in the arm spool.
2) On the other hand, P1 pump delivery oil
flows in P1 port of C/V (2), and flow in travel
right tandem passage through travel straight
section. Then because arm 2 spool was
switched, the delivery oil opens load check
valve LCAT2, and confluences with P2
pump delivery oil in the valve section, and is
flowed into arm cylinder head (H) side
through Aa port of C/V(2).
3) The return oil from arm cylinder (R) side
flows in Ba port of C/V(2) and is flowed to
arm lock valve CRar, but because the arm
lock valve CRar is open, the return oil goes
through arm lock valve CRar and flows in
arm 2 spool.

T2-2-24
HYDRAULIC SYSTEM E215B-E245B

ARM CIRCUIT: Arm in (Heavy load) operation, Arm confluence & recirculation cut function

SM0088

T2-2-25
E215B-E245B HYDRAULIC SYSTEM

This section describes the following operations. 12.7 NATURAL FALL PROTECTION WITH ARM
12.5 Arm out pilot circuit LOCK VALVE
12.6 Arm out 2 pumps conflux main circuit (1) Purpose:
12.7 Natural fall protection with arm lock valve To prevent the arm from falling naturally by the
weight of the arm and bucket.
(2) Principle:
12.5 ARM OUT PILOT CIRCUIT
Complete seat of the return circuit against the
(1) Operation: arm spool of the arm cylinder (R) side circuit.
1) When the arm out operation is performed, (3) Operation:
the secondary pilot proportional pressure
gets out of port 8 of the left pilot valve (9), 1) When the secondary pressure for arm
and acts upon the low pressure sensor (SE- operation disappears and the arm cylinder
8). At the same time, the oil is branched off stops, the pressure on the rod (R) side
in two flows and act upon the PBa1 and passes through the selector of the lock valve
PBa2 ports of C/V (2). from the Ba port of C/V, acts the back
pressure on the lock valve CRar and seats
2) The operating proportional secondary
the lock valve.
pressure flowed in PBa1 port of C/V (2)
switches the arm 1 spool. 2) Since the oil flow into the arm spool from the
lock valve is shut off completely, natural fall
3) Then, the operating secondary pressure
of the arm due to oil leaks through the arm
flowed in PBa2 port of C/V (2) switches the
spool is prevented.
arm 2 spool valve.

12.6 ARM OUT 2 PUMPS CONFLUX MAIN


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

T2-2-26
HYDRAULIC SYSTEM E215B-E245B

ARM CIRCUIT: Arm out operation, Confluence function

SM0089

T2-2-27
E215B-E245B HYDRAULIC SYSTEM

13. COMBINED CIRCUIT because the travel straight spool is shifted


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

13.2 BOOM UP / TRAVEL, MAIN CIRCUIT


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

T2-2-28
HYDRAULIC SYSTEM E215B-E245B

COMBINED CIRCUIT: Boom up & Travel forward 1st speed operation, Travel priority function.

SM0090

T2-2-29
E215B-E245B HYDRAULIC SYSTEM

In this section, the independent operation is omitted Position of arm 2 spool


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

Neutral position Meter-in passage


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

13.4 SWING / ARM IN, SWING PRIORITY MAIN


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

T2-2-30
HYDRAULIC SYSTEM E215B-E245B

COMBINED CIRCUIT: Swing / Arm in operation, swing priority function

SM0091

T2-2-31
E215B-E245B HYDRAULIC SYSTEM

14. PRESSURE DRAINING (RELEASING) 14.2 PRESSURE RELEASING MAIN CIRCUIT


CIRCUIT (1) Operation:
This section describes the following operations.
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
HYDRAULIC SYSTEM E215B-E245B

PRESSURE DRAINING (RELEASING) CIRCUIT: at pressure release mode

651 652

611
643 646
532

SM0092

T2-2-33
E215B-E245B HYDRAULIC SYSTEM

T2-2-34
ELECTRICAL SYSTEM E215B-E245B

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
ELECTRICAL SYSTEM E215B-E245B

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
E215B-E245B ELECTRICAL SYSTEM

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
ELECTRICAL SYSTEM E215B-E245B

B - MECHATRO CONTROLLER AND FUSES&RELAY BOX

SM0010

1 - Mechatro Controller Unit (C-1)


2 - Fuse & Relay box (E-1)
3 - DC-DC Converter (E-22)

T2-3-5
E215B-E245B ELECTRICAL SYSTEM

Fuse & Relay box


FUSES

SM0008

FUSES BOX FUSES BOX

FUSE No. PROTECTED CIRCUIT Rating FUSE No. PROTECTED CIRCUIT Rating
(A) (A)
FUSE 1 Cab Work Light 20 FUSE 19 Air Conditioner 5
FUSE 2 Cab Work Light 20 FUSE 20 Work Light 20
FUSE 3 Monitor 5 FUSE 21 DC-DC Converter 10
FUSE 4 Wiper , Washer 20 FUSE 22 Opt.8 (Bucket Control) 5
FUSE 5 Option 1 20 FUSE 23 Opt.8 (Roof Wiper) 15
FUSE 6 Option 3 20 FUSE 24 Option 20
FUSE 7 Air Conditioner 15 FUSE 25 Safety Look Lever 10
FUSE 8 Air Conditioner 5 FUSE 26 Mechatro Controller 5
FUSE 9 Opt. (Hand Control) 5 FUSE 27 Mechatro Controller 20
FUSE 10 Relay, Hour Meter 5 FUSE 28 Engine Controller (ECU) 15
FUSE 11 Cigarette Lighter 10 FUSE 29 Engine Controller (ECU) 15
FUSE 12 Horn, Horn Relay 10 FUSE 30 Monitor (Back Up) 5
FUSE 13 Radio 10 FUSE 31 Fuel Supply Pump 15
FUSE 14 Starter Key Switch 20 FUSE 32 Mechatro Contr. (Back Up) 5
FUSE 15 Room Lamp, Tuner 5 FUSE 33 Spare 5
FUSE 16 Opt.2 (Auto Grease) 10 FUSE 34 Spare 10
FUSE 17 Option 4 10 FUSE 35 Spare 15
FUSE 18 Solenoid Valve 10 FUSE 36 Spare 20

T2-3-6
ELECTRICAL SYSTEM E215B-E245B

RELAYS

SM0009

1 - Window washer motor relay (RLY 32) 16 - Wiper motor relay (RLY 29)
2 - Wiper motor reversing relay (RLY 30) 17 - Discharge pressure relay (RLY 17)
3 - Cab working light relay (RLY 9) 18 - Grease (forward) relay (RLY 27)
4 - Cab working light relay (RLY 11) 19 - Grease (reverse) relay (RLY 35)
5 - Working light relay (RLY 6) 20 - Safety relay (RLY 4)
6 - Alternator relay (RLY 28) 21 - Bucket control relay (RLY 10)
7 - Auto-Idle stop relay (RLY 24) 22 - Travel alarm relay (RLY 8)
8 - Lever look relay (RLY 26) 23 - Revolution right relay (RLY 12)
9 - Auto-Idle stop relay (RLY 23) 24 - Nibbler open relay (RLY 15)
10 - Engine emergency stop relay (RLY 25) 25 - Revolution left relay (RLY 13)
11 - Horn relay (RLY 5) 26 - Reserve relay (RE-RLY 5)
12 - Nibbler close relay (RLY 16) 27 - Reserve relay (RE-RLY 6)
13 - Reserve relay (RE-RLY 1) 28 - Reserve relay (RE-RLY 4)
14 - Reserve relay (RE-RLY 2) 29 - Reserve relay (RE-RLY 3)
15 - Wiper motor relay (RLY 31)

T2-3-7
E215B-E245B ELECTRICAL SYSTEM

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
ELECTRICAL SYSTEM E215B-E245B

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
E215B-E245B ELECTRICAL SYSTEM

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
ELECTRICAL SYSTEM E215B-E245B

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
E215B-E245B ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM

ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 1)

Item Description Code


1 Fuse box E-1
2 Key starter switch SW - 1
3 Fuse link box E - 25
4 Auto-Idle stop relay 1 R - 23
5 Starter motor M-1
6 Starter relay R-2
7 Safety relay R-4
8 Alternator relay R - 28
9 Battery relay R-1
10 Fuse link E - 26
11 Auto-Idle stop relay 2 R - 24
12 Alternator E-2
13 Reserve relay RY - 29
14 Battery E - 12
15 Engine emergency stop relay R - 25
16 Mega fuse E - 24
17 Fuel filter heater relay R - 40
18 Grid heater relay R-3
19 Water separator heater E - 19
20 Fuel filter heater E - 20
21 Grid heater E - 21
22 Engine stop solenoid SV - 15
23 Diode D - 21
24 Diode D - 30
25 Diode D - 20
26 Diode D - 19
27 Diode D - 13
28 Diode D - 14
29 Diode D-9
30 Diode D - 12
31 Diode D - 11
32 Diode D -18
33 Hour meter E-3
34 KSB soleniod ---
35 Mechatro Controller C-1

T2-3-12
ELECTRICAL SYSTEM E215B-E245B

ELECTRICAL SYSTEM DIAGRAM (No. 1)

19

17
1

20

31

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
E215B-E245B ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 2)

Item Description Code


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

T2-3-14
ELECTRICAL SYSTEM E215B-E245B

ELECTRICAL SYSTEM DIAGRAM (No. 2)

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
E215B-E245B ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 3)

Item Description Code


35 Mechatro Controller C-1
72 Engine oil pressure switch SW - 7
73 Air filter restriction switch SW - 8
74 Engine oil level sensor SE -12
75 Engine coolant level switch SW - 24
76 Conflux/single select switch SW - 15
77 Lever lock switch SW - 11
78 Lever lock relay R- 26
79 Operating lever lock solenoid valve SV - 4
80 Heavy lift switch SW - 35
81 Extra dis. Pressure relay opt. R - 17
82 Extra dis. Pressure solenoid valve opt. SV - 11
83 Extra dis. Pressure sensor opt. SE - 28
84 Prevent spark relay R - 31
85 Wiper motor relay R - 29
86 Wiper motor reversing relay R - 30
87 Window washer motor relay R - 32
88 Wiper motor M-3
89 Washer motor M-4
90 Wiper interlock switch SW - 19
91 Selector detect sensor opt. SE - 29
92 Selector solenoid opt. SV - 13
93 Air conditioner ampl. C-4
94 Receiver drier E - 10
95 Air compressor clutch E - 11
96 Cigarette lighter E - 14
97 Room light L-5
98 Horn relay R-5
99 Horn high E-5
100 Horn low E-6
101 Horn switch right opt. SW - 5
102 Horn switch left opt. SW - 10

T2-3-16
ELECTRICAL SYSTEM E215B-E245B

ELECTRICAL SYSTEM DIAGRAM (No. 3)

35

93

94 95
72

73
82
74 81

83
75

96

76 88

84 85
97

86

78 79
77
89
87

80 90

98
99
100
91 101
102

92

SM0095

T2-3-17
E215B-E245B ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 4)

Item Description Code


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

T2-3-18
ELECTRICAL SYSTEM E215B-E245B

ELECTRICAL SYSTEM DIAGRAM (No. 4)


35 115
113
116

112 117

114

111

118 119

109
104 107
120
105

106
121
110
108
103

123 124

122 SM0096

T2-3-19
E215B-E245B ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 5)

Item Description Code


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

T2-3-20
ELECTRICAL SYSTEM E215B-E245B

ELECTRICAL SYSTEM DIAGRAM (No. 5)

135

134

136
139
131
138 140

132 141
133
142

137 143

144

127
128

129
126

130

145

125

SM0097

(1)

T2-3-21
E215B-E245B ELECTRICAL SYSTEM

WIRING HARNESS
CLUSTER GAUGE WIRING HARNESS ASSEMBLY READING KEY

ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable


are from X side
SM0199

SM0251

T2-3-22
ELECTRICAL SYSTEM E215B-E245B

CLUSTER GAUGE WIRING HARNESS ASSEMBLY

SM0099

T2-3-23
E215B-E245B ELECTRICAL SYSTEM

PLATFORM WIRING HARNESS ASSEMBLY READING KEY

ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable


are from X side
SM0253 SM0199

T2-3-24
ELECTRICAL SYSTEM E215B-E245B

PLATFORM WIRING HARNESS ASSEMBLY

SM0252

T2-3-25
E215B-E245B ELECTRICAL SYSTEM

UPPER FRAME WIRING HARNESS ASSEMBLY READING KEY

ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable


are from X side
SM0199
SM0255

T2-3-26
ELECTRICAL SYSTEM E215B-E245B

UPPER FRAME WIRING HARNESS ASSEMBLY

SM0254

T2-3-27
E215B-E245B ELECTRICAL SYSTEM

ENGINE WIRING HARNESS (KSB & STOP) READING KEY

SM0257

WIRING DIAGRAM

1 2

SM0258

ASSEMBLY CABLES ON THE CONNECTORS

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
ELECTRICAL SYSTEM E215B-E245B

ENGINE WIRING HARNESS (KSB & STOP)

SM0256

T2-3-29
E215B-E245B ELECTRICAL SYSTEM

T2-3-30
COMPONENT OPERATION

M0103
COMPONENT OPERATION E215B-E245B

SECTION AND GROUP CONTENTS

Section 3 COMPONENT OPERATION


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
SECTION 3 E215B-E245B

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
HYDRAULIC PUMP ASSY E215B-E245B

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
E215B-E245B HYDRAULIC PUMP ASSY

HYDRAULIC PUMP

MAIN PUMP

953 806 789 532 (Three Bond N 1305N) 724 901 808 954 717 151 152
886 214 548 531 702 792 534 A
535 732
717 211

261
406

824
774
111

B B

127
123
710
212
401 251 490 271 153 156 157 468 313 124 710 116 467 466 312 885 314 141 271 113
728 727 725
05
04
Nm
401 M20 430 546
406 M8 29
407 M6 12 725
414 M10 57 727
466 PF 1/4 36
467 PF 3/8 74
468 PF 3/4 170
490 NPTF1/16 8.8
531,532 M24X2 240
806 M16 130
808 M20 240 A B-B
407 325

SM0747

111 Drive shaft (F) 313 Valve plate (R) 717 O-ring; 1B G145 (Q.ty 4)
113 Drive shaft (G) 314 Valve plate (L) 724 O-ring; 1B P8 (Q.ty 16)
116 Gear #1 325 Sensor block 725 O-ring; 1B P11 (Q.ty 9)
123 Roller bearing (Q.ty 2) 326 Cover 727 O-ring; 1B P14 (Q.ty 3)
124 Needle bearing (Q.ty 2) 401 Socket bolt; M20X210 (Q.ty 8) 728 O-ring; 1B P24 (Q.ty 4)
127 Bearing spacer (Q.ty 3) 406 Socket bolt; M8X20 (Q.ty 4) 732 O-ring; 1B P18 (Q.ty 2)
141 Cylinder block (Q.ty 2) 407 Socket bolt; M6X55 (Q.ty 3) 774 Oil seal
151 Piston (Q.ty 18) 466 VP plug; PF1/4 (Q.ty 2) 789 Back up ring; P18 (Q.ty 2)
152 Shoe (Q.ty 18) 467 VP plug; PF3/8 (Q.ty 2) 792 Back up ring; G35 (Q.ty 2)
153 Retainer plate (Q.ty 2) 468 VP plug; PF3/4 (Q.ty 4) 806 Nut; M16 (Q.ty 2)
156 Spherical bushing (Q.ty 2) 490 VP plug; NPTF1/16 (Q.ty 4) 808 Nut; M20 (Q.ty 2)
157 Cylinder spring (Q.ty 18) 531 Tilting pin; M24X2 (Q.ty 32) 824 Snap ring (Q.ty 2)
211 Shoe plate (Q.ty 2) 532 Servo piston 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
HYDRAULIC PUMP ASSY E215B-E245B

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
E215B-E245B HYDRAULIC PUMP ASSY

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
HYDRAULIC PUMP ASSY E215B-E245B

Operation

The pump assy is equipped with two pumps


arranged on the same axis that are connected with
gear (116) and distribute the rotating power to the
gear trains on a different axis. Thus the engine
rotation is transmitted to front shaft (111) that drives 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
E215B-E245B HYDRAULIC PUMP ASSY

SWASH PLATE GROUP


The swash plate group consists of swash plate
(212), shoe plate (211), swash plate support (251),
tilting bushing (214), tilting pin (531),and servo
piston (532). The swash plate is the cylindrical part 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
HYDRAULIC PUMP ASSY E215B-E245B

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
E215B-E245B HYDRAULIC PUMP ASSY

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
HYDRAULIC PUMP ASSY E215B-E245B

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
E215B-E245B HYDRAULIC PUMP ASSY

Flow rate increase

As the command current value I rises, the


secondary pressure P2 of electromagnetic
proportional pressure-reducing valve rises, and by
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
HYDRAULIC PUMP ASSY E215B-E245B

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
E215B-E245B HYDRAULIC PUMP ASSY

POWER CONTROL (IN EMERGENCY MODE)

When the load pressure rises, the pump tilt angle is


reduced preventing the overloading of engine. The 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
HYDRAULIC PUMP ASSY E215B-E245B

Flow rate recovery operation

Because the compensating rod (623) is pushed


towards (S) with the force of outer spring (625) and 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
E215B-E245B HYDRAULIC PUMP ASSY

Power shift control


The pump set power is controlled according to the
movement of control by power shift pressure Pf. As 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
No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min 4.6

T3-1-16
HYDRAULIC PUMP ASSY E215B-E245B

ADJUSTING THE INPUT HORSEPOWER


(AT BACK-UP CONTROL)
Since the regulator is of total horsepower control
type, turn the adjust screws of both the front (No. 1)
and rear (No. 2) pumps when changing horsepower 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
No. of turns for tightening 1/4
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
No. of turns for tightening 1/4
Increase in flow L/min 12
Increase in input torque Nm 58.7

T3-1-17
E215B-E245B HYDRAULIC PUMP ASSY

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
No. of turns for tightening 1/4
Increase Pilot pressure Pi MPa 0.13
Decrease in delivery flow L/min 18.5

Causes of fault resulting from regulator I (Pi)


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
Disassemble and clean it.

THE MAX. FLOW RATE IS NOT DELIVERED


1. Check that pilot differential pressure Pi is
normal.
2. Stick of pilot piston
Disassemble and clean it.
3. Stick of spool
Disassemble and clean it.

NOTE: when the damage of part is severe, replace


the part with new one.

T3-1-18
HYDRAULIC PUMP ASSY E215B-E245B

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
E215B-E245B HYDRAULIC PUMP ASSY

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
PILOT VALVE E215B-E245B

OPERATION

1. Lever in neutral (See Fig.SM0593)


The action of spring (509) (for secondary
pressure setting) that determines the output
pressure of the pilot valve does not act upon
spool (201).
Therefore, spool (201) (for return) is pushed up
by spring (221) [spring seat (216)]. The output
ports (2, 4) connect with the T port. The result
is that the output pressure is equal to the tank
pressure. 216

509

221

201

PORT (2,4) 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
E215B-E245B PILOT VALVE

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 E215B-E245B

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
E215B-E245B PILOT VALVE

CONSTRUCTION AND OPERATION

The hydraulic remote control valve in TH6NR type is operated with directly-operated pressure-reducing valve.
The pilot control equipment TH6NR in double foot pedal type is made up of the actuating section which is
equipped with 2 foot supports (1), 4 pressure-reducing valves (11), 4 damper system (12) and body (6).
Every pressure-reducing valve is made up of control spool (2), control spring (3), return spring (4) and plunger
(5).
The damper system is made up of plunger (8), orifice (9) and return spring (10).
In stationary condition, the pedal is held in neutral position by return spring (10).
In operation, the foot pedal pushes the plunger (5) used for pressure-reducing valve and plunger (8) used for
dumper system.
The hydraulic oil fed into damper chamber is restricted in the orifice (9) by the pressure corresponding to the
operating speed. [Similarly, when the foot pedal returns to the neutral position with the return spring, the
hydraulic oil trapped in the damper chamber is forced out. Consequently the return speed is controlled by the
flow rate of hydraulic oil led through orifice (9).]
Simultaneously, the plunger (5) is pushed against return spring (4) and control spring (3). The control spring
(3) first moves the control spool (2) downwards, and then closes the passage between control port and the
return pipe to tank port (T). At the same time, the control port is connected to passage (7). When the control
spool reaches to the position the force of control spring (3) balances the pressure of control port (1 or 2), it
starts retaining the condition.
The pressure of control port is proportional to the stroke of plunger (5) and the position of pedal (1) according
to the mutual relations between the control spool (2) and control spring (3). The closed circuit pressure control
makes proportional control of selector valve and high responsibility of hydraulic pump and motor possible in
relation with the characteristics of foot pedal (1) position and control spring (3)

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 E215B-E245B

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
E215B-E245B CONTROL VALVE

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
CONTROL VALVE E215B-E245B

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
E215B-E245B CONTROL VALVE

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 E215B-E245B

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
E215B-E245B CONTROL VALVE

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 E215B-E245B

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
E215B-E245B CONTROL VALVE

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
CONTROL VALVE E215B-E245B

Tightening torque Tightening torque


No. Parts Name Q.ty No. Parts Name Q.ty
Nm (lbfft) Nm (lbfft)
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
162 O-ring 15 328 Spring 1
163 O-ring 11 329 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
202 Cover 4 340 Stopper 1
203 Cover 1 511 Poppet 11
204 Cover 1
205 Cover 7 512 Poppet 2
206 Cover 1 514 Poppet 2
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
213 Plate 1 522 Spring 2
215 Boom dowering valve 1 523 Spring 1
216 Piston 1 524 Spring 2
261 O-ring 12 527 Spring 1
264 O-ring 10
266 O-ring 4 528 Spring 1
25~34 (18~25) 273 Socket bolt 40 230~260 (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
310 P2 unload spool 1
311 Option spool 1

T3-3-11
E215B-E245B CONTROL VALVE

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)


Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (lbfft) Nm (lbfft)
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
CONTROL VALVE E215B-E245B

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


Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (lbfft) Nm (lbfft)
69~78 (51~58) 101 Body; M27 1 541 Seat 1
69~78 (51~58) 102 Plug; M27 1 561 O-ring 1
161 O-ring 1 562 Backup ring 1
162 O-ring 1 563 O-ring 1
123 C-ring 1 564 Backup ring 1
124 Filter stopper 1 611 Poppet 1
125 Filter 1 612 Spring seat 1
301 Piston 1 621 Spring 1
511 Plunger 1 651 Adjust screw 1
521 Spring 1 661 O-ring 1
522 Spring 1 28~31 (21~23) 671 Lock nut; M14 1

T3-3-13
E215B-E245B CONTROL VALVE

Arm 2 spool (308)

351 371 361 340 319 308 317 340 361 371 350
SM0829

Arm 2 spool
Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (lbfft) Nm (lbfft)
16~18 (33~35)
308 Spool 1 350 Plug 1
Loctite #638
16~18 (33~35)
317 Plunger 1 351 Plug 1
Loctite #638
319 Plunger 1 361 O-ring 2
340 Spring 2 371 Backup ring 2

Boom spool (301)

301 317 340 361 371 350

SM0830

Boom spool
Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (lbfft) Nm (lbfft)
16~18 (12~13)
301 Spool 1 350 Plug 1
Loctite #638
317 Plunger 1 361 O-ring 1
340 Spring 1 371 Buckup ring 1

T3-3-14
CONTROL VALVE E215B-E245B

Lock valve selector (211)

101

171 164

201

321
PLc A B Dr

166 541 167 511 161

SM0831

Lock valve selector


Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (lbfft) Nm (lbfft)
10~14
101 Casing 1 171 Socket bolt 3
(7.4~10.3)
161 O-ring 4 49~59 (36~44) 201 Plug 1
164 O-ring 1 321 Spring 1
166 O-ring 1 511 Spool 1
167 O-ring 1 541 Sleeve 1

T3-3-15
E215B-E245B CONTROL VALVE

Bypass cut valve (606)

302 301 402 401

P Pi

T Dr

201 202 102 101


SM0832

Bypass cut valve


Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (lbfft) Nm (lbfft)
98~120 (72~89) 101 Plug 1 301 Plunger 1
102 O-ring 1 302 Spring 1
201 Poppet 1 69~78 (51~58) 401 Plug 1
202 Spring 1 402 O-ring 1

T3-3-16
CONTROL VALVE E215B-E245B

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


Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (lbfft) Nm (lbfft)
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
E215B-E245B CONTROL VALVE

Boost check valve (517)

104

107

102

101

SM0834

Boost check valve


Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (lbfft) Nm (lbfft)
20~29 (15~21)
101 Poppet 1 104 Plug 1
Loctite #262
102 Poppet 1 107 Spring 1

T3-3-18
CONTROL VALVE E215B-E245B

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
E215B-E245B CONTROL VALVE

OPERATION
1. In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through
unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic
tank through tank port T1. And when the operation of unloading valve is impossible due to failure of electric
control system, because the by-pass cut valve (606) located on the downstream of center by-pass
passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through travel priority spool
(306), and then flows though the center by-pass passage (52) which passes through travel right, boom,
bucket and arm 2 and the by-pass cut valve (606) on P1 side, and flows into low pressure circuit (D) and
boost check valve (517), and then returns to the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure
circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to
the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is impossible,
because the by-pass cut valve (606) located on the downstream of center by-pass passage (55) opens,
the hydraulic oil through hydraulic pump P2 port passes through main passage, and then flows though the
center by-pass passage (55) which passes through travel left, swing, arm 1 and option and the by-pass
cut valve (606) on P2 side, and flows into low pressure circuit (D) and boost check valve (517), and then
returns to the hydraulic tank through tank port T1.

(D)
606
Pss

517 52
306

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
CONTROL VALVE E215B-E245B

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
E215B-E245B CONTROL VALVE

b) In travel priority operation


When actuator other than travel operation and the travel operation are operated simultaneously in the
said item a) "In travel independent operation" the pilot signal from the outside acts on port PTb and the
travel straight spool (307) moves upward.
With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is
used for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B
and into main passage, and is used for right and left travel operations as hydraulic oil realizing the
actuator and travel simultaneous operation. (Travel priority function) At circuit (I) position, a part of
hydraulic oil delivered by hydraulic oil P1 passes through circular notch on travel priority spool (307)
and enters from P1 to B enabling the hydraulic oil to be supplied from actuator side to travel side. And
at circuit (II) position, the circular notch on travel priority spool (307) closes and the pump line on the
travel sides is independent from pump line on actuator.

CMR2 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
CONTROL VALVE E215B-E245B

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
E215B-E245B CONTROL VALVE

b) In bucket dumping operation


On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves
rightward the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered
by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511),
and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage,
and supplied to bucket cylinder rod side (R) through port (Bc).
In the meantime, the return oil from bucket cylinder head side (H) passes through between the
perimeter of bucket spool (304) and casing and flows through low pressure circuit (D), and returns to
the hydraulic tank through tank port T1. The return oil does not pass through boost check valve (517).
Downstream of boost check valve

53 (D*)
216

PAc

PCc
PBc

Bc Ac
LCc
322 321 304 511

(R) (H)
SM0840

(D*) Downstream of boost check valve


In bucket dumping operation

T3-3-24
CONTROL VALVE E215B-E245B

4. Boom
a) In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves
rightward against the force of springs (321) (322), and simultaneously the secondary pressure of
solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309).
And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of
springs (325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa
and switches unloading spools (310).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens
load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing
through U-shaped passage, and supplied to the both boom cylinders head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter
of boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517),
and returns to the hydraulic tank through tank port T1.

(R) (R)

(H) (H)

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
E215B-E245B CONTROL VALVE

b) In boom up conflux operation


The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel
passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter
of boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens
conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and
confluents the hydraulic oil from the hydraulic pump P1 side.

PB1

326

325

511

CCb

(B)

305 56 SM0842

(B): Conflux passage to Ab port of P1 casing


In boom up conflux operation (Boom conflux spool)

T3-3-26
CONTROL VALVE E215B-E245B

c) In boom down operation


On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves
leftward against the force of springs (321) (322) and the secondary pressure of solenoid proportional
valve [X1] acts on PCb and switches unloading spool (309). And simultaneously the spool of lock valve
selector (211) is switched, and the poppet (514) is released because the spring chamber of lock valve
poppet CRb (514) is connected to the drain circuit.
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and
opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and
casing through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb).
In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port
(Ab). Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool
(301) is released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH
chamber and passes through between the perimeter of boom spool (301) and casing, and flows
through low pressure circuit (D) and boost check valve (517), and the returns to the hydraulic tank
through tank port T1. And a part of the return oil flows into the inside of boom spool (301) through
circular notch of boom spool (301). Since the return oil contains sufficient pressure with the self weight
of boom, arm, etc. the return oil passes through inside passage of boom spool (301) and pushes and
opens poppet (317) leftward as shown in the figure and flows through the circular notch, and then
supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation function)

(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
E215B-E245B CONTROL VALVE

5. Arm operation
a) In arm out operation
On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302)
moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure
of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs
(321) (328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and
switches unloading spools (309).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens
load check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool
(302) and casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass
passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage,
and pushes and opens load check valve LCAP2 (515) provided with orifice, and flows into U-shaped
passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and
casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil
from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side
(R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of
arm 1 spool (302) and casing and passes though low pressure circuit (D) and casing inside passage
(HH) and then flows into low pressure circuit (D) through between the perimeter of arm 2 spool (308)
and casing.
The return oil in low pressure circuit (D) returns to hydraulic tank through tank port T1 without passing
through boost check valve (517).

(R) (H)
322 321 211 (AR) 514 302

511
CRar Ba LCa Aa

56
PBa1 PAa1 P1 LCAT2
(D')
LCAP2
Arm 1 (D)
RH (D') P1
RR HH PAa2
52 PBa2
(D') Dr Dr
Arm 2
(F)
PBa2 PAa2 Ba
(ROD) Aa (HEAD)

53 (G)
MU

AP2

LCAT2 LCAP2
328 321 308 511 515 SM0844

(F): To arm 1 spool


(G): To pilot cut valve
In arm out operation

T3-3-28
CONTROL VALVE E215B-E245B

b) In arm in operation (At light load: arm recirculation function)


On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302)
moves leftward against the force of springs (321) (322), and simultaneously the secondary pressure of
solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same
time, since the spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet
CRar (514) is connected to the drain circuit and the retention of poppet (514) is released.
And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308)
moves leftward against the force of springs (321) (328) and the secondary pressure of solenoid
proportional valve [X1] acts on port PCb and switches unloading spools (309). But in light load
operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in the
position of circuit (I).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens
load check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool
(302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic
pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2
(511) and enters U-shaped passage, and also the oil from parallel passage (53) pushes and opens load
check valve LCAP2 (515) provided with orifice and flows into U-shaped passage. And then the
hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing from U-shaped
passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic oil
from hydraulic pump P2 side.
The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa).
In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba).
Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302)
is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The
return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside
passage (RR), but because arm 2 spool (308) does not connect to low pressure passage (D) at circuit
(I), the entire flow rate flows into arm 1 spool (302).
The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing, and
flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular
notch (a) of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than
that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool
(308) passes through check valve (317) and flows into casing inside passage (HH) and the supplied
to arm cylinder head side (H) again. (Arm recirculation function)
And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319), and
flows through boost check valve (517) through load pressure circuit (D) and returns to the hydraulic tank
through tank port T1.

T3-3-29
E215B-E245B CONTROL VALVE

(R) (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


(G): To pilot cut valve
In arm in operation (At light load: arm recirculation function)

T3-3-30
CONTROL VALVE E215B-E245B

c) In arm in operation (In heavy load operation)


The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but
in heavy load operation (work required large power); the function causes the power loss. This control
valve selects the presence of recirculation function in light and heavy load operation with solenoid
proportional valve [XR]. (Variable recirculation function)
The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the
same as that in light load operation, differs from that of return oil. In heavy load operation, solenoid
proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from
arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve
poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes
and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led
to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR). But because arm 2
spool (308) is connected to low pressure passage (D) at circuit (II), almost all the return oil passes
through between the perimeter of arm 2 spool (308) and casing and flows through boost check valve
(517) through low pressure (D) and returns to the hydraulic tank through tank port T1.
The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing
and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through
circular notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head
side (H) is higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside
passage (HH), but flows through check valve (319) and passes through boost check valve (517)
through low pressure (D) and returns to the hydraulic tank through port T1.

(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


(G): To pilot cut valve
In arm in operation (In heavy load operation)

T3-3-31
E215B-E245B CONTROL VALVE

6. Swing operation
On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves
leftward or rightward against the force of springs (321) (322), and simultaneously the secondary pressure
of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through
shuttle valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot
pressure acts on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and
then is led to port Pss.
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load
check valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through
U-shaped passage and is supplied to swing motor A side or B side through port (As) or (Bs).
In the meantime, the return oil from swing motor A side or B side passes through between the perimeter
of swing spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and
boost check valve (517), and then returns to the hydraulic tank through tank port T1.

204

PAs
PBs

Pss

Bs As
LCs

(D) 56 511 (D) 303 321 322

B A
Swing motor
SM0847

Swing operation

T3-3-32
CONTROL VALVE E215B-E245B

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
E215B-E245B CONTROL VALVE

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
CONTROL VALVE E215B-E245B

b) In boom down operation (In arm in operation)


Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511)
moves rightward as shown in the figure. After the spool (511) was moved, orifice (a) of bushing (541)
first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving
from boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514).
And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR
through spring chamber (321).
With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of
bushing (541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet
(514) down as shown in the figure is released. And since lock valve poppet (514) receives holding
pressure from boom cylinder head side (H) to the pressure receiving section in ring type which is made
up of guide diameter and seat diameter of lock valve poppet (514), lock valve poppet (514) is pushed
upward and is open.
The said operation, in boom down operation, is performed before making the opening (meter out
opening) which is used to return the return oil from the boom cylinder head side of boom spool (301) to
the tank open, the operation has no effect on the operability of boom down operation.
In case of arm-in operation, the operation is the same.

RH 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
E215B-E245B CONTROL VALVE

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
CONTROL VALVE E215B-E245B

b) At the time when failure occurred


When the electric system is failed and consequently the secondary pressure of solenoid proportional
valves [X1] and [X2] is not produced, plunger (301) is moved upward by the force of spring (302). Since
the taper section at the top end of plunger (301) is lifted up from the seat section of plug (101), spring
chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other.
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and
enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring
chamber (b) of plug (101) are connected each other, the hydraulic oil in spring chamber (a) of poppet
(201) passes through from seat section of plug (101) to spring chamber (b) and flows into passage (Dr)
through passage (c). Consequently the pressure in spring chamber (a) of poppet (201) lowers, poppet
(201) receives the pressure of center by-pass passage (52) and is lifted up against the force of spring
(202), and the hydraulic oil from center by-pass passage (52) flows into low pressure passage (D)
through poppet (201) of by-pass cut valve (606). Therefore when the electric system is failed, P1
unloading spool (309) is shifted to the neutral position and the passage to low pressure passage (D) is
cut off, but because center by-pass passage (52) is connected to low pressure passage (D) through
by-pass cut valve (606), the abnormal rise of the pump pressure is prevented.

PBp1

301 302

(C) (b)

Dr 101

201 (a)

(D) 202

52

SM0970

By-pass cut valve (In condition of failure)

T3-3-37
E215B-E245B CONTROL VALVE

10. Boost check valve, By-pass check valve


a) Boost check valve
The boost check valve is located between low pressure passage (D) and tank port T1 and generates
boost pressure necessary for the low pressure passage.
a. In normal operation
The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against
the force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the
pressure generated by spring (527) is used as the boost pressure for the low pressure passage.
But the return oil used for the arm out and bucket dumping operation does not pass through boost
check valve (517), but returns from low pressure passage (D) to hydraulic tank through tank port
T1.
b. In make up operation
When supplying to make up the flow rate through low pressure passage (D) after the swing
operation is suspended, if the hydraulic oil quantity in low pressure passage (D) is not enough, the
deficient hydraulic oil is made up from hydraulic tank into low pressure passage (D).
When the deficient hydraulic oil in low pressure passage (D) is not sufficient, the pressure of low
pressure passage (D) is lowered. If the pressure of low pressure passage (D) is lowered to the
pressure at tank port T1, poppet (102) housed in boost check valve (517) receives the pressure at
tank port T1 on the receiving section in ring type which is made up of guide diameter and seat
diameter of poppet (102), and is pushed upward and opens, and the hydraulic oil flows from the
hydraulic tank to low pressure passage (D) to make up the deficient flow rate.

527

528
(D') T2
518
T1

102

1
517 (D) 528
527
T2 518
102
T1
517

(D) 2
SM0971

1. In normal operation
2. In make up operation
Boost check valve operation

T3-3-38
CONTROL VALVE E215B-E245B

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
E215B-E245B CONTROL VALVE

11. Emergency manual valve for leaving attachment


Needle valve (Emergency manual valve for lowering attachment) is equipped internally between Ab port
of boom cylinder head side and boom lock valve. For safety, this valve lowers risen attachment to the
ground, if the machine stops with engine trouble. Only in case that the boom is lowering, the pressure in
the cylinder of attachment can be released by operating arm or bucket control lever.
a) Functional explanation
In normal cases, the needle valve was blocked completely to prevent pressure leak of boom circuit.
a. Lowering of boom
Loosen lock nut at first and loosen the needle valve to the end of contact.
IMPORTANT: needle valve is provided the mechanism of stopper against falling out. But the mechanism might
cause break by undue force.
The oil of boom cylinder (1) head side (H) flows into drain passage (4) through orifice, and boom
lowers slowly. The time of boom lowering to the ground takes about 4 to 8 minutes in accordance
with machine position and holding pressure
b. Function of actuator
Oil pressure of XAb port is reduced by releasing holding pressure of boom cylinder head side to
drain passage (4) through orifice.
Operation of actuator with pilot control valve is possible by leading medium pressure via orifice from
XAb port to shuttle valve (7). In this function, this leading of medium pressure ensures primary
pressure of remote control (source of pressure). This function ensures that the cylinder movement
of boom, arm, bucket and others can be actuated only downward by self weight. Consequently the
releasing of pressure becomes possible.
But after attachment is lowered to the ground by lowering boom, holding pressure disappears, and
remote control, via pilot valve, becomes impossible.
c. Boom cylinder with holding valve
If the boom cylinder has holding valve, loosen above-mentioned needle valve together with port
relief valve of holding valve, and boom cylinder starts boom lowering.
Spool of holding valve moves to open side by back pressure of port relief valve, and holding
pressure of boom cylinder is led to Emergency manual valve for lowering attachment, operation of
actuator by pilot valve is possibile.

T3-3-40
CONTROL VALVE E215B-E245B

Emergency manual valve for lowering attachment operation

(R)

1
(H)
2
Ab

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
E215B-E245B CONTROL VALVE

NOTE:

T3-3-42
SWING DEVICE E215B-E245B

OUTLINE

General view

THREAD FOR
M L EYE BOLT 2-M10
PB DEPTH 18

B RELIEF VALVE
(B PORT SIDE)

(SH)

IP
PG

RELIEF VALVE
A (A PORT SIDE)
DB
PA
SM0570

Tightening torque
Symbol Port name Port size
Nm (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
SWING DEVICE E215B-E245B

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
E215B-E245B SWING DEVICE

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
SWING DEVICE E215B-E245B

Tightening Tightening
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
E215B-E245B SWING DEVICE

Swing reduction unit

Be careful about installation


direction of retaining ring. Caulk these 2 places
Apply Three Bond #1360 with punch.
or equivalent. 23
OIL FILLING PORT PT3/4
LEVEL PORT PT1/2
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

Tightening Tightening
torque torque
No. Parts Q.ty No. Parts Q.ty
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
SWING DEVICE E215B-E245B

HYDRAULIC MOTOR

Operation
If the high pressure oil flows into the cylinder
through the inlet port (a) of valve plate (131), as
shown on the figure on the right, the hydraulic
Cylinder block (111)
pressure acts upon piston (121) and creates force F
in the axial direction.
The force F may be divided into force F1 vertical to F2
shoe plate (124) via shoe (122) and force F2 at right F1
angles with the shaft. F
The force F2 is transmitted to cylinder block (111)
via pistons (121) and causes drive shaft to turn so
as to produce a rotating moment. Drive shaft (101)
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to drive
shaft by turns by pistons connected to inlet port of
high pressure oil.
If the oil supply and discharge directions are Valve
reversed, the drive shaft rotates in the opposite plate
direction. Shoe Shoe Piston (131)
Theoretical output torque T can be given by the plate (122) (121)
(122)
following equation. SM0575

PXq
T=
2X Low pressure oil High pressure oil

p: Effective differential pressure MPa


q: Displacement per revolution cc/rev
OUTLET INLET (a)

SM0576

T3-4-7
E215B-E245B SWING DEVICE

VALVE CASING SECTION

Operation of anti-cavitation check plunger


Since the system using this type of motor is not
equipped with a valve having a counterbalance
function, the motor is rotated beyond the oil feed
rate in some cases. 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
SWING DEVICE E215B-E245B

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
E215B-E245B SWING DEVICE

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
SWING DEVICE E215B-E245B

BRAKE SECTION

Operation
The cylinder (111) is jointed by drive shaft (101) and
a spline. Separator plate (743) is fixed in its
712
circumferential direction by circular grooves
provided in casing (301).
Now, if the friction plate (742) splined to the outer
circumference of the cylinder is pressed against 702
casing (301) via separator plate (743) and brake
712 743
piston (702) by the action of brake spring (712),
frictional force is created between friction plate (742) 742
and casing (301) and between separator plate (743) 702
and brake piston (702). The frictional force bounds
111 301
the drive shaft to brake the motor.
In the meantime, when brake release pressure 743 742 101
301
applied to the oil chamber formed between brake SM0588
piston (702) and casing (301) overcomes the spring
force, the brake is released as brake piston (702)
moves till friction plate (742) is separated from
casing (301).

T3-4-11
E215B-E245B SWING DEVICE

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
TRAVEL DEVICE E215B-E245B

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
E215B-E245B TRAVEL DEVICE

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
TRAVEL DEVICE E215B-E245B

Direction of rotation
When assembling the track drive on the machine and connecting the hoses, follow instructions shown in below
sketch for proper direction of rotation

SM0555

Oil inlet port Oil outlet port Direction of rotation


P1 P2 Clockwise
P2 P1 Counterclockwise

COSTRUCTION
Track drive E215B

SM0556

1- Hydraulic motor
2- Reduction stages

T3-5-5
E215B-E245B TRAVEL DEVICE

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
TRAVEL DEVICE E215B-E245B

Hydraulic motor and track drive E245B

SM0558

T3-5-7
E215B-E245B TRAVEL DEVICE

Hydraulic motor E245B

SM0559

T3-5-8
TRAVEL DEVICE E215B-E245B

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