SAFETY PRECAUTIONS

M0103

SAFETY PRECAUTIONS

E215B-E245B

INDEX
Section 1

GENERALITIES

Section 2

SAFETY PRECAUTIONS

Section 3

SAFETY PLATES

GENERALITIES

E215B-E245B

SAFETY PRECAUTIONS
GENERALITIES
Do not leave the machine until it has come to a
complete stop.

Read the Operation and Maintenance Instruction
Manual carefully before starting,
operating,
maintaining, fuelling or servicing the machine.

Always check height, width and weight limitations
which may be encountered in the working site and
ensure the machine does not exceed them.

Carefully read the explanation to each and all safety
signs in the special section of this Manual before
starting, operating, maintaining, fuelling or servicing
the machine.

Assess exact paths of gas ducts, water mains,
telephone lines, sewers, overhead and underground
electric lines and all other possible obstacles.

Machine-mounted safety plates are colour coded
yellow with black borders when they refer to points
where special ATTENTION must be paid and failure
to observe them may cause a serious DANGER to
the integrity of machine operators. They are white
with red borders and black lettering when they refer
to a FORBIDDEN practice.

Such paths should be opportunely defined by
competent Authorities. If necessary, require that the
service is interrupted or said installations are moved
prior to starting the work.
You must know the working capacity of the machine.
Define the rear upperstructure swing area and
provide for opportune barriers to prevent access into
it.

It is fundamental that all machine operators know
very well the meaning of each safety plate as this
considerably decreases operating hazards and
accidents.

Never exceed machine lifting capacity.
Remain within the limits shown in the loading
capacity chart which located on the machine.

Do not allow unauthorised personnel to operate or
service this machine.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get
caught in moving parts. Wear certified safety clothes
such as: hard hat, no-slip footwear, heavy gloves, ear
protection, safety glasses, reflector vests, respirators
every time the job requires it. Ask your employer
about safety regulations in force and protective
equipment.

STARTING
Never start or operate a failed machine. Walk all
around the machine before mounting.
Before operating the machine, make sure that any
possible dangerous condition has been properly
removed. Before starting machine, check that
steering and attachment controls are in the neutral
position and the safety lever is in the LOCK position.
Immediately report any malfunction of parts or
systems to the maintenance managers for proper
action.

Always keep the operator’s compartment, step
plates, grab-rails and handles clean and clear of
foreign objects, oil, grease, mud or snow to minimise
the danger of slipping or stumbling. Remove mud or
grease from your shoes before operating the
machine.

Prior to starting the engine, check, adjust and lock the
driver’s seat for maximum riding comfort and control
accessibility. Prior to operating the machine and/or
its attachments, check that bystanders are outside
the machine operating range. Sound the horn.

Do not jump on or off the machine. Always keep both
hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Do not use controls or hoses as hand holds. Hoses
and controls are movable parts and do not provide
solid support. Besides, controls may be inadvertently
moved and cause unexpected movement of the
machine or its attachments.

Obey all hand signals, safety indications and signs.

Never operate the machine or its attachments from
any position other than sitting in the driver’s seat.
Keep head, body, limbs, hands and feet inside the
operator’s compartment at all times to reduce
exposure to external hazards.

Ensure that nobody is within the excavator operating
area before starting the machine, swinging the upper
structure or moving in any direction.

Be careful of possible slippery conditions of the steps
and hand rails as well as of the ground around the
machine. Wear protective boots or shoes with the
soles made of highly no-slip rubber

Ensure that engine speed is appropriate to the job to
be carried out.

Due to the presence of flammable fluids, never
check fuel level, refuel, charge the batteries in the
presence of smoking materials, open flames or
sparks.

Adjust all rear-view mirrors for maximum visibility of
the area behind the machine.

S1 - 1

E215B-E245B

GENERALITIES

If any hydraulic control or system exhibits erratic
performance or responds abnormally, have the
machine checked for air in the system.

properly protected against possible backlash in
case of cable or chain failure or detachment.
Be alert of soft ground conditions close to newly
constructed walls. The fill material and machine
weight may cause the wall to collapse under the
machine.

Air in these circuits may cause incorrect movements
with consequent accident hazard. Refer to the
Operation and Maintenance Instruction Manual
about corrective action to be taken.

In darkness, check area of operation carefully before
moving in with the machine. Use all lights provided.
Do not move into low visibility areas.
If the engine tends to slow down and stall for
whatever reason under load or at idle, immediately
report this problem to the maintenance managers for
proper action.

OPERATING
Do not run the engine of this machine in closed
buildings without proper ventilation capable to
remove harmful exhaust gases which concentrate in
the air.

Do not operate the machine until this condition is
corrected. Regularly check all exhaust system
components, as exhaust fumes are toxic for the
operator.

Keep the operator’s compartment free of foreign
objects, especially if not firmly secured. Never use
the machine to transport objects, unless proper
securing points are provided.

Operators must know the performance of the
machine they are driving. When working on slopes or
near sudden level drops in the terrain, pay attention
not to lose adherence and avoid loose soft ground
since overturn or loss of machine control could result.

Do not carry riders on the machine. Study and
familiarise with escape routes alternative to normal
exit routes. For your personal safety, do not climb on
or off the machine while it is in motion.

If noise level is high and exceeds 90 dB (A) over 8
hours at the operator’s ear, wear approved ear
protection in compliance with local regulations.

Make sure that bystanders are clear of the machine
operating range before starting the engine and
operating the attachment. Sound the horn.
Obey all hand signals, safety indications and signs.

Do not operate the machine if you are extremely tired
or feel ill. Be especially careful towards the end of the
working shift.

When backing, always look to where the machine is
to be moved.

Where removable counterweights are provided, do
not operate the machine if they have been removed.

Be alert of the position of bystanders. Should
someone enter the work area, stop the machine.
Maintain a safe distance from other machines or
obstacles to ensure required visibility conditions.

When operating the machine, keep in mind height
limits of overhead doors, arches, overhead cables
and lines as well as width limits of corridors, roads
and narrow passages.

Always give way to loaded machines.

Also, get to know load limits of the ground and
paving type of the ramps you are to work on.

Maintain a clear vision of the surroundings of the
travel or work area at all times. Keep cab windows
clean and repaired.

Beware of fog, smoke or dust that obscure visibility.
Always inspect the working area to identify potential
risks such as: inclines, overhangs, trees, demolition
rubble, fires, ravines, steep slopes, rough terrain,
ditches, crowns, ridge trenches,diggings in traffic
areas, crowded parking lots, crowded service areas,
fenced zones. In such conditions, proceed with
extreme care.

When pulling loads or towing through a cable or
chain, do not start suddenly at full throttle. Take-up
slack carefully. Avoid kinking or twisting chains or
cables.
Carefully inspect the towing items for flaws or
problems before proceeding. Do not pull through a
kinked chain or cable as the high anomalous stresses
existing in this condition may induce failures in the
kinked portion.

Whenever possible, avoid crossing over obstacles
such as very rough terrain, rocks, logs, steps,
ditches, railroad tracks.

Always wear heavy gloves when handling chains or
cables.

When obstructions must be crossed, do so with
extreme care and at a square angle, if possible. Slow
down.

Chains and cables should be securely anchored
using suitable hooks. Anchor points should be strong
enough to withstand the expected load.

Ease up to the break-over point, pass the balance
point slowly and ease down the other side also using
the attachment, if necessary.

Keep anyone clear of anchor points and cables or
chains.

To overcome deep trenches or sinking ground, place
the machine perpendicular to the obstacle, drastically
reduce ground speed and start crossing using also

Do not pull or tow unless the operator’s
compartments of the machines involved are
S1 - 2

only after assessing that ground conditions allow the traverse safely and without risks. logs and rocks. . The excavator is no lifting and transportation means.3 . nor downhill when working on a slope as this would decrease machine stability. Never use the bucket or attachment as a man lift or carry riders. Working on slopes is dangerous. Do not lift and move the bucket overhead where persons are standing or working. . provides for the travel controls at the front and travel motors at the back. Grade the working area if possible. Position the machine dependent upon the loading and unloading areas in order to swing leftwards to load to obtain best visibility. load being handled. The word “bulldozing” generally refers to work in virgin rough terrain. Position the carriage at a right angle relative to slopes. Always ensure that slings and chains used for lifting are adequate to the load and in good condition. Incorrect fastening of slings or chains may cause boom/arm failure or failure of the lifting means with consequent bodily injuries and even death. other loads or the attachment above ground personnel or truck cabs. We emphasise the danger represented in these conditions by large tree limbs (possibly falling on the machine) and large roots (which may act as a leverage under the machine when up-rooted and cause the unit to overturn). There is no substitute for good judgement and experience when working on slopes. material piling up and loading characteristics. Avoid travelling across slopes. Load trucks from side or rear. When transporting a loaded bucket. Ground speed should be adequate to the load and ground conditions. by slowly swinging the upper structure by 360°.Nobody should be allowed to remain under the raised load or within the excavator operating range for any reason whatever. The load must always be properly arranged in the bucket. . etc. Standard use. Use only the type of bucket recommended considering machine type. The machine must not be improperly used for works not consistent with its features (such as pushing railway cars. move with extreme care when transporting oversize loads.GENERALITIES E215B-E245B the attachment if necessary. trucks or other machines). nor over any other surface irregularities that discontinue adherence or traction with the ground. ground type and other typical conditions of the work to be performed. Loads to be raised using the machine should be exclusively hooked to the hitch specially provided. hanging walls. Ensure the truck driver is in a safe place before loading the truck. Should it be exceptionally used to lift and lay building components. special caution must be taken as follows: Avoid faggots. Load the bucket from the uphill side. All loading capacities are referred to the machine on a level surface and should be disregarded when working on a slope. Always pay attention to people within the machine operating range. bushes. Remember that such hazards are likely to be concealed by bushes. undergrowth and such. Work with extreme care on ice or frozen ground and on stepped slopes or near drop-offs. materials to be handled. Avoid operating the attachment too close to an overhang or high wall. and visibility. Be alert to avoid changes in adherence conditions that could cause loss of control. to exit the working area easily. either above or below the machine.Secure the loads to be raised using cables or chains fastened with appropriate hooking mechanisms. especially near slopes or drop-offs. Never exceed specified loading capacity. Keep boom and arm as low as possible. Never move or stop the bucket. Proceed from uphill downhill and vice-versa. keep it as rolled-back as possible. machine type and speed. Do not move full bucket or a load from uphill downhill as this would reduce machine stability. Do not work with the bucket turned uphill as counterweights protruding downhill would reduce machine stability on the slope and increase risk of overturning. Never use the machine as a work platform or scaffolding. We recommend to work on slopes with the bucket downhill. Never drive over them. If machine starts slipping sideways when on a slope. Do not work with the bucket turned to the uphill side. The gradient you may attempt to overcome is limited by factors such as ground conditions. after checking machine stability with the bucket empty and attachment retracted. Should travel S1 . Beware of caving edges. falling objects and landslides. lower the bucket and thrust bucket teeth into the ground. Reduce work cycle time if it is not possible to grade the working area.The machine must be equipped compulsorily with the appropriate variant provided upon request. therefore it should not be used to position loads accurately. characterised by the presence of all the perils and risks listed above.

consult the Electric Power Company to know which precautions should be taken. any part of it and/or the load approaching the gas mains from a standpoint more favourable than the Operator’s. Support everywhere it is required to prevent possible cave-ins or landslides when: .4 . check that the walls are sufficiently propped up to avoid cave-in hazards. . as well as machine Operator. . Reaction time could be too slow and distance evaluation wrong.When working near gas mains or other public utilities installations. .Warn all ground personnel to keep clear of the machine and/or load at all times.Contact the company owner of the gas mains or its nearest branch before starting the work. . When digging. raise the load or brake abruptly if not required. .Digging trenches subject to vibration from railroads. Remind relative to travel direction that controls are reversed. any part of it and/or the load approaching the electric lines from a standpoint more favourable than the Operator’s. Owner and/or any natural person or legal entity having rent orleased the machine or being responsible at the time by contract or by law.Digging in bad ground conditions. This may cause accidents. This person will have the responsibility of observing the machine. . Prior to beginning the work near gas distribution mains or other public utilities: . Always check travel motor position before moving off. if previously advised and involved in the work. .Digging near previous trenches filled with material. . Working near electric lines can be very dangerous. This signal man (flag-man) must be in direct communication with the Operator and the Operator must pay undivided attention to the signals supplied. Within this Manual.Contact the Company owner of the electric lines or its nearest branch before starting the work. Make sure that the support surface is strong enough to prevent landslides. When working in or near pits. Pay the utmost attention when working near overhang walls or where landslides may take place. Should it be necessary to dig under the machine.Define together which precautions should be taken to guarantee work safety. appoint a person in charge of signalling duties. Never dig under the machine. Reaction time could be too slow and distance evaluation wrong. If the load has to be guided down for laying.Decrease work speed. . working machines or highway traffic. This person will have the responsibility of observing the machine. are liable for the adoption of the necessary precautions.Decrease work speed. far from the ditch . Owner and/or any natural person or legal entity having rent or leased the machine or being responsible at the time by contract or by law. Do not swing the upperstructure. Properly judge ground conditions with particular attention to consistency of the area you are going to work on. Keep the machine sufficiently edge. S1 . therefore some special precautions must be observed. if previously advised and involved in the work. always check that all controls are in the neutral position and that the safety lever is on the lock position to guarantee risk-free start-up. in ditches or very high walls. always ensure that digging walls are opportunely propped up against landslide to prevent the machine from falling into the trench. as well as machine Operator. Look up the number in the telephone directory.Define together with the Company representative which precautions should be taken to guarantee work safety. Always check ground conditions and conditions of the material to be removed. .E215B-E245B GENERALITIES . “work near electric lines” means when the attachment or load raised by the excavator (in any position) may reach the minimum safety distance established by local or international Safety Regulations.Look up the in the telephone directory. are liable for the adoption of the necessary precautions. motors be positioned at the front with regard to the actual travel direction. STOPPING To work without risks. When the machine is to be stopped for whatever reason.All electric lines should be considered as operative live lines even though it might be well known that the line in question is out of work and visibly connected to the ground.Appoint a person in charge of signalling duties. . This signal man (flag-man) must be in direct communication with the Operator and the Operator must pay undivided attention to the signals supplied. there is the risk of cave-ins and landslides.The Electric Power Company.The gas distributing Company. keep maximum possible distance from electric lines and never trespass minimum safety distance. .

Move engine controls to the shut-down position. Do not allow unauthorised personnel to repair or service the machine. such as ties. Wear certified safety clothes such as: hard hat. Retract possible auxiliary tools to the closed safety position. scarves. no-slip footwear. Follow stopping instructions contained in the Operation and Maintenance Instruction Manual. Never leave the machine unattended with the engine running. Ask your employer about safety regulations in force and protective equipment. hands. Do not wear rings.GENERALITIES E215B-E245B Read all safety plates mounted on the machine and observe instructions they contain before starting. MAINTENANCE GENERALITIES Carefully read the Operation and Maintenance Instruction Manual before starting. rocky hanging walls. position the machine at a right angle to the slope. or parking the machine to prevent accidental unauthorised start-up. areas with overhead electric lines. If this is not possible. If parking in traffic lanes cannot be avoided. feet or fingers near articulated cutting edges deprived of the necessary guards. Keep the operator’s compartment. Do not use controls or hoses as hand holds. wrist watches. grab rails and handles clear of foreign objects. and slopes before stopping it at the end of the working day. Always switch off the key-start switch before cleaning. trenches. fuelling or servicing the machine in any manner. especially if these are not secured. Move all controls to the position specified for machine stopping. Never lower the attachment or auxiliary tools other than from sitting in the operator’s seat. Check that all controls are in the neutral position. sound the horn and require that nobody remains near the machine. or both feet and one hand in contact with steps and/or grab rails. repairing. Align the upperstructure to the tracks in order to allow to easily get on and off the driver’s compartment. oil. Prior to leaving the driver’s seat. Refer the Operation and Maintenance Instruction Manual. Always lock all moving components or parts of the machine that must be lifted for maintenance purposes using adequate external means as required by local and national regulations. repairing. Do not place head. Should it be necessary to move the attachment for maintenance purposes. respirators when required. S1 . unless this person is an authorised operator assisting in the maintenance being carried out. provide appropriate flags. If you are not absolutely sure about your safety. torn clothing. Never service the machine with someone sitting in the driver’s seat. Hoses and controls are movable parts and do not provide solid support. reflector vests. Never attempt to operate the machine or its attachments from any position other than sitting in the operator’s seat. mud orsnow to minimise the danger of slipping or stumbling. Perform all necessary operations for stopping as detailed in the Operation and Maintenance Instruction Manual. controls may be inadvertently moved and cause unexpected movement of the machine or its attachments. Clean mud or grease from your shoes before climbing on the machine or driving it. Always keep both hands and one foot. making sure there is no danger of uncontrolled sliding. Drive the machine far from pits. Make sure that nobody is within the machine operating range.5 . limbs. fuelling or servicing the machine. Besides. Raise the attachment slowly. Switch off the key-start switch. Lower the attachment slowly. do not stay or walk under a raised attachment. operating. and after making sure that all people are clear of the machine. do not raise or lower the attachment from any other position than sitting in the operator’s seat. Do not allow anyone to pass or stay near or below a raised attachment. slowly lower the attachment until resting it safely to the ground. maintaining. Park the machine in a non-operating and no-traffic area. Return keys to the safe place previously agreed upon. unbuttoned or unzipped jackets that can get caught in moving parts. jewellery. Securely block and lock the machine every time you leave it unattended. body. Park on firm level ground. grease. Follow all recommended maintenance and service procedures. Do not jump on or off the machine. Consult the Operation and Maintenance Instruction Manual. Keep the driver’s seat free from foreign objects. operating. step plates. Sound the horn. safety glasses. barriers. flares and other signals as required to adequately warn the oncoming drivers. unless they are suitably and safely locked. loose or hanging garments. heavy gloves. Never park on an incline without accurately blocking the machine to prevent unexpected movement. Before starting the machine or moving its attachment. ear protection.

Use strong access ramps. alwaysuse appropriate aligning tools. wear safety glasses with side shields. check. Ensure the parts are supported by appropriate straps and hooks. Shop and/or field service platforms or ladders should be manufactured and maintained in accordance with local or national safety regulations in force. cables or chains. Keep all bystanders clear of the anchor point. Tie the machine securely to the trailer and block carriages and upperstructure. Do not pull or tow unless the operator’s compartments of the machines involved are fitted with proper guards against cable or chain backlash. Disconnect batteries and label all controls to warn that service work is in progress. Use lifting eyes provided to this aim. When using compressed air to clean parts. In case of field service. Pay attention to bystanders near the lifting area. Do not pile up oily or greasy rags as they represent a major fire hazard. Stop the engine and move the safey lever to the lock position before starting adjusting or repairing an assembly. battery chargers. nor allow open flames or sparks nearby while refuelling the unit or handling highly flammable materials. Keep the trailer flatbed free of mud. If work on an incline cannot be avoided.E215B-E245B GENERALITIES flammable fluids to clean parts. Make sure that all mechanical tools provided are in good condition at all times. use machine grab rails and steps. Always wear safety gloves to handle chains or cables. except when this is specifically required by the Operation and Maintenance Instruction Manual. Move the machine to level ground as soon as possible. non-toxic solvents only. Keep this contact from the beginning to the end of the fuelling operation to avoid possible generation of sparks due to static electricity. If such means are not available. Always wear eye protections with side shields. Should it be necessary to tow it. Also ensure that nobody is within the machine or attachment Never pour gasoline or diesel fuel into open containers. repair or adjust the machine with the engine running. Block the machine and all attachments to be raised according to local and national safety regulation requirements. Never use gasoline. Limit pressure to max. in accordance with local and national safety regulations in force. pumps and similar equipment to reduce electrical shock hazard. Do not check or fill fuel tanks or install batteries near burning or smoking materials and open flames due to the presence of flammable vapours. adjust and lock the operator’s seat. oil or slippery materials. In case of attachment tests during which the engine should be kept running. Do not run the engine of this machine in closed buildings without proper forced ventilation capable to remove toxic exhaust gases concentrating in the air. Move with extreme care when working under. Use a truck or trailer to haul a failed machine. move the machine to level ground and block it. a qualified operator must sit in the driver’s seat at all times while the mechanic is at work. 2 bars. provide for suitable danger signals as required by the local norms and regulations and observe recommendations given in the Operation and Maintenance Instruction Manual. Do not use open flames as light sources to look for leaks or inspect anywhere on the machine. securely block the machine and its attachments. use a ladder or step platform conforming to local or national regulations to reach the working area. Use proprietary certified non-flammable. Do not wear loose clothing. Keep hands and clothes far off moving parts. Keep the maintenance area clean and dry at all times. Before starting the machine or its attachment. jewellery near rotating parts. Do not smoke. The fuel filler pipe nozzle must be constantly kept in contact with the filler neck and this even before fuel starts flowing in. Load/unload the machine on firm level ground providing safe support to the wheels of the truck or trailer. Remove all sharp edges and burrs from re-worked parts. Always perform all service or maintenance work with the greatest care and attention. on or near the machine or its attachments.6 . When service or maintenance require access to areas that cannot be reached from the ground. Never use a twisted chain or cable for lifting or pulling. Use only approved and effectively grounded auxiliary power sources for heaters. solvents or other S1 . Be sure chains and cables are firmly fastened and that the anchor point is strong enough to withstand the expected load. Clean immediately all water and oil spillage. Never align holes or slots using your fingers. with adequate height and angle. Never lubricate. Do not carry out any work on the attachment without prior authorisation. Never use tools with mushroomed or damaged heads. Lift and handle heavy components using hoisting devices of appropriate capacity. according to local and national safety regulation requirements. Do not twist chains and cables. Always store them in closed metal containers. Observe maintenance and repair procedures.

safety shoes and gloves. Such limits must never be exceeded. keep the upperstructure aligned with the carriages. Wear appropriate safety clothing such as hard hat. in compliance with local or national safety regulations. Areas near articulated cutting edges where mechanical parts are in motion are where personal S1 . Always load and unload on level surface. Do not use makeshift jacks to adjust track sag. safety gloves and footwear always while welding or arc-cutting. Store containers in a cool well ventilated place where they could not be reached by unauthorised people. Get to know and respect local and national regulations. Use a ramp to load the machine on a trailer. block the carriages to prevent unexpected movement. Wear the appropriate welder’s equipment such as dark safety glasses or mask. Always wear certified protection clothes such as safety gloves and glasses while handling them. Keep the bucket down at all times during transfers. fabricate one using blocks. Always install the safety stays for the hood and other hinged covers before performing any maintenance or repair work in the engine compartment. gloves and footwear. block upperstructure swing to prevent accidental movement. TRANSFERS AND TRANSPORTATION Before moving or transporting the machine. Keep the bucket in a position to provide a possible anchor point into the ground in case of slipping. width. in a crowded area. Pay particular attention during transfer on inclines. Lower the attachment to the ground and relieve pressure from all circuits prior to carrying out any type of maintenance or repair work. Become acquainted with all your jacking equipment and their capacity. gears. Do not travel across the slope. The ramp should be sufficiently strong to support machine weight. Always support the load onto appropriate blocking means as a safety measure before proceeding with service or maintenance work. Do not service or repair the machine if it is parked downhill. Pay attention to machine shaking when the centre of gravity overcomes the obstacle. safety glasses when splinters or other particles may be ejected. Check distance between boom/arm and dimensional limits during transfer or transportation. Do not carry loose objects in your pockets that might fall unnoticed into open compartments. Handle all parts carefully. be sure the supports under the jack and between the jack and the machine are appropriate and stable. Cross obstacles at a right angle at low speed. Do not look the welding arc without proper eye protection. If this is unavoidable. Sound the horn. Rough terrain may cause the machine to sway and roll to such an extent that boom/arm could get to contact electric lines or other obstacles. Wear dark safety glasses when you are near a welding in progress. particularly if the work is to be carried out on the final reduction units or travel motors. protective clothing. Follow instructions given in the Repair Manual. hard hat. Prepare parts in well ventilated areas. Keep open flames away. The attachment is kept constantly in position by an oil column trapped into the high pressure circuit. Metal cables produce steel splinters. Ensure that the jacking point on the machine is appropriate for the load applied. Any equipment supported by a jack represents a possible hazard. or near people without having at least one person charged with hand-signals who could guide the Operator. Move the hydraulic system lock safety lever to the lock position when stopping the machine for whatever reason. both uphill and downhill. Never transfer the machine in the working site. If a ramp is not available. in case of emergency. Do not smoke. and weight. operating range before starting or operating the machine and/or its attachments. It is necessary to know load limits of bridges and dimensional limits of tunnels. You should also know machine height. Pay attention to prevent possible part movements by means of blocks or by keeping clear of such zones when motion may take place during maintenance or repair. Rust inhibitors are volatile and flammable. Consider boom/arm and upperstructure dimensions while turning.GENERALITIES E215B-E245B injuries are most likely to occur. During transfers on inclines.7 . Consult the Operation and Maintenance Instruction Manual for correct maintenance procedure. and similar. Always use and wear certified safety clothes such as safety glasses. Drive with the lights on and use appropriate signals and flags. Also. Sound the horn to inform that you are about to move off. both uphill and downhill. Have a signal-man help you when clearances are limited. Keep hands and fingers away from gaps.

Battery released gas is highly flammable. Immediately seek medical attention. If injured by escaping fluid. If any. limbs. Require that nobody remain near the machine. correct prior to proceeding with further work. S1 . Stop the engine and ensure pressure is relieved from all systems before removing side panels. Ensure proper ventilation is provided to avoid accidental explosions due to build-up of explosive gas released during charging. or clothes. Do not run the engine in closed buildings without proper ventilation capable to remove harmful exhaust fumes. do so exclusively while sitting in the driver’s seat. obtain medical attention immediately or serious infection or reaction may develop. Keep the exhaust manifold and tube free from combustible matters. ENGINE Disconnect batteries before working on the electrical system or carrying out any other type of work. Do not use hands. Do not use the machine to transport loose objects. hands or fingers near rotating fans or belts. TOOLS Always keep head. Batteries contain SULPHURIC ACID. Keep sparks or open flames away from batteries. Refer to the Operation and Maintenance Instruction Manual or Repair Manual. Pressure fluid escaping from a very small hole can be almost invisible and still have sufficient force to penetrate the skin.to -) at both ends. RINSE IMMEDIATELY IN WATER FOR AT LEAST 15 MINUTES. limbs. Never use gases other than nitrogen to charge the accumulators. as this increases fire hazard in case of fuel spillage. Do not run the engine with the air intakes open and not protected. housings. Do not place head. See the Operation and Maintenance Instruction Manual. unless proper securing devices are provided. especially if hot. Always move the key-start switch in the lock position before servicing or repairing the machine. Pay attention to connect connecting cables to correct poles (+ to +) and (. HYDRAULIC SYSTEM Loosen the radiator cap very slowly to relieve system pressure before removing it.8 . Do not shortcircuit terminals. ELECTRICAL SYSTEM Prior to any maintenance or repair work. Do not refuel with the engine running. and fingers away from the bucket and attachments. Leave the battery compartment cover open during recharging to improve ventilation. hands. Never check battery charge by placing metal objects across the posts. See the Operation and Maintenance Instruction Manual. If this cannot be avoided for service reasons. Do not recharge batteries in confined spaces. install all supports necessary to this aim according to local and national safety regulations. feet. eyes. Thoroughly follow instructions given in Operation and Maintenance Instruction Manual. Should acid contact skin. Always use gauges of adequate capacity for pressure testing. when in the raised position. make sure that there are no fuel or electrolyte leaks from the batteries. Tow the machine following the instructions contained in the Operation and Maintenance Instruction Manual. Be especially careful near blower fans. guards and covers. body. Raise the attachment slowly. In case the attachment is to be operated for maintenance or repair purposes. Always check any suspected pressure leaks using a piece of cardboard or wood. Do not adjust the fuel injection pump when the machine is operating. place protection meshes on all intakes before servicing the engine. Do not smoke near the battery to prevent explosion hazard. Fit the machine with shields and guards when working in the presence of combustible matter free in the air. Always top-up coolant level with the engine off or idling if hot. Do not lubricate the machine with the engine running. body. Never attempt to check or adjust fan belt tensions when the engine is running.E215B-E245B GENERALITIES Before any maintenance or repair. feet. Sound the horn before starting the machine or moving the attachment. Protect the eyes when working near the batteries against possible sprays of the acid solution.

ENVIRONMENTAL PROTECTION • This Manual also contains this symbol accompanying instructions for correct behaviour as regards environmental protection. if not avoided. may cause damage to the machine.DANGER. DANGER These words are always accompanied by the safety alert symbol. will result in death or serious injury.When you see this symbol on your machine or in this Manual. .CAUTION.SAFETY PRECAUTIONS E215B-E245B RECOGNISE SAFETY INFORMATION • This is your SAFETY ALERT SYMBOL . could result in death or serious injury.1 . if not avoided. S2 . DANGER: indicates an imminent hazardous situation which. . . if not avoided. may result in minor or moderate injury. NOTE: indicates an additional explanation for information purposes.Follow recommended precautions and safe operating practices. WARNING WARNING: indicated a potential hazardous situation which. if not avoided.WARNING. UNDERSTAND SIGNAL WORDS • In this Manual you will find the following words referring to different hazard risks: . be alert of the potential for personal injury. CAUTION IMPORTANT CAUTION: indicates a potential hazardous situation which. NOTE IMPORTANT: indicates a situation which.

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. authorised personnel to operate the machine. maintained. and replaced when necessary.Keep emergency numbers for doctors. qualified. it is impossible for these safety messages to cover every hazardous situation you may encounter. . • Safety messages in this Chapter “SAFETY PRECAUTIONS”. • Allow only trained.Thoroughly read and understand the label attached to the fire extinguisher to use it properly. .2 . . are intended to illustrate basic safety procedures of the machine.Establish emergency priority procedures to cope with fires and accidents.Unauthorised changes to the machine may impair function and/or safety and affect machine life. If you have any doubts. However. hospitals and fire department posted near the telephone. . . • Safety signs should be installed. PREPARE FOR EMERGENCIES • Be prepared if a fire starts or an accident occurs.If a safety sign or this Manual are damaged or missing. S2 . . • Learn how to operate the machine and its controls correctly and safely. • Keep the machine in proper working conditions. 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).Keep the first-aid kit and fire extinguisher on hand. ambulance service. consult your direct supervisor prior to operating or servicing the machine.

Safety glasses or face shield. INSPECT THE MACHINE • Inspect the machine carefully every day or workshift by an attentive visual inspection of machine outside prior to starting it to prevent damages and personal injuries.Safety shoes. Do not wear radio or music headphones while operating the machine. .Avoid wearing loose clothing. You need: . .Heavy gloves.Reflective clothing.3 E215B-E245B .Ear protection. . PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. . or other items that can catch on control levers or other parts of the machine. . . Be sure to correctly wear equipment and clothing for the job. S2 . • Operating equipment safely requires the full attention of the operator.A hard hat.Waterproof clothing. . .SAFETY PRECAUTIONS WEAR PROTECTIVE CLOTHING • Wear close-fitting clothing and safety equipment appropriate to the job. jewellery.Wear a suitable hearing protection such as earmuffs or earplugs to protect objectionable or uncomfortably loud noise. .Respirator or filter mask. .Do not take any chances.

.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. . move the seat fore and aft. . .Do not climb or leave the machine while holding tools or other objects in your hands. .If not.E215B-E245B SAFETY PRECAUTIONS USE HAND HOLDS AND STEPS • Falling is one of the major causes of personal injury. Do not jump on or off the machine. .Keep the access to the machine clear of foreign objects and clean. check that the fasteners of stepping points and the handrails are tightened and are undamaged. . always face the machine and maintain a three-point contact with the steps and handrails. Remove grease or mud from stepping points and rails to minimise the danger of slipping or stumbling.When you get on and off the machine. . ADJUST THE OPERATOR'S SEAT • A seat poorly adjusted for operator or work requirements may quickly fatigue the operator leading to improper operations.Do not climb or leave the machine while it is moving. .The operator should be able to fully press the pedals and correctly move the control levers with his back resting against the seat back. S2 .Prior to climbing or leaving the machine.The seat should be adjusted whenever machine operator changes. Repair them as required.4 . . and check again.

Prior to operating the machine.SAFETY PRECAUTIONS FASTEN SEAT BELT • Should the machine overturn. S2 .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. . swinging. Sound horn to inform bystanders that the machine is going to be operated.5 E215B-E245B . .When operating. . and attaching hardware. replace the seat belts even though they do not look damaged. or moving the machine in a congested area use a signal man. MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over.Pay the utmost attention not to run over bystanders. thoroughly examine belt webbing.Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. If any item is damaged or worn. the operator may be crushed by the overturning machine resulting in serious injury or even death. buckle. replace the seat belt or component before operating the machine. the operator may become injured and/or thrown from the cab. . . .After a significant accident. Not only.

If travel motors are located at the front of the cab. .Before driving the machine.Do not start the engine by shorting across starter motor terminals.Start the engine only from the operator’s seat.E215B-E245B SAFETY PRECAUTIONS OPERATE ONLY FROM THE DRIVER'S SEAT • Inappropriate engine starting procedures may cause the machine unexpected movement. 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. the machine will move reverse when travel controls are moved towards cab front. CONFIRM DIRECTION WHERE THE MACHINE IS TO BE DRIVEN • Incorrect travel controls operation may result in serious injury and even death. .6 . DO NOT CARRY PERSON ON THE MACHINE • Riders on the machine are exposed to serious injuries. possibly resulting in serious injury and even death. be aware of the undercarriage position relative to the operator’s position. . . S2 . .DO NOT carry riders on the machine. ensure that all control levers are in the neutral position.NEVER start the engine while standing on the track or on the ground.Before starting the engine. .

.SAFETY PRECAUTIONS AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure. the machine may hit or run over that person. S2 .No machine motions shall be made unless signals are clearly understood by both signalman and operator. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. • To avoid back-over and swing accidents: . heavy rain. . resulting in serious injury or death.Learn the meanings of all flags.Always make sure that rear mirrors are clean and correctly adjusted.7 E215B-E245B . reduce speed and use proper lighting.Dust.USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. fog. when work conditions require a signal person. can reduce visibility.. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. BE SURE THAT ALL BYSTANDERS ARE CLEAR.Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. which conform to your local regulations. etc. . .Use hand signals. signs. . . . and markings used on the job and confirm with the person in charge of signalling. As visibility decreases.

lower the bucket immediately. . . If turning on an incline is absolutely unavoidable.Turning on an incline may cause the machine to tip over. . .If machine starts to skid or becomes unstable. confirm which way to move travel pedals/levers for the corresponding direction you wish to go. possibly resulting in serious injury or death. When travelling (ascending/descending) on a slope.When traveling up or down a grade.Pushing down on the front of the travel pedals or pushing the levers forward moves the machine towards the idlers.E215B-E245B SAFETY PRECAUTIONS DRIVE MACHINE SAFELY • Before moving the machine. be sure to point the tracks uphill/downhill. S2 . do so at a place where the slope is gentle and the surface is firm.Traveling across the face of a slope may cause the machine to skid or to overturn.Do not travel on slopes with an angle exceeding 30°. . • Traveling on a grade may cause the machine to slip or to overturn. Do not travel across hill on slopes exceeding an angle of 15°. . approximately 20 to 30 cm (A) above the ground. keep the bucket in the direction of travel.8 .

In case the engine is cut-off. .SAFETY PRECAUTIONS AVOID OVERTURNING • When working on a slope or on unstable terrain. close the windows.Actuate the controls slowly and carefully to prevent the machine from making unwanted slippery manoeuvres or movements.Pay the utmost attention when working on a slope. S2 .Pull the safety lever (pilot-control shut-off lever) to the LOCK position. . .9 E215B-E245B . the danger of tipping over is present with the possibility of subsequent serious damages or fatal injuries. when the ambient temperature increases. .Decrease the operating speed and actuate the controls carefully. . when snow is present and on frozen ground. The snow could hide invisible dangerous spots. the cab door and all panels.Remove the ignition key from the key switch. PARK MACHINE SAFELY • To avoid accidents: . move the controls in neutral and restart the engine.Lower bucket to the ground. level first the work area. . to prevent sudden movements that could result in slipping or tipping over.Avoid swing or steering the machine on a slope. . lower the bucket to the ground.Run engine at slow idle speed without load for 5 minutes.Operate carefully when in snowy conditions. .Even on minor slopes. . . . • Pay the utmost attention when operating the machine on frozen ground or in snowy conditions. .Turn key-start switch to OFF to stop engine.Park machine on a level surface. If possible.Frozen ground. unwanted slippery manoeuvres or movements of the machine could occur. tends to be less firm jeopardising the stability of the machine.Turn auto-idle switch off. . . .Prior to leaving the machine.

. . in case of collision. If necessary. . make sure that protection structures are installed: F. .DO NOT dig too near the machine. Contact a Dealer to verify the functionality. falling objects or landslides. Any type of modification could weaken the structural integrity of the safety system.P. Make sure that the structure and the conditions of the ground are safe before starting operations.When working on a slope or near the edge of the road. .S. . with serious consequences for the operator.DO NOT install any cab lifting device to the protection structures. 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.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.After an accident. .Working near edges and ditches presents a risk for the stability of the machine.O. to repair or to completely or partially replace the protective structures.DO NOT weld. drill or modify protective structures. have a flagman available.Always position the tracks perpendicular to the edge of the digging with the travel motors on the rear side. . (Falling Object Protection Structure) and FRONT GUARD. prop the edges appropriately to prevent caving-ins. S2 .Make sure that the digging area is sufficiently stable and firm to support the weight of the machine during the work operations. DO NOT try to straighten or repair protective structures.10 . Check first that edges and the walls of the digging are sufficiently strong.

.Take care to avoid hitting overhead obstacles with the boom or arm. Doing so may result in serious eye injury.) to obtain information about underground utility lines. and personal injury may results as well. . . .SAFETY PRECAUTIONS DIG WITH CAUTION • Accidental severing of underground cables or gas lines may cause an explosion and/or fire. telephone. AVOID ELECTRIC LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.Contact local authorities and/or the utility companies directly (electric power. If a fiber optic cable should be accidentally severed. possibly resulting in serious injury or death. check the location of cables. S2 . telecommunications.Keep the minimum distance required by law from cables. . do not look into the end. sewers. such as a bridge. and water lines. OPERATE WITH CAUTION • If the front attachment or any other part of the machine hits against an overhead obstacle.Wet ground will expand the area that could cause any person on it to be affected by electric shock. NEVER MOVE any part of the machine or load closer than 5 m plus twice the line insulator length (L). . etc.When operating near an electric line. gas lines.11 E215B-E245B .Check and comply with any local regulations that may apply. gas lines.Before digging. .Keep all bystanders or co-workers away from the site. gas. and water lines. . water. both the machine and the overhead obstacle will be damaged.

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. NEVER MOVE THE BUCKET OVER ANY ONE • Never lift. or swing bucket above anyone or a truck cab.Keep all persons clear from the area of operation and machine movement. in any case. . S2 . . There is a danger for explosions and potentially deadly injuries. SP0030 DO NOT OPERATE IN TUNNELS • DO NOT operate the machine in enclosed spaces or. move. resulting in serious injury or death. set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area. without appropriate ventilation. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket. Please comply with the ATEX regulation relative to devices to be used in a potentially explosive environment. Operations in tunnels or underground sites where potential explosive conditions exist are not allowed.12 .Before operating the machine.

All loading capacities are referred to the machine on a level surface and should be disregarded when working on a slope.In any case. . .Always ensure that slings and chains used for lifting are adequate to the load and in good condition.Secure the loads to be raised using cables or chains fastened with appropriate hooking mechanisms. In the event. the following indications must be strictly implemented: .Nobody should be allowed to remain under the raised load or within the excavator operating range for any reason whatever. thus it must not be used to handle suspended loads. Also.The machine must be equipped compulsorily with the appropriate variant provided upon request.Never exceed specified loading capacity. under exceptional conditions. totally comply with the safety precautions for the operation of the excavator as a lifting equipment. comply with the current national or local regulations on this matter. . S2 . . . .Never hook cables or chains to the bucket teeth. .SAFETY PRECAUTIONS NEVER UNDERCUT A HIGH BANK • The edges could collapse or a land slide could occur causing serious injury or death.13 E215B-E245B . it becomes necessary to handle materials. Incorrect fastening of slings or chains may cause boom/arm failure or failure of the lifting means with consequent bodily injuries and even death. SAFETY LOADS MOVING • The excavator is a machine designed specifically to perform digging/loading works.

. .Do not exceed the prescribed load limits. S2 . • DO NOT swing the turret or the undercarriage when the attachment boom is fully lowered.Do not try digging exploiting the mass of the machine. Use the undercarriage for travelling only. an excessive stress on the front attachment could results in damages to the structure.14 . Under these conditions there is the danger that the boom collides with the track chains. PAY ATTENTION WHEN DIGGING DEEPLY • When digging deeply.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 USE THE TRACTION FORCE OF THE MACHINE FOR DIGGING • Do not travel the machine to dig. An excessive stress on the front attachment could results in damages to the structure reducing the operating life of the swing system. DO NOT USE THE TURRET SWING FOR DIGGING • Do not use the turret swing for digging or moving rocks.Do not use the strength of the attachment to travel or move the machine. Also. pay special attention to prevent contacts of the attachment and the relevant hydraulic hoses with the ground. In doing this. this inappropriate use of the machine could cause serious injuries or fatalities. .

Secure safely the machine to the trailer with appropriate chains or cables.SAFETY PRECAUTIONS DO NOT USE THE BUCKET AS A HAMMER • The use of the bucket as a hammer or for piling operations could cause serious damages to the bucket itself and the components of the front attachment.15 E215B-E245B .Use a truck or trailer appropriate for transporting the machine. appoint a signal person to co-ordinate the job site. . S2 . provide signals commonly known by all personnel involved. Make sure that all personnel obey the signal person’s directions. Also. This could cause damages to the cylinders.Make sure that you comply with National and local regulations when transporting the machine on open roads. 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. this inappropriate use of the machine could cause serious injuries or fatalities. Please refer to the chapter "TRANSPORTATION" of this Manual for the safe loading and unloading procedures. Also. . To remove residues from the bucket. Tolerance A ≥ 50 mm PROVIDE SIGNALS FOR JOBS INVOLVING A NUMBER OF MACHINES For jobs involving several machines. . use water under pressure or remove them manually. 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.

oil.Never work under a machine kept raised by the boom.If the machine is to be raised. .Keep the working area clean and dry. . . .Disconnect the negative cable (-) from the battery before carry out any work on he electrical sysem or arc-welding on he machine. 9. 6. . . Switch off the Auto-Idle. This tag can be applied o the left-hand control lever. Lock machine components which should be raised for maintenance or repair using suitable supporting means. .Immediately repair any damage. repair or replace as necessary. . place boom and arm at an angle 90 to 110°. Lower the bucket to the ground. . Remove grease. Park the machine on the level ground. 3. Let the engine idle with no load for at least five minutes until it has cooled down. feet and clothes far from moving parts. Move the key-start switch position to stop the engine. Apply the "Maintenance in progress" tag (see SAFETY PLATE in this Chapter). Immediately repair any fault. Remove the ignition key from the start switch. .Replace worn or failed components.E215B-E245B SAFETY PRECAUTIONS SAFE MAINTENANCE • To avoid accidents: . Refer to the Chapter MAINTENANCE in this Manual. debris build-ups. S2 . 5. 4.16 .Keep hands.Do not leave the machine unattended if servicing requires the engine running.Do not lubricate or service the machine when it is in motion.Do not spray water or steam inside the cab.Inspect certain component regularly. 2. Move the safety lever (pilot-control shut-off lever) to the LOCK position. to the OFF 7. safety lever or cab door.Keep all components in good condition and properly install. 8.Understand maintenance procedure before starting the work. . Prior to service in the machine: 1. Let the engine cool down.

or props that may crumble under continuous load.If you must work on a lifted machine or attachment. to cut-off the engine immediately in case of necessity.Always lower the attachment or tool to the ground before working on the machine. securely support the machine or attachment. S2 . .Do not support the machine on cinder blocks. 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. . .17 E215B-E245B .SAFETY PRECAUTIONS WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury. Trapping by moving parts could cause serious injuries. . This tag can be applied o the left-hand control lever. attach a maintenance in progress tag (see also SAFETY PLATES in this Chapter) . SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first.Before performing any work on the machine. safety lever or cab door. STOP THE ENGINE PRIOR TO PERFORMING • DO NOT perform any maintenance operation with the engine running.Do not work under a machine that is supported solely by a jack. bollow tires.

Clear the area from all the objects that can be dangerous for mechanics or people in the working area. accidentally broken. fuel. into drains. S2 . Do not use containers for food or beverages which may induce drinking. . .18 .Make sure that the lamp is shielded by a cage.Do not spill waste over the ground. brake fluid. WORK IN A CLEAN AREA . can cause fuel or oil fire. .Obtain information about the correct methods to recycle or dispose of waste from local Authorities. Potentially dangerous waste used on the excavators includes lubricants.Used sealed containers when discharging fluids. .E215B-E245B SAFETY PRECAUTIONS DISPOSE OF WASTE IN THE APPROPRIATE MANNER • Waste improperly disposed of represents a danger for the envinronment. collection centres or your Dealer. the incandescent filament of a lamp.Before starting an operation. coolant. filters and batteries. . or water beds. clean 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.

.Do not spray water or steam in the cab. in order to avoid people accidents or damages to things. . corrode clothes and cause blindness.Use proper emergency starting techniques. is poisonous.Immediately see a doctor. .Fill the batteries in airy areas. It is strong enough to scald the skin.Rinse your eyes with water for 10-15 minutes. oil and deposits. after stopping the engine. PREVENT ACID SCALDS • The sulphuric acid.Avoid breathing the electrolyte vapours when topping up. If you are touched with acid sprays: .SAFETY PRECAUTIONS KEEP CLEAN THE MACHINE • Keep clean the engine compartment. . if it is sprayed into the eyes. Open the access doors in order to quicken the engine cooling process and clean the compartment. IN THESE CASES. . .19 E215B-E245B .Avoid spilling or dripping the electrolyte.The engine compartment temperature can quickly rise. fuel tank and operator's position. contained in the battery. .Immediately see a doctor. If you have swallowed the acid: . • Remove all the traces of grease. . BE CAREFUL TO POSSIBLE FIRES. S2 .Wear eye protections and rubber gloves. To avoid dangers: .Put on your skin sodium bicarbonate or clay to help the acid neutralization.Rinse your skin well with water. batteries. hydraulic pipes. radiator. .

E215B-E245B SAFETY PRECAUTIONS STARTING THE ENGINE WITH BOOSTER BATTERIES • If the engine is to be started using booster batteries.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. . . • Battery electrolyte is poisonous. and flames away from the top of battery. .The operator should be sitting in the driver’s seat to keep the machine under control when the engine starts. If the battery should explode. . lighted matches. . battery electrolyte may be splashed into eyes. . Use a voltmeter or hydrometer.Be sure to wear eye protection when checking electrolyte specific gravity.Keep sparks. possibly resulting in blindness. it may explode.Do not charge a frozen battery. .Never check battery charge by placing a metal object across the posts. Warm battery to 16 °C.Do not use batteries that have been stored in the cold for a long time. Starting the engine with booster batteries is a two man operation. ensure to comply with all procedures detailed in the chapter OPERATING INSTRUCTIONS.20 . S2 .

Hot water or steam is contained in the engine. reduction gear oil and hydraulic oil also become hot during operation. Hot fluids and surfaces: • Engine oil. When opening. radiator and heater lines. Allow all pressure to be released before removing the cap. . engine coolant is hot and under pressure.The hydraulic oil tank is pressurized. hoses. Again.Wait for the oil and components to cool down before starting any maintenance or inspection work.To prevent possible injury from hot spraying water.Keep bystanders away from storage areas.21 E215B-E245B . lines and other parts become hot as well. Do not remove the radiator cap until the engine is cool. . S2 . Skin contact with escaping hot water or steam can cause severe burns.Securely store attachments and implements to prevent falling. STORE ATTACHMENTS SAFELY • Stored attachments such as buckets. be sure to release all pressure before removing the cap. . . hydraulic breakers and blades can fall and cause serious injury or death. turn the cap slowly to the stop.SAFETY PRECAUTIONS PREVENT BURNS Hot spraying fluids: • After operation. . The engine.

. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. see a doctor familiar with this type of injury immediately.Search for leaks with a piece of cardboard. then gradually loosen the air release plug to release pressure.As pieces may fly off. .22 SP0047 . • Travel reduction gears are under pressure. or death. be sure to keep body and face away from air release plug to avoid injury. . S2 . connections before applying . blindness or death. Wait for gear oil to cool down.Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.As pieces may fly off. Failure to follow the precautions below may result in serious injury. Reduction gear oil is hot. take care to protect hands and body from highpressure fluids. Wear a face shield or goggles for eye protection. blindness. . . be sure to keep body and face away from valve.In an accident occurs.NEVER attempt to remove GREASE FITTING or VALVE ASSEMBLY.Tighten all pressure.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. PREVENT PARTS FROM FLYING OFF • Grease in the track adjuster is under high pressure. .

If fuel ignites. .Do not refuel the machine while smoking or when near open flame or sparks. . and some antifreeze fluids are flammable.AVOID FIRES • Handle fuel with care: it is highly flammable. wear goggles or safety glasses.23 E215B-E245B . S2 .Always stop the engine before refuelling the machine. HANDLE FLUIDS SAFELY .SAFETY PRECAUTIONS PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body. .Fill the tank outdoors. • All fuels. possibly resulting in serious injuty or death. serious injury may result. . an explosion and/or a fire may occur.Keep bystanderds away from the working area before striking any object. they can ignite and burn spontaneously. most lubrificants.Do not store oily rags. .Store flammable fluids well away from fire hazards. .Guard against injury from flying pieces of metal or debris. .Do not burn or puncture pressurized containers. .

Never install bent or damaged lines. lines. .E215B-E245B SAFETY PRECAUTIONS PREVENT FIRES • Check for Oil Leaks: . . .Tighten. . .Damaged or missing heat shields may lead to fires.Clean and tighten all electrical connections. and other flammables may cause fires. kinked.DO NOT OPERATE MACHINE if cable or wires are loose..Always check key-start switch function before operating the machine every day: 1. and loose oil-cooler flange bolts which may cause oil leaks. • Check Heat Shields: .Damaged or missing heat shields must be repaired or replaced before operating the machine. . . etc. hydraulic oil and lubricant leaks can lead to fires.Spilled fuel and lubricans. • Clean up Flammables: .Fuel.Check before each shift or after about ten (10) hour operation for loose.Check before each shift or after about ten (10) hour operation for missing or damaged terminal caps. debris. lines or hoses that rub against each other. . kinked. 2. hardened or frayed electrical cables and wires. accumulated coal dust. repair or replace any missing. Turn the key-start switch to the OFF position to confirm that the engine stops. . .Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately.24 . be sure to repair them before operating the machine. oil-cooler and oilcooler flange bolts. . loose or damaged clamps. grease.If a fire breaks out. failure to stop the engine will escalate the fire. . hoses.Short circuits can cause fires. and trash. kinked hoses. • Check for Shorts: . Start the engine and run it at slow idle.If any abnormalities are found. • Check Key-start Switch: .Check for missing or loose clamps. S2 . pipes. hampering fire fighting. damage to the oil-cooler. or hoses.Do not bend or strike high-pressure lines.

.Exit the machine.If you must operate in a building. BEWARE OF EXHAUST FUMES • Prevent asphyxiation. be sure there is adequate ventilation.Use tools of correct size to tighten or loosening securing elements. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area. Engine exhaust fumes can cause sickness or death. . in order to avoid injuries caused by a wrench getting out of control. . SP0062 USE APPROPRIATE TOOLS • Use tools appropriate for the job to be performed.S.Inappropriate tools.25 .SAFETY PRECAUTIONS E215B-E245B EVACUATING IN CASE OF FIRE • If a fire breaks out. evacuate the machine in the following way: . Standard or British Standard tools on metric fasteners and vice versa. .Do not use U. • Use only genuine spare parts (please refer to the Spare Parts Catalogue). .Use a fire extinguisher if there is time. S2 . . parts and procedures might generate dangerous conditions.Stop the engine by turning the key-start switch to the OFF position if there is time.

Dispose of paint and solvents properly. . soldering.26 . . Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.E215B-E245B SAFETY PRECAUTIONS AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines. Wear an approved respirator. Do not heat by welding. If you use solvent or paint stripper. Allow fumes to disperse at least 15 minutes before welding or heating.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. 2. REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paints is heated by weiding. these fumes may cause sickness.Avoid breathing potentially toxic fumes and dust. AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS . resulting in severe burns to yourself and bystanders. or using a torch near pressurized fluid lines or other flammable materials. Remove solvent or paint stripper containers and other flammable material from area. . or using a torch. If inhaled. avoid breathing the dust. Install temporary fire resistant guards to protect hoses or other materials when welding. soldering.Do all such work outside or in a well-ventilated area. . soldering. remove stripper with soap and water before welding.Remove paint before welding or heating: 1. If you sand or grind paint. etc. S2 . .

Remove all paint and inspect the parts with penetrating liquid or a magnetic particle tester. appropriate safety rules must be implemented by all the personnel involved in the operations.27 E215B-E245B .Wear gloves and adequate clothing to protect the skin. below 16 °C. . .Connect the ground cable of the welder at least 1 m from the component to be welded.SAFETY PRECAUTIONS WELDING REPAIR INTERVENTIONS • Welding repair interventions must be performed only by a certified welder with sufficient experience. .Clean accurately the zones involved.Move the starter switch into position "OFF" and wait for 4 seconds to cut-off electricity from the system. .Avoid welding pieces at low temperature i. can generate toxic fumes. . e.Disconnect the negative terminal (-) from the battery. . Also. S2 . .Remove paints from all surfaces prior to warming-up or welding. If necessary. . .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. . .Identify first all the fracture points and the zones in which welding is required. The duration through time of the welding depends upon the quality and the accuracy with which the operation is performed.Use appropriate masks or protective glasses. Painted surfaces. when warmed-up or when welded. warm-up the part involved prior to welding it.

28 .E215B-E245B SAFETY PRECAUTIONS NOTE: S2 .

S3 . 2. Attachment operating range safety plate. Track adjuster plate.1 E215B-E245B .SAFETY PLATES SAFETY PLATES Triple articulation version Triple articulation version 1.

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

Background: yellow Border and icons: black 3 .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. Background: yellow Border and icons: black S3 . Danger of severe injuries.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.SAFETY PLATES 1 .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. Sound the horn. Sound the horn.3 E215B-E245B . Background: yellow Border and icons: black 2 .

E215B-E245B SAFETY PLATES 4 . Background: yellow Border and icons: black 5 .4 .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. refuelling or carrying out any other work on the machine.Boom and arm movement warning plate (triple articulation version) It shows the danger represented by the bucket hitting the cab. servicing. operating.Read-your-manual plate It is positioned in the cab to recommend to carefully read the Operation and Maintenance Instruction Manual prior to starting. Background: yellow Border and icons: black SP0073 6 . Background: yellow Border and icons: black S3 . Pay special attention as no stops are provided to prevent this problem.

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. he must move the safety lever to the LOCK position. pulleys. Controls are disabled and therefore no accidental machine or attachment movement is possible. Background: white Border and icons: black S3 . When the operator is about to leave the cab with the engine running.SAFETY PLATES 7 . Background: yellow Border and icons: black 8 . Background: yellow Border and icons: black 9 . safety lever or cab door.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. even if for a short time. This tag should be applied to the left-hand control lever. and belts.5 E215B-E245B .Controls lock/unlock plate It shows the position that the safety lever can assume when the engine is running.

Background: yellow Border and icons: black 11 . bleed the pressure by actuating the appropriate bleeding button located on the cap. Background: yellow Border and icons: black S3 . at operating temperature.Hydraulic oil pressurised tank warning plate It indicates that the hydraulic oil is pressurised.6 . Consult the Operation and Maintenance Instruction Manual.Safety distance plate It instructs to keep at a safe distance from a zone dangerous for personal safety. since the zone is characterised by high temperature. The hydraulic oil.E215B-E245B SAFETY PLATES 10 .Burns danger plate It indicates that a burns danger exists. Background: yellow Border and icons: black 12 . Prior to intervening on the hydraulic oil tank. can cause burns in case of contact with the skin.

Background: yellow Border and icons: black S3 .7 E215B-E245B . Background: yellow Cross: red Border and icons: black 14 .SAFETY PLATES 13 . Pay special attention as no stops are provided to prevent this problem.Special equipment movement warning plate It shows the danger represented by the special equipment hitting the cab.No-stepping warning plate It instructs not to step on the zone where this decal is attached.

8 .E215B-E245B SAFETY PLATES NOTE: S3 .

OPERATIONAL PRINCIPLE M0103 .

.

OPERATIONAL PRINCIPLE E215B-E245B SECTION AND GROUP CONTENTS Section 1 GENERAL Group 1 Specifications Section 2 SYSTEM Group 1 Group 2 Group 3 Group 4 Mechatro Control System Mechatro Controller Hydraulic System Electrical System Section 3 COMPONENT OPERATION Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8 Hydraulic Pump Assy Pilot Valve Control Valve Swing Device Travel Device Swing Joint Cylinders Air Conditioner .

.

..................................... T1-1-11 Transporting dimensions E215B (Triple Articulation Version) ................. T1-1-17 Bucket applications as a function of the arms E245B .. T1-1-1 Hydraulic components ............Specifications Main components ....................... T1-1-18 E215B-E245B ................................... T1-1-10 Transporting dimensions E215B (Monoblock Version) . T1-1-16 Transporting dimensions E245B (Triple Articulation Version) .... T1-1-13 Digging data E245B (Monoblock Version) ................. T1-1-9 Digging data E215B (Triple Articulation Version) ............................................................... T1-1-14 Digging data E245B (Triple Articulation Version) .. T1-1-12 Bucket applications as a function of the arms E215B .........SECTION 1 GENERAL CONTENTS Group 1 .. T1-1-5 Excavator performance............................ T1-1-15 Transporting dimensions E245B (Monoblock Version) . T1-1-8 Digging data E215B (Monoblock Version) ..............................................

SPECIFICATIONS

E215B-E245B

MAIN COMPONENTS

12345678910 -

Bucket
Bucket link
Idler link
Bucket cylinder
Arm
Arm cylinder
Boom
Boom cylinder
Cab
Swivel joint

11 12 13 14 15 16 17 18 19 20 -

Swing motor
Fuel tank
Hydraulic oil tank
Control valve
Engine muffler
Hydraulic pump
Engine
Counterweight
Engine radiator
Travel motor

T1-1-1

21 22 23 24 25 26 27 28 29 -

Track link
Batteries
Upper roller
Track guide
Lower roller
Air cleaner
Crawler adjuster
Front idler
Shoe plate

E215B-E245B

SPECIFICATIONS

Main Components – Upper Structure

1

8

7

2

6

5

3

4
SM0012

1-

Control Cab

5-

Hydraulic Pump

2-

Proportional Solenoid Valve Block

6-

Control Valve

3-

Radiators

7-

Swing Motor Unit

4-

Engine

8-

Center Joint

T1-1-2

SPECIFICATIONS

E215B-E245B

Main Components – Under Carriage

5

4

1

2

3

section A - A
SM0013

1-

Right Travel Motor Unit

4-

Swing Gear

2-

Left Travel Motor Unit

5-

Front Idler Assy

3-

Center joint

T1-1-3

E215B-E245B

SPECIFICATIONS

Main Components – Front Attachment

2

7

5

1
3

6

4

2

8

7

3

1

SM0014

1-

Boom cylinder

5-

Monoblock Boom

2-

Arm cylinder

6-

Boom (Triple Articulation Version)

3-

Bucket Cylinder

7-

Arm

4-

Positioning Cylinder (Triple Articulation
Version)

8-

Positioner (Triple Articulation Version)

T1-1-4

SPECIFICATIONS

E215B-E245B

HYDRAULIC COMPONENTS
HYDRAULIC PUMP
Main pump

Gear pump for pilot

Pump

Item

K3V112DTP1KMR-YTOK-HV

ZX10LPRZ7-07G

Type

Variable displacement plunger
pump: regulator attached type

Fixed displacement type gear
pump

110 x 2

10

2000

Max. displacement capacity

cm3

Revolution

rpm
(Clockwise
seen from
shaft end)

Pressure

Rated
Rated
ATT boost

34.3

MPa

Max. flow

L/min

Max. input Power
(at 2000 rpm)
Max. input torque
(at 1200 rpm)

220 x 2 at 7.8 MPa

20

kW

118

3.4

Nm

665

14.7

Model
Regulator

Mass

5.0

37.8

KR3G-YTOK-HV

Control
function

Electric flow control, positive flow control, total power control at
emergency mode and power shift control

Others

With solenoid proportional reducing valve (KDRDE5K-31/
30C50)

kg

143

NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump.

CONTROL VALVE
Item

STD VALVE

Model

KMX15YD / B44041

Max. flow rate
Main relief valve set pressure

L/min

220 x 2

MPa

34.3 at 70 x 2 L/min

When power boost pressure
Over load relief valve set pressure

37.8 at 60 x 2 L/min
MPa

Boom H, Bucket H, Arm R

39.7 at 30 L/min

Boom R, Bucket R, Arm H
Mass

37.8 at 30 L/min
kg

Item

OPT VALVE

Model
Over load relief valve set pressure

KADV22Y / 501103A03
MPa

Positioner R

39.7 at 30 L/min

Positioner H
Mass

232

37.7 at 30 L/min
kg

T1-1-5

2.8

1.E215B-E245B SPECIFICATIONS PILOT VALVE ATTACHMENT TRAVEL PV48K2004 6TH6NRZ 5.35 MPa Model Primary pressure Secondary pressure Rated flow Mass 20 L/min 25 L/min Approx.5 Speed reduction type Planetary 2-stage Reduction unit Reduction ratio Total mass 15.2 MPa 0.0 Extreme pressure lithium base # 2 grease Grease volume kg Approx.2 Working pressure MPa 32.0 Relief set pressure MPa 29 Mass kg 49 Type Mass Hydraulic motor assy mass 2KAR6P72/240-712 kg 2.54 ~ 2.4 Max.9 MPa 0. 8 kg Hydraylic motor SWING MOTOR UNIT Antireaction valve block Model M5X130CHB–10A–41C/295 Type Swash-plate type.5 kg 51.5~5.0 Mass kg 145 kg Approx.6 ~ 3. flow L/min 220 Braking torque Nm 655 Release pressure MPa 2. 2 kg Approx.38 Lubicate oil Lubicate oil volume Gear oil SAE90 (API class GL–4 grade) L Grease 3.0 MPa 4. fixed-displacement plunger motor Displacement cm3 129. 197 T1-1-6 .

pressure parking brake release Relief valve set pressure 11 bar cracking 311 bar at 1. Stroke (mm) (mm) Center distance of pins Full extend B / Full retract A (mm) Boom Ø 120 / Ø 85 1345 3200 / 1855 Arm Ø 135 / Ø 95 1558 3637 / 2079 Bucket Ø 120 / Ø 80 1080 2684 / 1604 Positioning Ø 145 / Ø 90 992 2662 / 1670 Use T1-1-7 Cushion Mass (kg) With cushion on rod side With cushion on both sides With cushion on rod side Without cushion 176 255 153 220 .2 L/min total flow 353 bar at 40 L/min Mass 235 kg 262 kg CYLINDERS Cylinder bore / Rod Dia.3 cm3/rev 220 L/min 246 L/min high speed 38949 Nm 42827 Nm low speed 24469 Nm 25600 Nm static 32060 Nm 25000 Nm dynamic 26707 Nm 20900 Nm Max.2 cm3/rev 112.2 Travel motor Two speed. three-stage planetary type Model 710 C3 K Gearbox ratio 1 : 55. axial piston swash plate type Model Displacement MAG 170 VP MAG 170 VP high speed 81.3 cm3/rev 181. gearbox torque 1 : 43. flow Max.2 output Parking brake torque Min.SPECIFICATIONS E215B-E245B TRAVEL DEVICE Item E215B Reduction gear unit E245B Epicycloidal.6 cm3/rev low speed 129.

.............................2 km/h Speed ENGINE DATA MAIN SPECIFICATIONS - Manufacturer .................................................................5:1 - Net power at flywheel (at 2000 rpm) (ISO 14396)............................... 2 x 12 V ............................................................................................................................................................................NCB1 28V 35-70A - Voltage ...............................2 km/h Second speed 6.........4 kW ALTERNATOR - Manufacturer ..... - Model ................................................................6 km/h 3...........Output ....................................................................................................... BOSCH - Type ..........................55A T1-1-8 .....................................Capacity....................................................... 24V ............................................ turbocharged - Number of cylinder .................................................................. direct injection............................................... 132 mm - Total displacement .................................................. Diesel.......................................................................................................................... 800 rpm INJECTION PUMP - Type ..................6 in-line - Bore ............................................................................................................................................E215B-E245B SPECIFICATIONS EXCAVATOR PERFORMANCE GRADEABILITY ............................................................. 104 mm - Stroke.......................................VE6/12 F 1000 LV - Injection order ............................................................................................................................ 28V .............................................................................................................................................................................................................................................................Output .0 km/h 5.............................. CNH U................................................................................ 70% TRAVEL SPEED Excavator E215B E245B First speed 3..............................................................................100 Ah STARTER MOTOR - Manufacturer ...........................................................................................................................................................................................................667TA/MEB - Type ..................................................... 4 stroke...................................................................6728 cm3 - Compression ratio .....................................................K........................670 Nm - Engine idle at no-load ................... BOSCH - Voltage ......................... 17...................................................................................... 118 kW - Torque (at 1200 rpm) ............................................. 1-5-3-6-2-4 BATTERY - Voltage ...................................................................................................................

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 .

36 0.32 0. ground pres.40 0.36 0.55 0.SPECIFICATIONS E215B TRANSPORTING DIMENSIONS E215B (Monoblock Version) VERSIONS E215BEL E215BL E215BLC A 3656 3656 3656 B 4451 4451 4451 C D 1035 1035 1035 2800 2800 2800 E F (1) 9617 (1) 3133 (2) 9580 (2) 3044 (3) 9493 (3) 2884 (4) 9568 (4) 3044 (1) 9617 (1) 3133 (2) 9580 (2) 3044 (3) 9493 (3) 2884 (4) 9568 (4) 3044 (1) 9617 (1) 3133 (2) 9580 (2) 3044 (3) 9493 (3) 2884 (4) 9568 (4) 3044 G H I L 2503 3027 948 471 2503 3027 948 471 2503 3027 948 471 Arm: (1) 2080 mm (2) 2400 mm (3) 2940 mm (4) 3500 mm (dimensions in mm) E215BEL E215BL E215BLC M Track shoe width (mm) 500 600 700 600 700 800 900 600 700 800 900 N Gauge (mm) 2490 2590 2690 2800 2900 3000 3100 2990 3090 3190 3290 (*) Working weight Spec.47 (*) With arm 2940 mm and bucket 1.41 0.47 0. (kg) 20590 20850 21120 20920 21190 21460 21730 20940 21210 21480 21750 (bar) 0.32 .3 m3 T1-1-11 0.47 0.41 0.

42 0.3 m3 T1-1-12 0.37 0. ground pres. (kg) 21220 21490 21760 21560 21830 22100 22360 21580 21850 22120 22390 (bar) 0.42 0.37 0.48 (*) With arm 2940 mm and bucket 1.33 .E215B SPECIFICATIONS TRANSPORTING DIMENSIONS E215B (Triple Articulation Version) E G D H I L F C M A B N VERSIONS E215BEL E215BL E215BLC A 3656 3656 3656 B 4451 4451 4451 C D 1035 1035 1035 2800 2800 2800 NH0148 E F (1) 9683 (1) 3062 (2) 9665 (2) 3014 (3) 9643 (3) 2954 (4) 9631 (4) 3237 (1) 9683 (1) 3062 (2) 9665 (2) 3014 (3) 9643 (3) 2954 (4) 9631 (4) 3237 (1) 9683 (1) 3062 (2) 9665 (2) 3014 (3) 9643 (3) 2954 (4) 9631 (4) 3237 G H I L 2503 3027 948 471 2503 3027 948 471 2503 3027 948 471 Arm: (1) 2080 mm (2) 2400 mm (3) 2940 mm (4) 3500 mm (dimensions in mm) E215BEL E215BL E215BLC M Track shoe width (mm) 500 600 700 600 700 800 900 600 700 800 900 N Gauge (mm) 2490 2590 2690 2800 2900 3000 3100 2990 3090 3190 3290 (*) Working weight Spec.42 0.33 0.48 0.57 0.48 0.

8 t/m3) Slightly heavy digging work (specific weight of material < 1.5 t/m3) Loading work (specific weight of material < 1.SPECIFICATIONS E215B BUCKET APPLICATIONS AS A FUNCTION OF THE ARMS E215B E215B Monoblock BUCKETS Width (mm) Capacity (dm3) SAE J296 (ISO 7451) Mass (kg) 750 525 503 850 625 537 1000 789 634 1200 1000 651 1300 1105 698 1500 1315 760 E215BEL E215BL E215BLC Arm (mm) Arm (mm) Arm (mm) 2080 2400 2940 3500 2080 2400 2940 3500 2080 2400 2940 3500 E215B Triple Articulation BUCKETS Width (mm) Capacity (dm3) SAE J296 (ISO 7451) Mass (kg) 750 525 503 850 625 537 1000 789 634 1200 1000 651 1300 1105 698 1500 1315 760 E215BEL E215BL E215BLC Arm (mm) Arm (mm) Arm (mm) 2080 2400 2940 3500 2080 2400 2940 3500 2080 2400 2940 3500 General digging work (specific weight of material < 1.2 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 .

37 (**) With arm 2940 mm and bucket 1.41 0.51 0.3 m3 (*) Asymmetric type shoes T1-1-16 . (bar) 0. ground pres.E245B SPECIFICATIONS TRANSPORTING DIMENSIONS E245B (Monoblock Version) VERSIONS E245B A 3840 B 4645 C D 1053 2800 E F (1) 9617 (1) 3141 (2) 9577 (2) 3050 (3) 9487 (3) 2886 (4) 9564 (4) 3044 Arm: (1) 2080 mm (2) 2400 mm (3) 2940 mm (4) 3500 mm G H I L 2503 3045 970 486 (dimensions in mm) E245B M Track shoe width (mm) 550(*) 700 800(*) N Gauge (mm) 2490 2690 2890 (**) Working weight (kg) 22000 22500 22850 Spec.

3 m3 (*) Asymmetric type shoes T1-1-17 .42 0.SPECIFICATIONS E245B TRANSPORTING DIMENSIONS E245B (Triple Articulation Version) E G D H I L F C M A B N VERSIONS E245B A 3840 B 4645 C D 1053 2800 NH0148 E F (1) 9684 (1) 3067 (2) 9665 (2) 3014 (3) 9641 (3) 2957 (4) 9634 (4) 3235 Arm: (1) 2080 mm (2) 2400 mm (3) 2940 mm (4) 3500 mm G H I L 2503 3045 970 486 (dimensions in mm) E245B M Track shoe width (mm) 550(*) 700 800(*) N Gauge (mm) 2490 2690 2890 (**) Working weight (kg) 22600 23100 23450 Spec.38 (**) With arm 2940 mm and bucket 1. (bar) 0. ground pres.53 0.

5 t/m3) T1-1-18 .E245B SPECIFICATIONS BUCKET APPLICATIONS AS A FUNCTION OF THE ARMS E245B E245B Monoblock BUCKETS E245B Arm(mm) Width (mm) Capacity (dm3) SAE J296 (ISO 7451) Mass (kg) 750 525 503 850 625 537 1000 789 634 1200 1000 651 1300 1105 698 1500 1315 760 2080 2400 2940 3500 E245B Triple Articolation BUCKETS Capacity (dm3) Width (mm) SAE J296 (ISO 7451) E245B Mass (kg) 750 525 503 850 625 537 1000 789 634 1200 1000 651 1300 1105 698 1500 1315 760 Arm (mm) 2080 2400 2940 3500 General digging work (specific weight of material < 1.8 t/m3) Slightly heavy digging work (specific weight of material < 1.

refer to the hydraulic system and the electric system. Regarding the conditions before and after each conversion. This chapter summarizes the mechatro system and the function of the mechatro controller related apparatuses.MECHATRO CONTROL SYSTEM E215B-E245B 1. PREFACE This chapter explains only those related to the electro hydraulic conversion as mechatro control. T2-1-1 .

1 MECHATRO CONTROL SYSTEM IN GENERAL ELECTRIC CONTROLLER INPUT SIGNAL HYDRAULIC   PILOT SECONDARY PRESSURE VOLTAGE OUTPUT L1 SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT LH RH LH RH OPTION PILOT VALVE PILOT VALVE FOR TRAVEL PILOT VALVE FOR ATT SE-9 SE-10 SE-11 LOW PRESSURE SENSOR SE-4 (4) GAUGE CLUSTER LCD DISPLAY FOR SELECTION FUEL GAUGE COOLANT TEMP. GAUGE SWITCH SENSOR BLOCK SE-3 SE-7 SCREEN CHANGE BUZZER STOP (1) (8) (7) L4 (6) WASHER SE-5 WIPER ACCEL DIAL SE-16 SERIAL COMMUNICATION TRAVEL AUTO-IDLE (5) OUTPUT VOLTAGE MODE SERIAL COMMUNICATION (2) SE-1 SE-8 L2 L3 (3) SE-2 PSV-R SHORT-CIRCUIT VALVE PROPORTIONAL VALVE SE-23 HIGH PRESSURE SENSOR C-1 SE-22 MECHATRO CONTROLLER ENGINE GOVERNOR MOTOR M-2 A1 L5 A2 A3 SPEED SENSOR SE-13 PSV -P1 P1 PUMP PROPORTIONAL VALVE : HIGH PRESSURE SENSOR (FOR P1.E215B-E245B 2 MECHATRO CONTROL SYSTEM SUMMARY OF MECHATRO CONTROL SYSTEM 2.P2 : 2pcs) PSV -P2 P2 PUMP PROPORTIONAL VALVE : GOVERNOR MOTOR : E/G SPEED SENSOR L6 : LOW PRESSURE SENSOR (ATT : 7pcs. TRAVEL : 2pcs) L7 VOLTAGE 24V PROPORTIONAL COMMAND CURRENT SM0116 T2-1-2 .

MECHATRO CONTROL SYSTEM

L1

E215B-E245B

MAIN CONTROL VALVE
SE-29

(3)

UP

REVERSE

REVERSE

L2
L3

LEFT ARM OUT

(5)

(7)

SV-13
N&B
SELECTOR VALVE

(8)

OPTION

(6)

BOOM UP
CONFLUX
P2 UNLOAD

TRAVEL LEFT

PL1
ATTACHMENT BOOST
P1 P2

(3)

ARM 1 SPEED

DIGGING

FORWARD

(4)

SWING

(1)

DOWN FORWARD

TRAVEL
P1 UNLOAD
STRAIGHT

BUCKET

ARM 2 SPEED

(2)

TRAVEL RIGHT

DUMP

(8)

BOOM LOW SPEED

ARM OUT

SOL

RIGHT ARM IN

SOLENOID VALVE

L4
SWING MOTOR PARKING RELEASE

PSV
-A

PSV PSV PSV
-D
-C
-B

SV
-2

SV
-3

SV
-1

BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX

SAFETY LOCK LEVER

SWING PARKING BRAKE

TRAVEL 1,2 SPEED

ATTACHMENT BOOST

P2 UNLOAD

TRAVEL STRAIGHT

P1 UNLOAD

L5

ARM IN 2 SPEED

TRAVEL MOTOR 1,2 SPEED SELECT

SV
-4

ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX

(7)

ARM IN

L6

BUCKET CYLINDER
DIGGING / DUMP CONFLUX

L7
PROPORTIONAL VALVE
SOLENOID VALVE

) BLOCK
SM0117

T2-1-3

E215B-E245B

P2

(LEFT)

(RIGHT)

OPTIONAL
PILOT VALVE

PILOT
VALVE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX
P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

UNLOAD VALVE CONTROL

OPTION

2.2

MECHATRO CONTROL SYSTEM

P1

PILOT
VALVE

PILOT VALVE
FOR TRAVEL

SE-11
SE-10

SE-9

LOW
LOW
PRESSURE PRESSURE
SENSOR
SENSOR
SE-1~4

SE-5,7,8

pi

PILOT SIGNAL
PROCESS

PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS

P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0118

1. On starting any one of operations, the control pilot secondary pressure switches spools and enters in
respective low pressure sensors.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3. Each unload pressure proportional valves output pilot secondary pressure according to the command
output by mechatro controller and switches each unload spools.
4. With this operation, the bleed opening according to lever manipulated movement is obtained, consequently
the pump pressure which is used to actuate each actuators are delivered and makes each actuator start
operating.
T2-1-4

MECHATRO CONTROL SYSTEM

P2

SE-23

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

OPTIONAL
PILOT VALVE

P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

POSITIVE CONTROL & P-Q CONTROL

OPTION

2.3

E215B-E245B

P1

SE-22

SE-11

(LEFT)

(RIGHT)

PILOT
VALVE

PILOT
VALVE

PILOT VALVE
FOR TRAVEL

SE-10

SE-9

LOW
LOW
PRESSURE PRESSURE
SENSOR
SENSOR
SE-1~4

SE-5,7,8

pi

PILOT SIGNAL
PROCESS

P2 PUMP
PROPORTIONAL
VALVE COMMAND

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

PILOT SECONDARY PRESSURE

pi

pi

PILOT SIGNAL
PROCESS
PILOT SECONDARY PRESSURE

P1 PUMP
PROPORTIONAL
VALVE COMMAND

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE

SECONDARY PRESSURE
SM0119

T2-1-5

E215B-E245B

MECHATRO CONTROL SYSTEM

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

P-Q CONTROL

PILOT SIGNAL PROCESS

PUMP PROPORTIONAL
SECONDARY PRESSURE

PUMP PROPORTIONAL
SECONDARY PRESSURE

POSITIVE CONTROL

PILOT PRESSURE

PILOT SIGNAL PROCESS

PUMP DELIVERY PRESSURE

SM0120

T2-1-6

MECHATRO CONTROL SYSTEM

P2

PILOT
VALVE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX
P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

BOOM UP CONFLUX CONTROL

OPTION

2.4

E215B-E245B

P1

LOW
PRESSURE
SENSOR
SE-3

pi

PILOT SIGNAL
PROCESS

BOOM UP PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS

BOOM UP PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS

BOOM UP PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS
MECHATRO
CONTROLLER
BOOM UP PILOT SECONDARY PRESSURE

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

P2 UNLOAD
PROPORTIONAL
VALVE PSV-D

pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

SM0121

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

T2-1-7

E215B-E245B

P2

LOW
PRESSURE
SENSOR
SE-1~6

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

PILOT
VALVE

P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

ARM IN RECIRCULATION & CONFLUX CONTROL

OPTION

2.5

MECHATRO CONTROL SYSTEM

P1

LOW
PRESSURE
SENSOR
SE-7

CONTROL PROCESS
FOR 2 SPEED

pi

PILOT SIGNAL
PROCESS

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

ARM IN PILOT SECONDARY PRESSURE
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SECONDARY PRESSURE
PILOT SIGNAL
PROCESS

P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM IN PILOT SECONDARY PRESSURE
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

pi
PILOT SECONDARY PRESSURE

pi

ARM PILOT SECONDARY
PRESSURE

P2 PUMP PRESSURE

REVERSE PROPORTIONAL
VALVE CONTROL
PROCESS FOR ARM
2 SPOOL

MECHATRO
CONTROLLER

REVERSE PROPORTIONAL
VALVE FOR ARM
2 SPOOL PSV-A

pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0122

T2-1-8

MECHATRO CONTROL SYSTEM E215B-E245B 1. 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. P2 unload spools and arm 2 spool are switched according to the command output by mechatro controller. and switch P1. P2 unload valve. 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. These proportional valves change the delivery rate of P1. 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. arm-in operating pilot secondary pressure is input to arm 1 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. P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool. T2-1-9 . And the mechatro controller processes pilot signal according to the combined operation and outputs command. and P1. In case of combined operation. P2 pumps. the pilot pressure other than arm-in operation is input to low pressure sensor and the output voltage is input to mechatro controller. P1. P1 unload proportional valve and reverse proportional valve for arm-in 2 spool. (Arm 2 spool controls recirculation rate and conflux rate.) The other proportional valves output proportional secondary pressure according to command from mechatro controller. 2. which is different from the armin independent operation. and consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil during arm operation. Recirculation and conflux (Low loading) 1) On starting arm-in operation. P2 pump. 4) The arm 1 spool is switched according to original oil pressure command. Recirculation cut The voltage output by high pressure sensor on P2 side is input to mechatro controller. and consequently recirculation passage is blocked. to P1 pump proportional valve.

4. 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.E215B-E245B P2 LOW PRESSURE SENSOR SE-7 ARM 2 SPEED BUCKET BOOM TRAVEL RIGHT P1 UNLOAD TRAVEL LEFT TRAVEL STRAIGHT PILOT VALVE P2 UNLOAD SWING SOLENOID ARM 1 SPEED N&B SELECTOR VALVE BOOM UP CONFLUX ARM-IN ANTI-CAVITATION CONTROL OPTION 2. T2-1-10 . 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. On starting arm-in operation. arm-in operating pilot secondary pressure switches arm 1 spool and is input to low pressure sensor. Low pressure sensor output voltage is input to mechatro controller. 3. Each proportional valve outputs pilot secondary pressure according to each command output by mechatro controller. And also outputs command according to input pressure output by potentiometer to reverse proportional valve for arm 2 spool. 2. The engine speed command output by accel potentiometer is input to mechatro controller. 5.6 MECHATRO CONTROL SYSTEM P1 ACCEL POTENTIO pi PILOT SIGNAL PROCESS ARM IN PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS pi P2 PUMP PROPORTIONAL VALVE PSV-P2 REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL PSV-Bpi ARM IN PILOT SECONDARY PRESSURE pi REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL COMMAND ENGINE SPEED (COMMAND VALUE) MECHATRO CONTROLLER REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A pi pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0123 1.

7 E215B-E245B P1 LOW PRESSURE SENSOR SE-8 pi PILOT SIGNAL PROCESS P2 PUMP PROPORTIONAL VALVE PSV-P2 ARM OUT PILOT SECONDARY PRESSURE pi P1 PUMP PROPORTIONAL VALVE PSV-P1 ARM OUT PILOT SECONDARY PRESSURE pi P2 UNLOAD PROPORTIONAL VALVE PSV-B ARM OUT PILOT SECONDARY PRESSURE pi MECHATRO CONTROLLER ARM OUT PILOT SECONDARY PRESSURE P1 UNLOAD PROPORTIONAL VALVE PSV-D pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0124 1. arm 1 spool and arm 2 spool are switched and also with the command output by mechatro controller. With original hydraulic pressure command. and consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation. 2.MECHATRO CONTROL SYSTEM PILOT VALVE P2 ARM 2 SPEED BUCKET BOOM TRAVEL RIGHT P1 UNLOAD TRAVEL STRAIGHT TRAVEL LEFT BOOM UP CONFLUX P2 UNLOAD SOLENOID SWING N&B SELECTOR VALVE ARM 1 SPEED ARM-OUT CONFLUX CONTROL OPTION 2. T2-1-11 . 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 pressure control valves. arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is input to low pressure sensor. P1 and P2 pumps and P1 and P2 unload valves are switched. On starting arm-out operation. 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 proportional valves and P1 and P2 unload proportional valves.

3. 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.8 MECHATRO CONTROL SYSTEM P1 LOW PRESSURE SENSOR SE-1(2) pi PILOT SIGNAL PROCESS P2 PUMP PROPORTIONAL VALVE PSV-P2 BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS P1 PUMP PROPORTIONAL VALVE PSV-P1 BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS P2 UNLOAD PROPORTIONAL VALVE PSV-B BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS P1 UNLOAD PROPORTIONAL VALVE PSV-D BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS TRAVELSTRAIGHT PROPORTIONAL VALVE PSV-C MECHATRO BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0125 1. 2. 4. 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.E215B-E245B P2 ARM 2 SPEED BUCKET BOOM TRAVEL RIGHT P1 UNLOAD BOOM UP CONFLUX TRAVEL LEFT TRAVEL STRAIGHT PILOT VALVE P2 UNLOAD SOLENOID SWING N&B SELECTOR VALVE ARM 1 SPEED BUCKET DIGGING (DUMP) CONFLUX CONTROL OPTION 2. T2-1-12 . 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. bucket digging (dump) operating pilot pressure switches bucket spool and is input to low pressure sensor. On starting bucket digging (dump) operation. P1 and P2 unload proportional valves and travel straight proportional valve.

9 E215B-E245B P1 LOW PRESSURE SENSOR SE-1 (2) pi PILOT SIGNAL PROCESS BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS ACCEL POTENTIO P2 PUMP PROPORTIONAL VALVE PSV-P2 P1 PUMP PROPORTIONAL VALVE PSV-P1 P2 UNLOAD PROPORTIONAL VALVE PSV-B BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS P1 UNLOAD PROPORTIONAL VALVE PSV-D TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS BUCKET ANTI-CAVITATION PROCESS ATT BOOST SOLENOID VALVE SV-2 ENGINE SPEED (COMMAND VALUE) MECHATRO CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE P1 PUMP PRESSURE T2-1-13 SM0126 .MECHATRO CONTROL SYSTEM P2 ARM 2 SPEED BUCKET BOOM TRAVEL RIGHT P1 UNLOAD TRAVEL STRAIGHT TRAVEL LEFT BOOM UP CONFLUX PILOT VALVE P2 UNLOAD SOLENOID SWING N&B SELECTOR VALVE ARM 1 SPEED BUCKET DIGGING ANTI-CAVITATION CONTROL OPTION 2.

6. 5. P1 and P2 unload proportional valves and travel straight proportional valve. 2.E215B-E245B MECHATRO CONTROL SYSTEM 1. 7. bucket digging operating pilot pressure switches bucket spool and is input to low pressure sensor. 4. the boost solenoid valve does not work to control the stroke limit of bucket spool. etc. The engine speed command output by accel potentiometer is input to mechatro controller. 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. the solenoid valve is closed according to the pump pressure. T2-1-14 . and actuate stroke limiter and then controls the stroke of bucket spool. and when the pump pressure is high. When P1 pump pressure was raised at cylinder stroke end. 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. The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and pump delivery rate is low. and outputs secondary pressure. ATT boost solenoid valve turns the solenoid valve on according to the engine speed. 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. 3. On starting bucket digging operation.

and consequently the return oil on arm cylinder rod side is recirculated into arm cylinder head side. 4. 5. 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. making the operation with minimum speed drop possible. T2-1-15 . 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. travel straight spool and arm 2 spool are switched enabling for two pump flow rates to be supplied to the arm cylinder head side. Because the return oil on the arm rod side is recirculated. With original hydraulic pressure command. 2. arm 2 spool. and swing operation pilot secondary pressure switches swing spool and is input to low pressure sensor. P1 and P2 unload spools. During arm-in operation. P1 and P2 unload pressure proportional valves. and operated by the recirculated oil. travel straight spool. arm 1 spool and swing spool are switched and also with the command by mechatro controller. 3. the working pressure is raised and pump delivery rate is used for swing operation by priority. travel straight valve and reverse proportional valve for arm 2 spool.MECHATRO CONTROL SYSTEM E215B-E245B P2 ARM 2 SPEED BUCKET BOOM TRAVEL RIGHT P1 UNLOAD TRAVEL STRAIGHT TRAVEL LEFT BOOM UP CONFLUX P2 UNLOAD SOLENOID SWING N&B SELECTOR VALVE ARM 1 SPEED PILOT VALVE OPTION 2.10 SWING PRIORITY CONTROL P1 LOW PRESSURE SENSOR SE-5 SE-7 pi ARM IN PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS pi pi SWING PILOT SECONDARY PRESSURE P1 PUMP PROPORTIONAL VALVE PSV-P1 P2 UNLOAD PROPORTIONAL VALVE PSV-B P1 UNLOAD PROPORTIONAL VALVE PSV-D ARM IN PILOT SECONDARY PRESSURE SWING PILOT SECONDARY PRESSURE P2 PUMP PROPORTIONAL VALVE PSV-P2 TRAVEL STRAIGHT PROPORTIONAL VALVE COMMAND TRAVEL STRAIGHT COMMAND PROPORTIONAL VALVE PSV-C REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A MECHATRO CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0127 1. 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).

E215B-E245B MECHATRO CONTROL SYSTEM (RIGHT) PILOT VALVE P2 PILOT VALVE FOR TRAVEL ARM 2 SPEED BUCKET BOOM TRAVEL RIGHT P1 UNLOAD TRAVEL LEFT BOOM UP CONFLUX PILOT VALVE TRAVEL STRAIGHT (LEFT) P2 UNLOAD SOLENOID SWING N&B SELECTOR VALVE ARM 1 SPEED OPTIONAL PILOT VALVE OPTION 2.11 TRAVEL STRAIGHT CONTROL P1 SOLENOID SHORT CIRCUIT VALVE SE-10 SE-9 SE-11 LOW PRESSURE SENSOR VALVE SIGNAL TRAVEL STRAIGHT SIGNAL pi PILOT SIGNAL PROCESS PROPORTIONAL VALVE PSV-R IN SHORT-CIRCUIT VALVE ‫ޓޓ‬ PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C ‫ޓޓ‬ PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS P2 PUMP PROPORTIONAL VALVE PSV-P2 ‫ޓޓޓ‬ PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS P1 PUMP PROPORTIONAL VALVE PSV-P1 PILOT ‫ޓ‬ SECONDARY PRESSURE pi PILOT SIGNAL PROCESS P2 UNLOAD PROPORTIONAL VALVE PSV-B PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS PILOT‫ޓޓޓ‬ SECONDARY PRESSURE T2-1-16 P1 UNLOAD PROPORTIONAL VALVE PSV-D SM0128 .

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. the following commands are output to each proportional valve. pilot pressure switches each travel spool and is input to low pressure sensor on carrying out attachment system operation. Judgment travel straight 1) During travel operation (right and left). bucket. option) pilot pressure during operation.) 1) Travel straight proportional valve outputs switching pressure according to the high priority select pressure in the attachment system operating (Boom. ATT operation Boom Arm Right travel operation (P1) Left travel operation (P2) T2-1-17 Bucket Swing Option . 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. 3) P1 unload proportional valve outputs switching pressure according to the high priority select pressure in the attachment system 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. swing.MECHATRO CONTROL SYSTEM E215B-E245B 1. 3) On turning travel straight signal on. arm. 4) P2 unload proportional valve outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation. 2. 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) 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.12 PRESSURE RELEASE CONTROL P1 SE-23 SE-22 ENGINE (M-2) PRESSURE RELEASE CONTROL ENGINE SPEED CONTROL pi pi pi pi PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS MECHATRO CONTROLLER P2 PUMP PROPORTIONAL VALVE PSV-P2 P1 PUMP PROPORTIONAL VALVE PSV-P1 P2 UNLOAD PROPORTIONAL VALVE PSV-B P1 UNLOAD PROPORTIONAL VALVE PSV-D pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0130 1. etc. PRESS" on gauge cluster. 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.) the mechatro controller. 2. Once mechatro controller decides it as pressure release control.E215B-E245B MECHATRO CONTROL SYSTEM P2 ARM 2 SPEED BUCKET BOOM TRAVEL RIGHT P1 UNLOAD TRAVEL STRAIGHT TRAVEL LEFT BOOM UP CONFLUX PILOT VALVE P2 UNLOAD GAUGE CLUSTER SWING SOLENOID ARM 1 SPEED N&B SELECTOR VALVE OPTION 2. 1) Outputs minimum tilt angle command to P1. 3. For detail of changing mode method. T2-1-18 . Change mechatro controller to “PRESSURE DRAING MODE” by operating switch on gauge cluster. refer to “Pressure draining (releasing) circuit” on GROUP 2 HYDRAULIC CIRCUIT. 4. accel potentiometer. decides the pump pressure and displays "DRAINING HYD. 2) Outputs command of pressure release to control step-by step motor (M2) and fixes engine speed to pressure release control speed. Mechatro controller senses output voltage from the main pump high pressure sensor. PRESS" or "FAIL DRAIN HYD. regardless of each input signal (operating pilot. P2 pump to minimum tilt angle. P2 pump proportional valves and fixes P1.

Nibbler circuit 1) Select A mode through gauge cluster. error display is output to 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. 2) Breaker display appears on gauge cluster. It is in normal when there is an output from sensor in B mode. 4) When selecting B mode through gauge cluster. Breaker circuit 1) Select B mode through gauge cluster. 2) Nibbler display appears on gauge cluster. and in cases of other than above. It is in normal when there is no output from sensor in A mode. T2-1-19 .13 N&B SWITCH CONTROL (OPTION) P1 A MODE B MODE GAUGE CLUSTER pi B MODE SWITCH MECHATRO CONTROLLER pi : OUTPUT OF N&B SELECTOR SOLENOID SM0131 1. and in cases of other than above. the breaker pressure sensor has not function to output. error display is output to gauge cluster. 2. 4) When selecting A mode through gauge cluster. the breaker pressure sensor outputs signal.MECHATRO CONTROL SYSTEM E215B-E245B P2 ARM 2 SPEED BUCKET BOOM TRAVEL RIGHT P1 UNLOAD TRAVEL STRAIGHT TRAVEL LEFT BOOM UP CONFLUX P2 UNLOAD SWING SOLENOID OPTION PRESSURE SENSOR N&B FOR BREAKER SELECTOR SE-29 VALVE ARM 1 SPEED 2. 3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.

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. 3. Select the Conflux with the aid of Conflux/Single switch. 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.E215B-E245B MECHATRO CONTROL SYSTEM P2 LOW PRESSURE SENSOR ARM 2 SPEED BUCKET BOOM TRAVEL RIGHT P1 UNLOAD TRAVEL STRAIGHT TRAVEL LEFT BOOM UP CONFLUX P2 UNLOAD SOLENOID SWING PILOT VALVE ARM 1 SPEED N&B SELECTOR VALVE OPTION 2. option operating pilot pressure switches option spool and is input to low pressure sensor. 2. 4. On starting option operation.14 OPTION CONFLUX CONTROL (OPTION) P1 SINGLE / CONFLUX SWITCH SE-11 pi PILOT SIGNAL PROCESS OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS P2 PUMP PROPORTIONAL VALVE PSV-P2 P1 PUMP PROPORTIONAL VALVE PSV-P1 OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS OPTION PILOT SECONDARY PRESSURE P2 UNLOAD PROPORTIONAL VALVE PSV-B P1 UNLOAD PROPORTIONAL VALVE PSV-D TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C MECHATRO pi : PROPORTIONAL VALVE CONTROLLER SECONDARY PRESSURE SM0132 1. P1 and P2 unload pressure proportional valves and travel straight proportional 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 .

E215B-E245B MECHATRO CONTROLLER 3. 1. Controls SWING PARKING BRAKE RELEASE SWITCH GAUGE CLUSTER SAFETY LOCK LEVER RIGHT CONTROL LEVER WITH ATT BOOST SW.MECHATRO CONTROL SYSTEM 3. FUSE & RELAY BOX STARTER SWITCH ACCEL DIAL DETAIL A SM0133 A 2. Gauge cluster 11 22:00 H 1 2 3 10 4 9 8 5 7 6 No. Name 1 Engine coolant temperature gauge 2 Fuel level gauge 3 Screen change switch 4 Buzzer stop switch 5 Work mode select switch 6 Washer switch 7 Wiper switch 8 Travel high speed.1 SUMMARY OF MULTI DISPLAY Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster. low speed select switch 9 Auto accel switch 10 Select switch 11 Multi display (LCD) SM0134 T2-1-21 .

E215B-E245B MECHATRO CONTROL SYSTEM 3. 㧴 B mode 10:25 For the work with breaker. Screen selection by work mode select switch After starting engine. select "B mode" without fail. 10:25 For the work with crusher (nibbler). 㧮 A mode 㧭 T2-1-22 . Select efficient work mode according to the working condition and the purpose from the following table. The work modes "S". select "A mode". 㧿 10:25 H mode "H mode"is suitable for heavy duty digging work which gives priority to the workload at the high speed. • • • • S mode: For standard digging work H mode: For heavy duty digging work B mode: For works with breaker A mode: For works with crusher (nibbler) 10:25 H SM0135 Work mode Display S mode 10:25 Contents "S mode"is suitable for standard digging and loading works and is in fuel saving and is maintained well-balanced relations with workload. "S" mode is usually set."H"."B" and "A" are selected in order every time ( ) is pressed. The selected mode is displayed on the left lower corner on multi display.

In this condition. In this machine. T2-1-23 . 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. press FEED (4)/ (5) and the flow rate value increases or decreases.MECHATRO CONTROL SYSTEM 1) Pump flow rate adjustment (A mode /B mode) 1 No. it is required to change the flow rate for service circuit. 3) Select "A" and A mode screen is displayed. B mode 130 L/m Flow rate 100 L/m 130 L/m B (b) (c) SM0141 1) Turn starter key switch on and display main screen (a). the double flow rate 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. Change the flow rate in accordance with the procedure mentioned below. Main screen Attachment mode (A mode) 10:25 Flow rate H 130 L/m Flow rate Enter A (a) Flow rate 100 L/m (b) (d) 100 L/m A Increase/Decrease In Breaker mode (B mode) Flow rate 130 L/m Flow rate Enter B Screen in Attachment/Breaker mode A mode Flow rate (c) (d) Flow rate A 100 L/m B Increase/Decrease When the conflux switch is tuned on. 5) Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value. The adjustment (increase or decrease) of flow rate is changeable by 10L/min step. Switches 1 Screen change switch 2 Buzzer stop switch 3 KPSS work mode select switch 4 Washer switch 5 Wiper switch 6 Travel speed select switch 7 Auto accel switch 8 Select switch 8 E215B-E245B 2 3 7 4 5 6 SM0140 According to some kind of attachment. last set flow rate has been stored and the initial flow rate is 210L/min. and select "B" and B mode screen is displayed.

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. 992Hr HYD. OIL H NOTE: • The display automatically changes to the main screen. 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.E215B-E245B MECHATRO CONTROL SYSTEM 4. 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.000 Hr Hydraulic oil 5.000 Hr This menu is available for confirmation of the following items.6 “SET PROCEDURE OF MAINTENANCE SCHEDULE”. 4992Hr 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. MAINTENANCE SCREEN DISPLAYS This screen displays the remaining time to the end of recommended replacement/change interval specified for filter/oil. Replacement interval Item Default Engine oil 500 Hr Fuel filter 500 Hr Hydraulic oil filter 1. see the following table. see the paragraph 3. 1) Remaining time display to the engine oil change This display shows the remaining time to the coming engine oil change. The maintenance screen changes each time the screen change switch is pressed. T2-1-24 . For the initial set value of recommenced replacement/change time.

...............Displays remaining time up to replacement/change of following items....MECHATRO CONTROL SYSTEM E215B-E245B 5. etc........... screen for operator is displayed on multi screen..When abnormality is detected on mechatro system like sensor.. see items shown on the next page..Specifies failed section automatically for failures which are not detected by self diagnosis and displays the results.. (1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil 3) Failure history display function.....Screen usually displayed during operation 1. CLOCK DISPLAY SELF DIAGNOSIS / WARNING MACHINE CONDITION H MULTI DISPLAY INDICATIONS SM0146 1) Display function for operator ...1 Clock display function . (For warning contents....... proportional valve command.................Displays machine operating condition....Displays procedure for adjustment of mechatro system like output adjustment and unload adjustment.. proportional valve........ 2) Display function for maintenance... etc.............Stores abnormality occurred on mechatro system in the past and displays in order of recent occurrence.. 1.. 4) Mechatro adjustment display ..... output by mechatro controller 6) Failure diagnosis mode display function .......................... etc. Gauge cluster display After key is switched on and logo mark display disappears...........) 1.....................3 Warning display ... 5) Service diagnosis display...................... T2-1-25 ...When machine was thrown into dangerous state..........................Current time is displayed................4 Machine condition display .Displays information like pressure sensor sensed value... The display functions of multi display are explained below.. displays warning symbol......... or was failed. this displays error code.2 Self-diagnosis display .............. 1..

CPU CHARGE ERROR W004 DATA COMMUNICATION ERROR LOW ENG WATER LEVEL W001 W010 SWING BRAKE DISENGAGED DRAIN WATER SEPARATOR LOW FUEL LEVEL AUTO WARMING UP W008 ENG LOW PRESSURE (ENGINE STOP) CLOGGED AIR FILTER CHANGE ENG OIL NOTE: Error codes were stored as trouble history. and displayed on the monitor by the trouble history display function.E215B-E245B MECHATRO CONTROL SYSTEM • Warning table These descriptions indicate error codes stored as “trouble history code” W009 CAUTION ATTACHMENT W005 LOW ENG OIL PRESS. T2-1-26 . W011 PREHEAT W006 POWER BOOST ON HIGH ENG WATER TEMP.

The failed items are displayed on multi display of gauge cluster.3 sec. during machine operation through self diagnosis. 3 DRAIN WATER SEPA 3 CLOGGED AIR FLTR 3 (SELF DIAGNOSIS SCREENS) 3 PREHEAT 4 CHARGE ERROR No signal from the alternator 4 LOW FUEL LEVEL The fuel level is less than 10 % 4 LOW ENG WATER LEVEL 5 AUTO WARMING UP 5 CHANGE ENG OIL The air filter is clogged According to the self diagnosis control The heater relay contact is faulty The warter engine coolant reservoir is low The auto warming up control is activated The remaining time is reached zero Huors (*) 1: these extremely influence safety and the machine performance 2: these warn the machine control mode is switched 3: fatal failure 4: normal priority warning 5: low priority message 3. 3: Beep ON 0. proportional valve.5 sec. SELF DIAGNOSIS DISPLAY CONTROL 1. OFF 0.MECHATRO CONTROL SYSTEM E215B-E245B Warning Condition Level Priority (*) A Screen 1 DATA COMMUCATION ERROR 1 SWING BRAKE DISENGAGED 1 ENGINE STOP 2 FAIL DRAIN HYD.0 sec.5 sec. Pressure Auto Stop O 3 x O O O 2 O O 1 O x O 1 x O Possible to drain hyd. Electric circuit diagram or harness is available to identify wire No. OFF 0. 1 Condition Engine Only Key ON Run Data from Mechatro controller is not received The swing parking brake switch is turned ON Engine is stopped after engine oil pressare low warning Impossible to drain hyd. PRESS. I/O configuration Pressure sensor.5 sec. and wire color. Governor motor INPUT Proportional valve. O O 3 x O W006 O O 3 x O W010 O O 3 x O W008 O O 3 x O O O 3 O O O O W001 W009 - O The engine water is more than 105 °C Water in water separator filter is increased 3 HIGH ENG. WATER TEMP. 4: Beep ON 0.. refer to the section "Mechatro Control Equipment" explained later. OFF 1. For connector No. Battery relay Selector valve (SOL) SERIAL COMMUNICATION Gauge cluster (Buzzer sound) SM0147 T2-1-27 . etc.2 sec. Outline This function identifies abnormality of control I/O signal like pressure. and pin No. PRESSURE 2 DRAINING HYD.2 Type (**) O Disconnection B Trouble History Manual Code Stop Buzzer sounds O O - O - O O O O - O - W011 W004 (**) 1: Continuation 2: Beep ON 0. 2. Pressure O 4 x O CAUTION ATTACHMENT The selector valve (OPT) is malfunction O 2 x O 2 POWER BOOST ON The power boost switchis turn ON 2 FINISH WARM-UP After finishing warming up control O 2 O x Low engine oil pressure O 2 x O W005 3 LOW ENG OIL PRESS.

Self diagnosis display items As-displayed clock (Usually main screen). ERROR CODE SM0148 ALPHABET A Controller memory B C Low pressure sensor High pressure sensor D Proportional valve for E F Proportional valve for 2 nd Solenoid valve G Speed sensor Throttle Boom up P1 pump P1 unload P1 pump ATT boost Step motor 02 Torque adjust data Boom down P2 pump P2 unload P2 pump Swing parking brake Step motor 03 Unload adjust data Arm out Boom head Travel straight 05 Bucket digging 06 Bucket dump 07 Swing 09 Travel right 10 Travel left 11 Selector position K R Communication Battery relay Relay output Battery relay Wiper ark prevention AND 3 DIGIT 01 Arm in I rd Engine adjust data 04 H Potentiometer etc. This failure symbol is displayed simultaneously with error code during failure diagnosis. 10:25 B 01 3 B013 Last 2nd and 3rd digits: Specifies failed section. When error occurred. Wiper ark forward Travel 1. Last 1 digit: Specifies failure type. Alphabet: Decide system failure occurred.E215B-E245B MECHATRO CONTROL SYSTEM 3. specifies failed section and the failure type with the aid of error code.2 speed Wiper ark reverse Option selector Washer motor Arm 2 spool for arm in Fuel sensor 13 14 PSV-R Short Cricuit valve 15 16 P1 side option AIS relay2 17 P2 side option Engine stop relay Safety lock lever relay 18 21 Adjustment data sector 1 22 Adjustment data sector 2 23 Hourmeter sector 1 24 Hourmeter sector 2 25 Proportional valve adjust Safety relay Cluster communication 31 LAST DIGIT Larger than normal range 0 1 - 2 - Larger than normal range Transistor OFF failure/ Wrong output Wrong output 3 - Disconnection Disconnection 4 - Power source short circuit Power source short circuit 5 Transistor ON failure Disconnection Transistor ON failure Disconnection Over run Transistor ON failure / Disconnection Disconnection Power source short circuit Obnormal data T2-1-28 Time is over Contact point is melted and adhered Power source short circuit .

The screen number displayed by each mode is as follows.3→No. and the present mode is displayed in "Screen No.3 to No. and then returns to No. 1.1.. Washer switch: Screen gains by 1 in order. The service diagnosis is classified into three modes.1→.1→No. 1.1". This section explains the operating procedure and examples of each screen.50 3) The screen changes each time each switch is pressed from now on. 2.30 • Mode No.) Auto idling switch: Service diagnosis number advances from No.4→.3. (No.22→.3 E215B-E245B SERVICE DIAGNOSIS DISPLAY FUNCTION The current service diagnosis is displayed on multi display based on the data received from mechatro controller. 2 speed switch: Service diagnosis number advances from No.24→No. the screen changes in service diagnosis mode. T2-1-29 .1" is displayed first.3. 2) After logo mark is displayed. (No.3→No. The screen number each mode can display differs..2→No.1~No. "Screen No. • Mode No. Screen No... Screen No. (No.1 to No. The service diagnosis screen "Mode No.31~No. attachment position. etc.23→No.40 • Mode No.1: Screen No. The values in display changes according to the conditions like engine speed..1→No..1.2: Screen No..) Travel 1.3: Screen No.1. (No.3→No.2→No. Service diagnosis display screen operating procedure 1) Turn starter switch ON keeping buzzer stop switch pressed.. and 3.1.MECHATRO CONTROL SYSTEM 3. and then returns to No.2→No.3→.1".41~No.) Wiper switch: Screen loses by 1 in order.) 4) Turn key switch OFF and the display of service diagnosis mode is closed.

VALVE F-1 POWER BOOST COMP. MEAS.0 M B-17 P2 OPT.0 M NO.4 V 0. SWITCH 5 1000 1000 LIVE 20 °C OFF H 0.6 PRESS.5 PRESS.0 M B-9 TRAVEL (R) 0. POS.) 1) Service diagnosis “Mode No.0 V 0.0 M B-6 BUCKET DUMP 0.5 A OFF No load setting rpm Actual rpm Engine oil pressure Coolant temperature sensor / Coolant tempreature switch Work mode Potentiometer voltage Voltage % indication Number of step Step % indication A phase current B phase current Limit switch 6 OFF OFF OFF Set value in computer Measured value Switch ON ON OFF Set value in computer Measured value Switch OFF OFF OFF Set value in computer Measured value Switch Displays Contents NO. Service diagnosis display screen (Example) The service diagnosis display screen list is shown below.1” No. 0. engine low speed and lever to neutral position. The conditions for display are H mode.4 V 0. 0.3 SOL.4 V 0.0 M B-2 BOOM LOWER 0.4 RELAY K-1 AIS RELAY 2 K-2 SAFETY RLY K-3 ENG STOP KEY SWITCH START SWITCH CHARGE K-4 LOCK LEVER SWITCH Program version indication SERVICE DIAG 1 2 No. COIL A COIL B G-2 LIMIT SW.0 M B-3 ARM OUT 0.00 P/No.4 V 0. RELEASE SW F-3 1/2-TRAVEL COMP.5 A 1. WATER TEMP Service diagnosis mode MODE H-1 ACCEL VOLT.SENSOR B-1 BOOM RAISE 0. 1 Displays Contents NO.4 V 0.4 V 0.4 V 0.00 2-VER 0. MEAS.SENSOR B-7 SWING 0.E215B-E245B MECHATRO CONTROL SYSTEM 2.0 M B-16 P1 OPT.0 M B-10 TRAVEL (L) 0.2 ENG G-3 SPEED SET MEAS G-5 ENG PRS. MEAS. 4 NO. indication NO.4 V 0.0 M B-18 DOZER 1 0.0 M B-5 BUCKET DIG 0. SWITCH F-2 SWING-BRAKE COMP.3 V 0% 30 0% 1.0 V 0.1 MAIN CONT. 3 NO. G-1 MOTOR STEP POS.0 M B-4 ARM IN 0.4 V 0.5 V 0. P/N YN22E00207F1 PROGRAM VERSION 1-VER 2.0 M B-19 DOZER 2 0.0 M ON ON OFF ON OFF LIVE OFF ON Indicated value Indicated value Indicated value Key switch Starter switch Alternator Indicated value Switch Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value SM0149 T2-1-30 .4 V 0.

0 M 0.5 V 0.21 DIGITAL OUTPUT DO1 COMP.SWITCH H-9 FUEL LEVEL 1.20 DIGITAL INPUT DI29 OFF DI30 --DI31 --DI32 --DI33 ON DI34 --DI35 --DI36 OFF DI37 --DI38 OFF DI39 --DI40 OFF DI41 --DI42 --- ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication NO. 0 mA D-15 P1 BY PASS VALVE COMP.4 V 0.0 M D-3 S-TRAVEL COMP. OFF MEAS. --- Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value See Mechatro controller connector SM0150 T2-1-31 . OFF MEAS.0 M MEAS. 0 mA 2.0 M PROPO-VALVE E-3 OPT RELIEF 1 COMP. --MEAS.10 SENSOR.6M Set value in computer / Converted value from pressure Measured value / Converted value from pressure 0.0 V 0. 350 mA 0. LIVE ENG OIL FILTER --FRONT WINDOW OFF DOUBLE FLOW ON KPSS SW --HEATER OFF ENG OIL LEVEL OK COOLANT LEVEL OK NO. 0 mA 2.SENSOR PROPO-V C-1 PUMP P1 0. --MEAS. --DO7 COMP.0 V 0.16 PRESS. 417 mA MEAS.15 PROPO-VALVE D-11 P1 I-TRAVEL COMP. OFF MEAS.0 V 0 ͠ GLOW --AIR FILTER LIVE WATER SEPA.2 V 77% H-10 HYD. 417 mA MEAS. 417 mA POWER SHIFT FLOW RATE E-2 P2 PUMP COMP. OFF MEAS.0 M C-3 BOOM-HEAD 0. MEAS.0 M Set value in computer / Converted value from pressure Measured value / Converted value from pressure 0. 7 8 9 10 11 Displays Contents NO.0 M E215B-E245B Contents Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value NO.0 M MEAS.9 PROPO-VALVE E-1 P1 PUMP COMP. No. 0 mA MEAS. 750 mA 3.0 V 0.VALVE F-4 OPT SELECT COMP. ON DO9 COMP. --MEAS.SENSOR B-11 0.19 DIGITAL INPUT DI15 --DI16 ON DI17 ON DI18 OFF DI19 --DI20 OFF DI21 --DI22 --DI23 ON DI24 OFF DI25 ON DI26 --DI27 OFF DI28 --- ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication NO. --DO6 COMP.0 M Set value in computer / Converted value from pressure Measured value / Converted value from pressure 0. 347 mA D-16 P2 BY PASS VALVE COMP.0 M Set value in computer / Converted value from pressure Measured value / Converted value from pressure Displays NO. 347 mA MEAS.MECHATRO CONTROL SYSTEM No. OFF DO3 COMP. 0 mA Set value in computer Measured value (Feed back value) Spool position Mode of selector valve Set value in computer Measured value Set value in computer Measured value 22 0. OFF DO5 COMP. 0 mA 2. 750 mA 0.0 M 0. OFF DO2 COMP.0 M B-14 0. 750 mA 0. OFF DO10 COMP. OFF MEAS. --MEAS. 0 Ma D-12 P2 I-TRAVEL COMP. ON MEAS.0 M B-20 0. 750 mA 3. OFF MEAS. OFF DO4 COMP. 0 mA 2. --MEAS.0 M 1.0 M E-4 OPT RELIEF 2 COMP.0 M MEAS.11 SOL. --MEAS.0 M 1.0 M 0 mA 30 L Set value in computer / Converted value from pressure Measured value / Converted value from pressure Power shift Flow rate of pump P1 Power shift Flow rate of pump P2 20 Fuel level Hydraulic oil temperature Glow switch Air filter clogging Water separator clogging Engine oil filter clogging Front window open/close switch Conflux/Single flow select switch Command from grid heater Engine oil level Coolant level 21 OFF OFF SPOOL POS.0 V 0.18 DIGITAL INPUT DI1 OFF DI2 ON DI3 OFF DI4 OFF DI5 OFF DI6 OFF DI7 --DI8 OFF DI9 OFF DI10 OFF DI11 --DI12 --DI13 ON DI14 --- ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication NO.0 M D-2 P2 UN-LOAD(BP-CUT) COMP.7 P.0 M B-13 0. OFF Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value NO.0 M Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure NO. --MEAS.6 M 0.0 V 0.0 V 0.0 M 0 mA 30 L Set value in computer / Converted value from pressure Measured value / Converted value from pressure 1. 750 mA 3.0 M 0. --MEAS. 0 mA MEAS.4 V 0. 0 mA MEAS.0 M B-12 0.22 DIGITAL OUTPUT DO8 COMP.0 M B-15 0. 750 mA 3. OFF DO12 COMP. NIB SELECT SWITCH NIB F-5 FAN PUMP COMP.0 M MEAS.6 M MEAS. --- 15 18 19 NO.6 M D-6 ARM IN-2-SPEED COMP. --F-6 COMP.4 V 0. --DO11 COMP. OFF MEAS. --DO13 COMP. 350 mA 0.3 M C-2 PUMP P2 0.0 M MEAS. 417 mA POWER SHIFT FLOW RATE Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure 1.0 M NO.9 M C-4 BOOM-ROD 0.8 PROPO-VALVE D-1 P1 UN-LOAD(BP-CUT) COMP. --DO14 COMP. 16 NO.OIL TEMP 0.

--MEAS. 23 24 25 MECHATRO CONTROL SYSTEM Displays Contents NO.23 DIGITAL OUTPUT DO15 COMP. --DO23 COMP. --- Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value NO. --DO25 COMP.E215B-E245B No. --DO26 COMP. --MEAS.24 DIGITAL OUTPUT DO22 COMP. ON DO24 COMP. OFF MEAS. OFF DO18 COMP. OFF MEAS. --MEAS. OFF DO20 COMP. --MEAS. OFF DO19 COMP. OFF MEAS. --MEAS. ON DO17 COMP. --DO28 COMP. ON Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value NO. --DO16 COMP. --DO21 COMP. --MEAS. --MEAS. ON MEAS. OFF MEAS. ON MEAS. --DO27 COMP. --MEAS.25 WIPER SYSTEM WIPER SW RISEUP SW REVERSE SW PREVENT ARC CW MOTOR RLY CCW MOTOR RLY WASHER SW MOTOR RELAY OFF ON ON OFF OFF OFF OFF OFF Wiper switch Wiper rise-up switch Wiper reverse rotation switch Wiper motor ark prevention relay Wiper normal rotation relay Wiper reverse rotation relay Washer switch Washer motor relay SM0151 T2-1-32 .

0M 1000 0 mA Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Boom up pressure sensor Boom down pressure sensor Engine actual speed Power shift current NO.0 M 0. P/N YN22E00207F1 PROGRAM VERSION 1-VER 2.0 M 417 mA 417 mA 750 mA 750 mA 350 mA 0. indication Program version indication MERIT controller program version Service diagnosis mode 3 44 Engine speed high idle Current at pump adjustment Current correction at pump adjustment Pressure at pump adjustment Engine speed sensor rpm P1 unload corrective current P2 unload corrective current Angle adjustment Angle adjustment Angle adjustment Angle adjustment Displays NO.0 M 417 mA 417 mA 750 mA 750 mA 350 mA 0. 33 Service diagnosis mode 2 34 NO. 1 Displays NO.0 M 0.0 M 0.0 M 0.0 M E-1 P1-PSV 417 mA E-2 P2-PSV 417 mA D-1 P1-UL(BPC) 750 mA D-2 P2-UL(BPC) 750 mA D-3 S-TRAVEL 350 mA E-3 OPT RELIEF 110 mA B-16 P1 OPT 0. 1 Displays Contents NO.0 M 417 mA 417 mA 750 mA 750 mA 350 mA 750 mA 0.34 TRAVEL C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) D-3 S-TRAVEL B-9 TRAVEL(R) B-10 TRAVEL(L) Pi-P1 Pi-P2 G-3 ENG SPEED POWER SHIFT 0.0 M 417 mA 417 mA 750 mA 750 mA 0.43 MACHINE-INFORM. indication Program version indication MERIT controller program version SERVICE DIAG 2 31 32 No.00 2-VER 0.1 MAIN CONT.32 ARM.0 M 0.1 MAIN CONT.44 MACHINE-INFORM.2 M C-2 P2 PUMP 0. P/N YN22E00207F1 PROGRAM VERSION 1-VER 2. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3% Coolant temperature distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours SM0153 T2-1-33 .0 M B-17 P2 OPT 0.31 BOOM C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) B-1 BOOM RAISE B-2 BOOM LOWER G-3 ENG SPEED POWER SHIFT 0.0 M 0.2 M 0.0 M F-4 OPT SELECT NIB DOUBLE FLOW SW OFF G-3 ENG SPEED 1000 POWER SHIFT 0 mA Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current P1 side option pressure sensor P2 side option pressure sensor Optional selector SOL (Nibbler line) Conflux/ Single selector switch Engine actual rpm Power shift current SM0152 3) Service diagnosis “Mode No.00 SERVICE DIAG 3 41 NO.2 M 0.3” No.0 M 1000 0 mA Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Travel right pressure sensor Travel left pressure sensor Pilot pressure at travel straight (P1 side) Pilot pressure at travel straight (P2 side) Engine actual rpm Power shift current NO.0 M 0. PUMP PRESS.0 M 0.2 M 0.2 M 0. 43 P/No. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3% Pump pressure distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours WATER TEMP.MECHATRO CONTROL SYSTEM E215B-E245B 2) Service diagnosis “Mode No.0 M 1000 0 mA Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current Arm out pressure sensor Arm in pressure sensor Boom up pressure sensor Swing pressure sensor Engine actual speed Power shift current 35 Displays Contents NO.00 2-VER 0. HOUR METER 3550 TRIP METER 3500 OPERATION 3300 TRAVEL 300 SWING 3000 HAMMER 100 CRANE 100 STARTER 1200 Contents Hour meter of controller Trip meter of controller All accumulated operating time All accumulated traveling time All accumulated swing time All accumulated breaker operating time All accumulated high-reach crane operating time All accumulated starter operating time NO.35 OPT C-1 P1 PUMP 0.00 P/No.0 M 1000 0 mA Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Bucket digging pressure sensor Bucket dump pressure sensor Engine actual speed Power shift current NO.33 BUCKET C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) D-3 S-TRAVEL B-5 BUCKET DIG B-6 BUCKET DUMP G-3 ENG SPEED POWER SHIFT 0.0 M ESS N 930 UN-LOAD P1 565 mA P2 565 mA BOOM 0 0 ARM 0 0 OFFSET 0 0 INTER-B 0 0 Contents No.41 ADJUSTMENT 1 ENG HI-IDLE 2230 PUMP ACT I 515 mA 7 mA PUMP P 35.2” No.SWING C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) D-3 S-TRAVEL D-6 ARM-IN-2 B-3 ARM OUT B-4 ARM IN B-1 BOOM RAISE B-7 SWING G-3 ENG SPEED POWER SHIFT 0.

0 M B-1 BOOM RAISE 0. • The current of proportional valve is not the measured value. • The value in display during operation shows the value in steady state. Service diagnosis data list Preface and precaution The following is the data decided as normal status after service diagnosis for every operation.0 M B-2 BOOM LOWER 0.2~1.31 BOOM C-1 P1-PRES 33. • The values in following display are reference values with standard attachment attached machine.0 M G-3 ENG SPEED POWER SHIFT 1970~2030 G-3 ENG SPEED 0 mA POWER SHIFT 1770~1830 0 mA Operation No. SWING No.32 ARM.31 BOOM No.E215B-E245B MECHATRO CONTROL SYSTEM 3. When compared to performance check reference criteria. • The value in display may differ according to software version.2 : No operation S mode Hi idle No.0~35.0 M G-3 ENG SPEED POWER SHIFT 1970~2060 G-3 ENG SPEED 0 mA POWER SHIFT T2-1-34 1970~2060 0 mA . • Check on machine after sufficiently warming up machine. Operation No. but command value.4 : Boom up in full lever operation & in operation H mode Hi idle No. rather than. The measured value should be confirmed by the value in the displayed value for each proportional valve.3 : Boom up in full lever operation & relief H mode Hi idle Operation No.0~35.8 M C-1 P1-PRES 11.0 M B-7 SWING 0. • The current value of pump proportional valve is reference value because it varies according to pump pressure and adjusted torque value.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. measure it with the aid of calibrated measuring instrument.2~1.0 M B-2 BOOM LOWER 0.8 M C-2 P2-PRES 11.1 : No operation H mode Hi idle Operation No. SWING C-1 P1-PRES 0. at start of operation.0 M B-4 ARM IN 0.5 M C-2 P2-PRES 0. • The value of pressure sensor is calculated taking variation into accounts.0 M B-1 BOOM RAISE 3.0~16.0 M B-1 BOOM RAISE 0.0~16. Contact our dealer/distributor. Use these data to decide normal/abnormal status.5 M C-1 P1-PRES 0.5 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-4 ARM IN 0.32 ARM.0 M C-2 P2-PRES 33.0 M B-7 SWING 0.0 M B-3 ARM OUT 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 0.5 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-7 SWING 0.32 ARM.5~16.0 M B-3 ARM OUT 0.0 M C-2 P2-PRES 0.8 M C-1 P1-PRES 12.8 M C-2 P2-PRES 12.32 ARM. SWING No.MECHATRO CONTROL SYSTEM E215B-E245B Operation No. SWING H mode Hi idle C-1 P1-PRES 33.0 M B-2 BOOM LOWER 3.31 BOOM C-1 P1-PRES 12.0 M B-1 BOOM RAISE 0.0 M B-4 ARM IN 3.5~16.2~1.0 M G-3 ENG SPEED POWER SHIFT 1970~2060 0 mA Operation No.0 M B-7 SWING 0.0 M G-3 ENG SPEED POWER SHIFT 1970~2060 G-3 ENG SPEED 0 mA POWER SHIFT T2-1-35 1970~2060 0 mA .5~16.6 : Arm-in in full lever operation & relief H mode Hi idle Operation No.0~35.0~35.5 M C-2 P2-PRES 33.0 M B-1 BOOM RAISE 0.5 : Boom down in full lever operation & in operation H mode Hi idle No.0 M B-4 ARM IN 3.7 : Arm-in in full lever operation & in operation No.

0 M B-1 BOOM RAISE 0. SWING C-1 P1-PRES 33.0 M B-4 ARM IN 0.0 M B-1 BOOM RAISE 0.9 : Arm-out in full lever operation & in operation H mode Hi idle No.0 M B-3 ARM OUT 3.5 M C-2 P2-PRES 28.0 M B-1 BOOM RAISE 0.0 M C-2 P2-PRES 33.0 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 0.32 ARM.0~15.8 M C-2 P2-PRES 15.0~22.2~1.0 M B-4 ARM IN 0.0 M G-3 ENG SPEED 1970~2060 POWER SHIFT G-3 ENG SPEED 0 mA 1970~2060 POWER SHIFT 0 mA * Measure the values after a lapse of 5 minutes or after release of low temperature mode * Measure the values after a lapse of 5 minutes or after release of low temperature mode Operation No.0 M B-1 BOOM RAISE 0.11 : Swing in full lever operation & in operation H mode Hi idle No.0 M B-4 ARM IN 0.8 M C-2 P2-PRES 10.0~22.8 : Arm-out in full lever operation & relief H mode Hi idle Operation No.E215B-E245B MECHATRO CONTROL SYSTEM Operation No.0~35.5 M C-1 P1-PRES 0.0~35.2~1. SWING No.10 : Swing in full lever operation & relief H mode Hi idle Operation No.0 M B-7 SWING 3.0 M B-7 SWING 0.32 ARM.0 M G-3 ENG SPEED POWER SHIFT 1970~2060 G-3 ENG SPEED 0 mA POWER SHIFT T2-1-36 1970~2060 0 mA .32 ARM.0 M B-7 SWING 0. SWING No.0 M B-7 SWING 3. SWING C-1 P1-PRES 0.8 M C-1 P1-PRES 15.0 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 0.32 ARM.0~35.0 M B-4 ARM IN 0.

0~35.0~35.0 M C-2 P2-PRES 33.0~8.8 M 6.13 : Bucket digging in full lever operation & in operation H mode Hi idle No.0~15.0 M B-5 BUCKET DIG 3.8 M C-2 P2-PRES 4.15 : Bucket dump in full lever operation & in operation H mode Hi idle No.14 : Bucket dump in full lever operation & relief H mode Hi idle Operation No.0~35.33 BUCKET No.33 BUCKET No.33 BUCKET C-1 P1-PRES 33.12 : Bucket digging in full lever operation & relief H mode Hi idle Operation No.0 M C-2 P2-PRES 6.0~35.0 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-6 BUCKET DUMP 3.0 M G-3 ENG SPEED POWER SHIFT 1970~2060 G-3 ENG SPEED 0 mA POWER SHIFT T2-1-37 1970~2060 0 mA .8 M C-1 P1-PRES 4.33 BUCKET C-1 P1-PRES 33.8 M C-1 P1-PRES C-2 P2-PRES 33.0 M G-3 ENG SPEED 1970~2060 POWER SHIFT G-3 ENG SPEED 0 mA POWER SHIFT 1970~2060 0 mA Operation No.0 M E-1 P1-PSV 415~525 mA E-2 P2-PSV 415~525 mA E-1 P1-PSV 650~750 mA E-2 P2-PSV 540~563 mA D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 720 mA B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 0.0 M B-6 BUCKET DUMP 3.0~15.MECHATRO CONTROL SYSTEM E215B-E245B Operation No.0~8.0 M B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.

* Conflux switch is OFF.34 TRAVEL C-1 P1-PRES 5.0 M Pi-P2 0.0~2.E215B-E245B MECHATRO CONTROL SYSTEM Operation No.35 OPT C-1 P1-PRES 22.5 M Pi-P1 0.0 M B-16 P1 OPT 0. Relief set pressure is value of shipping.2~1.0 M B-17 P2 OPT 2.0~2. Relief set pressure is value of shipping.0 M G-3 ENG SPEED POWER SHIFT 1970~2060 G-3 ENG SPEED 0 mA POWER SHIFT T2-1-38 1970~2060 0 mA .6 M F-4 OPT SELECT DOUBLE FLOW SW.19 : Travel left in full lever operation & travel idling H mode Hi idle No.0 M B-10 TRAVEL (L) 2. 1970~2060 G-3 ENG SPEED 0 mA POWER SHIFT BRK OFF 1970~2060 0 mA * Conflux switch is ON.2~1.34 TRAVEL No.18 : Travel right in full lever operation & travel idling H mode Hi idle Operation No.5 M C-2 P2-PRES 22.5~26. G-3 ENG SPEED POWER SHIFT NIB F-4 OPT SELECT ON DOUBLE FLOW SW.5~26.0 M C-1 P1-PRES 0.0~2.0~12.5~26.5 M C-2 P2-PRES 5.0 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 0.2~1. Operation No.35 OPT No.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 M C-2 P2-PRES 22.0 M B-10 TRAVEL (L) 0.0 M Pi-P1 0.5 M C-2 P2-PRES 0.0 M Pi-P2 0.0~2.5 M B-9 TRAVEL (R) 0.16 : P2 side option in full lever operation & relief A mode Hi idle Operation No.0 M C-1 P1-PRES 0.6 M B-17 P2 OPT 2.0~12.17 : P2 side option in full lever operation & relief B mode Hi idle No.

MECHATRO CONTROL SYSTEM
3.4

E215B-E245B

TROUBLE HISTORY DIAGNOSIS

The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as
one of history. And the errors are able to be indicated on the multi display.

A part of warning contents is stored (the stored items are listed in warning table).
The error code for self diagnosis is stored.

1. How to display
1) Turn starter switch on.
2) Press buzzer stop switch continuously 5 times and the trouble history screen is displayed.

(Example)
No errors

NO ERROR

Error detected in the past

SM0154

3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
• Press washer switch ( ) A, and the item moves upward.
• Press wiper switch ( ), and the item moves downward.
5) Turn starter switch off, and the display is disappeared.
2. How to delete contents of trouble history
1)
2)
3)
4)

Display trouble history screen.
Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
When "NO ERROR" is displayed, the deletion is completed.
Turn starter switch off.

NOTE: all the stored items are erased. It is impossible to erase data partially.

T2-1-39

E215B-E245B
3.5

MECHATRO CONTROL SYSTEM

TROUBLE DIAGNOSIS MODE

The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be
detected through the use of self diagnosis function (the failure can be specified through the use of error code)
like disconnection and abnormal output. This is useful to save the time for troubleshooting.
1. Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are
automatically actuated, the sensor detects the machine status and the mechatro controller identifies
the normal condition or failed condition of the system.
For details of how to use, refer to Chapter: “TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".

T2-1-40

MECHATRO CONTROL SYSTEM
3.6

E215B-E245B

SET PROCEDURE OF MAINTENANCE SCHEDULE

This machine is equipped with multi-display which allows confirmation of remaining time to the coming
replacement/change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the
remaining time reaches to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc.
and perform the initial setting by the following order.
NOTE: interval of replacement of parts is mentioned
below.



Screen change
switch

Buzzer stop
switch

KPSS work mode
select switch
Washer
switch

Engine oil : 500 Hr
Fuel filter : 500 Hr
Hydraulic filter : 1,000 Hr
Hydraulic oil : 5,000 Hr

Select
switch

Auto accel
switch

Travel speed
select switch

Wiper
switch
SM0155

Procedure

1

2

3

4

5

Operating Procedure

Display on Multidisplay
NEW HOLLAND

Turn starter key switch on.

KOBELCO

Press "
" switch press once display
change switch on the switch panel once. And
the clock display changes to the display of
remaining time for coming engine oil change.
Press "
" switch press once select
switch once and the display for the engine
oil change reverses.
When required to adjust the interval to the coming
change time by 10 hours, press "
" switch
and the time to the coming engine oil change is
added. Press "
" switch and the time to the
coming engine oil change is reduced.
When desired to return to the initial set time,
press "
" buzzer stop switch once.
Press "
" select switch once and the set
time is stored.

10:25
H

250 Hr
ENGINE OIL

H

250 Hr
ENGINE OIL

500 Hr
ENGINE OIL

After several seconds,
display is changed to
clock autmatically.

Press screen change
switch
once more.

Press select switch
once more.

Replacing interval is
changed with each
pressing of switch.

To set the desired interval,
press the select switch

10:25
H

250 Hr
ENGINE OIL

H

250 Hr
ENGINE OIL

500 Hr
ENGINE OIL

500 Hr
ENGINE OIL

H
SM0156

NOTE:
1. After displaying the display for setting by pressing the display change switch, set the respective
maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does
not sound.

T2-1-41

E215B-E245B
3.7

MECHATRO CONTROL SYSTEM

ADJUSTING PROCEDURE OF DISPLAY

1. For operator
1) Clock Adjustment Switches
No.

1

2

3

4

Switches

1

Screen Change Switch

2

Buzzer Stop Switch

3

Work Mode Select Switch

4

Washer Switch

5

Wiper Switch

6

Travel Speed Select Switch

7

Auto Accel Switch

8

Select Switch
Main screen

10:25

8

7

6

SM0140

(a)
SWITCH STATUS
CLOCK/CONTRAST

13:15

H
(a)

5

H
(b)

(c)
SWITCH STATUS
CLOCK/CONTRAST

(d)

(e)

ADJUST CLOCK
ADJ CONTRAST

Y M D H M
06 04 01 13 15

Select Year/Month/Day/Hour/Minute

Enter

Increase/Decrese
SM0157

1) Turn starter key switch on and display main screen (a) for operator, and then press select switch (8)
and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2) In operations of FEED
(4) and FEED
(5), move cursor to "CLOCK/CONTRAST" screen (c) and
then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4) Select any of "Y•M•D•H•M" in operation of FEED
operations of FEED (6) and FEED (7).

(4) and FEED

(5) and vary the values in

5) After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting
is completed, and then the screen returns to main screen (a).

T2-1-42

MECHATRO CONTROL SYSTEM

2) Contrast Adjustment Switches
No.

1

E215B-E245B

2

3

4

Switches

1

Screen Change Switch

2

Buzzer Stop Switch

3

Work Mode Select Switch

4

Washer Switch

5

Wiper Switch

6

Travel Speed Select Switch

7

Auto Accel Switch

8

Select Switch
Main screen

10:25

8

7

5

6

SM0140

SWITCH STATUS
CLOCK/CONTRAST

H
(a)

(b)

(c)
SWITCH STATUS
CLOCK/CONTRAST

(d)

(a)

ADJUST CLOCK
ADJ CONTRAST

10:25
H

(e)
ADJUST CLOCK
ADJ CONTRAST

(f)
Enter

ADJ CONTRAST
55555

Adjustable range
11111~99999
(Default 55555)

Increase/Decrease
SM0158

1) Turn starter key switch on and display main screen (a), and press select switch (8) and display
"SWITCH STATUS CLOCK CONTRAST" select screen (b).
2) In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.
3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and
then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4) Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5) Vary the values by pressing the desired figure in operations of FEED (4) and FEED
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) → 99999 (clear) * The initial set value is 55555.

(5).

6) Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).

T2-1-43

E215B-E245B

MECHATRO CONTROL SYSTEM

2. Function for service
Following items are provided for adjustment of service function.

LANGUAGE/LOGO
Function

Explanation

Range

All language data is stored in 15
one gauge cluster
languages

LANGUAGE

To change language

LOGO

To change Company Logo

Note

5 Logos

Default
ISO
NHK

ADJUSTING MODE 1
Function

Explanation

RISE-UP WIPER

Note

To change wiper control, when special
CAB is installed on demolition OFF is for special CAB
machine

Range
ON/OFF

Default
ON

P1 OPT SENSOR To activate the self-diagnosis when P1 Switch to ON when 2PB is
ON/OFF
ACTIVE
OPT pressure sensor is failed
installed

OFF (*)

P2 OPT SENSOR To activate the self-diagnosis when P2 Switch to ON when N&B
ON/OFF
ACTIVE
OPT pressure sensor is failed
option is installed

OFF (*)

PRIORITY MODE

Only for EU, to activate the priority
valve

ON/OFF

OFF

LEFT
ACTIVE

To use P1 option pedal for P4-rotation
circuit, releasing auto accel. And not
activating unload valve

ON/OFF

OFF

PEDAL

SELECT
SYSTEM

OPT

1:No selector valve
Switch to ON when N&B
2:Selector Valve + Mechanical relief
1 or 3
option is installed
3:Selector Valve + Electrical relief

1 or 3 (*)

ADJ
OVERLOAD To change the pressure for overload
PRESS
alarm in EU

10 - 27

18

ENG
DISPLAY

ON/OFF

OFF

SPEED To activate the engine
information for customer

speed

AUTO ACCEL

To change auto accel control type

START MODE

To change
(S,H,B,A)

the

starting

6, 8, 10, 12,
18
14, 16, 18

MODE X: return to default MODE
S, H, B, A, X S
when key sw is ON

To cancel the low temp. mode to
CANCEL
LOW
OFF = Low Temp. Mode
prevent hydraulic hunching at low
ON/OFF
TEMP MODE
ACTIVE
temp.

OFF

DRAIN
PRESS

OFF

HYD. To activate the
pressure function

drain

hydraulic When switch is ON, this
ON/OFF
function starts.

To adjust Pressure and Flow for
ADJ OPT HAMMER
Follow setting procedure
Hammer (9set)

20
35
15 Mpa (at
Pressure
220 L/min)
30 - 220
220 L/min
Flow rate

To adjust Pressure and Flow for
Follow setting procedure
Nibbler (9set)

20
35
15 Mpa (at
Pressure
220 L/min)
30 - 220
220 L/min
Flow rate

ADJ OPT NIBBLER

(*) Autodetect

T2-1-44

the screen shows display (D). at the same time.MECHATRO CONTROL SYSTEM E215B-E245B 2. for example: ENG (English). Press SELECT button (2).00 SERVICE DIAG 1 1 EU (ISO icons only) 2 ITA (B) USA LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY CHN IDN THA SELECT LANGUAGE ESP (C) FRA ENG FEED DEU VNM 4 MYS 3 MMR TAM SELECT LANGUAGE POR (D) ENG FRA FEED JPN SELECT LANGUAGE (E) FRA FEED SM0070 T2-1-45 . move the STARTER SWITCH onto “OFF”. for example FRA (French). once or more until the symbol of the desired language is displayed. move the STARTER SWITCH onto “ON”. 3. SM0069 NO. Press SELECT button (2) to memorize the language selected. Press WIPER button (3) or WINDSHIELD WASHER button (4). the screen shows display (E). 1 (A) List of the languages available: MAIN CONT. 10:25 2.1 Setting the language To modify the language. P/N YN 22E 00207 F1 PROGRAM VERSION 1 VER 2. the language is selected and after about three seconds returns automatically to display (B). proceed as follows: 1. S 1 4 5 3 2 5. To exit the program. At this stage. Keep BUZZER CUT-OFF button (1) pressed. then press SELECT button (2) three times. the screen shows display (B). the screen shows display (C) indicating the symbol of the language previously set. 4. the screen shows display (A). Keep BUZZER CUT-OFF button (1) pressed and.00 2 VER 0.

3Adj. to increase the pressure. move the STARTER SWITCH onto “OFF”. the screen shows display (B).00 SERVICE DIAG 1 x3 1 (B) 2 LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY 3 (C) 4. or WIPER button (3). the screen shows display (A) 2. move the STARTER SWITCH onto “ON”. (C) 2 3 2. To exit the program.2 Setting Adjusting Mode 1 NO. at the same time. display (F). To enter the other functions. to return back. to move forward or WINDSHIELD WASHER button (4). Press WINDSHIELD WASHER button (4). 1 To enter the displays Adjusting Mode 1 proceed as follows: 1. Press WINDSHIELD WASHER button (3) to get ADJUSTING MODE 1. the first function is shown on the screen. Set the desired pressure value (for example: 11).E215B-E245B MECHATRO CONTROL SYSTEM 2. to decrease it. Keep BUZZER CUT-OFF button (1) pressed. display (G). 4. (A) MAIN CONT. proceed as follows: 1. LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY 11 RISE-UP WIPER ON (D) FEED 3 4 2. Keep BUZZER CUT-OFF button (1) pressed and. In function Adjusting Mode 1. then press SELECT button (2) three times. the screen shows display (C). to select function 63 ADJ OVERLOAD PRESS on display (E). actuate WIPER button (3). LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY ADJ OVERLOAD PRESS 18 FEED 63 (F) ADJ OVERLOAD PRESS 18 FEED 3 4 63 (G) ADJ OVERLOAD PRESS 11 FEED 63 ADJ OVERLOAD PRESS 11 FEED 5 SM0073 T2-1-46 . display (D). By pressing SCREEN CHANGE button (5) you return to display (C). Press SELECT button (2) to choose the number relative to the setting pressure. 18 = 180 bar 63 (E) 3.00 2 VER 0. display (C). By pressing SELECT button (2) you enter the Adjusting Mode 1 functions. Overload Press (tip-over momentum device) SM0071 To modify the value of the pressure at which the pressure sensor goes ON to operate the tip-over momentum device. press SELECT button (2) to memorise it. 3. P/N YN 22E 00207 F1 PROGRAM VERSION 1 VER 1. press SELECT button (2) to enter the functions and use WIPER button (3).

” this means that the pressure draining operation has not been performed correctly. PRESS. press SELECT button (2) to enter the functions and using WIPER button (3). select on the display function DRAIN HYD. Press To drain the hydraulic pressure from the system. The screen shows display (M). DRAIN HYD PRESS OFF FEED 4. with the engine in operation. In this case. display (C). repeat the operation. display (L). Press SELECT button (2) to show the writing OFF. (H) 3.MECHATRO CONTROL SYSTEM E215B-E245B 2. actuate the pilot valves performing all the movements so that the pressure is drained from all the actuators. In function Adjusting Mode 1. (L) DRAIN HYD PRESS ON FEED 10:25 (M) PR S SM0072 T2-1-47 . At this point. proceed as follows: 1. display (H).4 Drain Hyd. (I) DRAIN HYD PRESS OFF FEED 4 NOTE: if the monitor displays “FAIL DRAIN HYD PRES. The function is automatically deactivated by returning the STARTER SWITCH onto “OFF”. Press WINDSHIELD WASHER button (4) to activate function ON. display (I). Press SELECT button (2) and start the engine. (C) LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY 3 2 2.

8 MECHATRO CONTROL SYSTEM MECHATRO CONTROL EQUIPMENT 1.5V 0V 0V 0.5V Power output 5V Power output 5V 0.5~4.5~4.5~4.5~4. Port name CN101 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 GA A1 +5VA +5VA A2 GA GA A3 +5VA +5VA A4 GA GA A5 +5VA +5VA A6 GA TXD1 RXD1 GP SHG1 TXD3 RXD3 DL GP CANH1 CANL1 DO 20 DO 21 DO 22 DO 23 DO 24 DI 36 Function Input/putput Boom up Input Boom down Input Arm in Input Arm out Input Bucket digging Input Bucket dump Input Gauge cluster Transmission Down load Transmission Reception Reception Spare Spare Safety relay Spare Extra pressure release Spare Heavy lift Output Output Output Output Output Input Signal level 0V 0.5V Power output 5V Power output 5V 0.5~4.E215B-E245B 3.5~4. C-1 Mechatro controller 1) Outside view 2 1 10 6 2 1 22 18 4 2 1 8 2 1 16 26 34 27 CN101 CN105 9 CN102 16 12 CN103 28 22 CN104 CN106 CN107 CN108 CN109 21 7 2 16 21 9 21 7 21 21 10 31 22 16 24 8 17 12 17 7 28 10 22 13 19 20 15 16 8 SM0159 2) List of connectors Connector No. Pin No.5V 0V 0V 0.5V Power output 5V Power output 5V 0.5V 0V RS232C communication RS232C communication 0V Shield GND RS232C communication RS232C communication EARTH / OPEN(5V㧕 0V CAN communication CAN communication EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN SM0160 T2-1-48 .

5~4.5V Power output 5V Power output 5V 0.5V Power output 5V Power output 5V 0.5V Power output 5V GND / OPEN Signal level 0V 0.5V 0V 0V 0.5~4. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Port name GA A +5VA +5VA A11 GA GA A12 +5VA +5VA A15 GA GA A16 +5VA Function E215B-E245B Input/putput Travel right Input Travel left Input Accelation Input P1 option Input P2 option Input Spare Input Spare Input Spare Input Function Input/putput Swing Input P1 pump Input P2 pump Input Boom angle Input Arm angle Input Reserved Signal level 0V 0.5~4.5~4.5V 0V 0V 0.5V 0V 0V 0.5V Power output 5V Power output 5V 0. CN103 Pin No.5V Power output 5V SM0161 T2-1-49 .5~4.5~4.5~4.5~4.5V 0V 0V 0.5~4.5~4.MECHATRO CONTROL SYSTEM Connector No.5~4.5V Power output 5V Power output 5V 0. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Port name GA A8 +5VA +5VA A9 GA GA A10 +5VA +5VA A13 GA GA A14 +5VA +5VA A27 GA GA A28 +5VA D1 37 Pin No.5V Power output 5V Power output 5V 0.5~4. CN102 Connector No.5V 0V 0V 0.

2 speed select valve P2 unload Output Travel straight Output Arm in Output P1 pump Output Battery (-) OPT changeable relief 1 P2 pump Output Output Spare Output Spare Output Spare Output Battery direct connection 0V 0.5V Power output 5V GND / OPEN Signal level 20~32V 20~32V 20~32V 24V/OPEN 24V/OPEN 24V/OPEN 24V/OPEN 0V 0V +0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA -0~800mA +0~800mA 20~32V SM0162 T2-1-50 .2 speed select valve Output Attachment boost select valve Output Battery (-) Battery (-) OPT changeable relief 1 Output P1 unload Output Travel 1. CN105 MECHATRO CONTROL SYSTEM Pin No. 1 2 Port name +24V +24V 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 +24V DO 7 DO 8 DO 9 DO 11 GND GND D10+ D1+ D1D2+ D2D3+ D3D4+ D4D5+ D5GND D10D6+ D6D7+ D7D8+ D8D9+ D9+24V Function Input/putput Signal level 0V 0.5~4.5~4.5V 0V 0V 0.5V 0V 0V 0.5V Power output 5V Power output 5V 0.5V 0V Boom head (Over load) Input Spare Input Extra pressure source Input Spare Input Engine coolant temperature Input Resistor Fuel level Input Resistor Spare Input Resistor Selector detection Input Extra pressure source Input Spare Input Starting point of accel motor Input Function Input/putput Battery relay output side Battery relay output side Output Swing P/B select valve Output Travel 1.5㨪4.5~4. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Port name GA A17 +5VA +5VA A18 GA GA A19 +5VA +5VA A20 GA A21 GA A22 GP A23 GA GA A24 +5VA +5VA A25 GA GA A26 +5VA DI 1 Pin No.5V Power output 5V Power output 5V 0.E215B-E245B Connector No.5~4. CN104 Connector No.5~4.5~4.5V Power output 5V Power output 5V 0.

MECHATRO CONTROL SYSTEM Connector No.5A +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V +0~800mA -0~800mA XX~XXVp-p 0V Shiled GND CAN communication CAN communication Signal level +24V/OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN SM0163 T2-1-51 . CN106 Connector No.5A 1.5A 1.5A 1. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Port name DI 3 DI 8 DI 9 DI 10 DI 11 DI 12 DI 13 DI 14 DI 15 DI 20 DI 28 DI 32 DI 38 DI 39 DI 40 DI 41 Function Battery relay secondary side E215B-E245B Input/putput 0 Oil level (spare) Output Output Output Output 0 OPT changeable relief 2 Output Spare Output Bypass valve Output Spare Output Battery (-) Spare Output Accel motor A phase Accel motor A phase Accel motor B phase Accel motor B phase E/G speed sensor Input Proportional vlave expand unit Input/putput Function Grid heater feedback Input Engine coolant temperature Input Input E/G oil pressure Air filter Input Spare Input Spare Input E/G coolant level Input Spare Input Spare Input Heater temperature of fuel filter Input Spare Input Hand control nibbler Input Quick coupler Input Spare Input Heater temperature Input Spare Input Reserved Signal level 20~32V Shield GND 1. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Port name +24V SHGF F1+ F1F2+ F2OIL OILG D11+ D11D12+ D12D13+ D13D14+ D14GND D12+ D12E1+ E1SHG3 CANH2 CANL2 Pin No. CN107 Pin No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Connector No. CN109 Pin No. CN108 MECHATRO CONTROL SYSTEM Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Port name DI 2 DI 4 DI 5 DI 6 DI 7 DI 16 DI 17 DI 18 DI 19 DI 21 DI 22 DI 23 DI 24 DI DI DI DI DI 25 26 27 29 30 GP DI 33 DI 34 DI 35 H1+ H2H2+ H2Port name DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 12 DO 13 DO 14 DO 15 DO 16 DO 17 DO 18 DO 19 GP TXD2 RXD2 RTS CTS SHG2 DO 10 Input Input Input Input Input Input Input Input Input Input Input Input Input Signal level +24V / OPEN +24V / OPEN GND / OPEN +24V / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN +24V / OPEN +24V / OPEN +24V / OPEN GND / OPEN Front window open or close Spare Conflux/single select Overload select Spare Reserved Input Input Input Input Input GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN Charge Spare Spare Reserved Spare Input Input Input ~12V / 12V~ +24V / OPEN +24V / OPEN Function Key switch (ON) Water separator Swing P/B release E/G start Spare Wiper rise up㩩 Wiper reverse ATT boost Spare Spare Spare Lever lock Hand control rotation Input/putput 0~5V 0V 0~5V 0V Spare Function Wiper arc prevention Wiper normal moving Wiper reserve moving Washer motor Spare Reserved Spare Swing flasher (RH) Swing flasher (LH) Travel alarm Auto idle stop relay Engine stop Lever lock Grid heater Reserved Input/putput Output Output Output Output Output Output Output Output Output Output Output Output Output Output Signal level GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN 0V Tranmission RS232C communication Spare Spare Reception RS232C communication RS232C communication RS232C communication Shiled GND 24V/OPEN SV SM0164 T2-1-52 .E215B-E245B Connector No.

b. 6. WORK MODE SWIHCH SM0165 2) Connector CN-600 (Harness side) No. Gauge cluster (symbol C-2) 1) General view 4.MECHATRO CONTROL SYSTEM E215B-E245B 2. displays them in lamps. 4) Summary of display and drive item No. MULTI DISPLAY LCD 2. Item name Wire color 1 Gauge cluster → Mechatro controller (RS232C communication) White 5 GND source (+24V Battery direct connection) Yellow / Black 2 Mechatro controller → Gauge cluster (RS232C communication) Red 6 GND Black 3 — — 7 Source (+24V starter switch ON) White 4 — — 8 GND communication) Black (RS232C 3) Function a. Item name Wire color No. It processes signals by communication between the gauge cluster and the mechatro controller.. BUZZER STOP SWITCH 7. COOLANT TEMPERATURE GAUGE FUEL LEVEL GAUGE MATED SIDE AMP 040 HOUSING : 174044-2 TERMINAL : 173681-2 5. fuel level signals and panel switch signals to the mechatro controller through the communication port. It outputs coolant temperature signals. Item Remarks 1 Monitor display LCD dot 120×168 2 Gauge display (Coolant temp. Fuel level) Stepping motor 3 — 4 Buzzer 5 Screen change switch 6 Buzzer stop switch 7 Work mode select switch Piezo-electricity type T2-1-53 . BUZZER 1. displays them in LCDs and actuates the buzzer. SCREEN CHANGE SWITCH ETC.

E215B-E245B MECHATRO CONTROL SYSTEM 3. CODE IN CIRCUIT PARTS NAME SM0166 T2-1-54 . Relay & fuse box (symbol E-1) 1) General view (Overhead view of box) LABEL INSIDE Note) These circles indicate the parts which are used in standard specification 1 14 CN2-1 20 1 14 1 12 CN2-2 20 CN4-1 17 11 22 1 7 1 10 CN5 15 1 3 26 13 13 1 CN3-2 12 8 16 24 12 CN8 9 1 17 CN3-1 1 26 13 2 1 CN9 2 9 20 6 12 1 CN2-3 3 1 2 2 2 6 1 3 1 3 6 2 6 1 3 1 3 2 2 CN15 2 3 CN12 CN1 3 6 CN14 CN4-2 1 CN17 CN16 CN13 6 2 1 4 6 2 CN10 LOCATION OF CONNECTORS (Seen from backside) LOCATION OF RELAY & FUSE LABEL OF RELAY & FUSE BOX No.

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 .

5 OUTPUT (+) INSURANCE RESISTANCE : 100M POWER SOURCE (+) PLASTIC POTTING (BETWEEN CASING AND ALL IN/OUT TERMINAL TERMINALS AT 50V DC MEGGER) CONDENSER DIE ELECTRIC CONNECTING DIAGRAM CASING FLEXIBLE BOARD CIRCUIT OR MORE HOUSING COVER (Ex. Construction of internal controller) SPECIFICATION : PRESSURE RANGE : 0 3.5V DC) PIPE THREAD STRUCTURE SM0170 5) Low pressure sensor : YX52S00013P1 Tightening torgue Vout 29.m (21.0+0.5V DC OUTPUT : 1/10Vs-9/10Vs COMMON (Vs=5V DC 0.0+0.3lbf.5N.ft) 4.0 MPa RATED VOLTAGE : 5.725.3N.5V DC OUTPUT CHARACTERISTIC INSURANCE RESISTANCE : 50M OR MORE (BETWEEN BODY AND EACH TERMINAL AT 50V DC MEGGER) SM0171 T2-1-58 .434.ft) PF1/4 Vcc GND ELECTRIC CONNECTING DIAGRAM (Ex. Construction of internal controller) DIAPHRAGM O-RING P14 JIS B2401 CLASS1B PF 3/8 Tightening torgue 73.m (54.2lbf.E215B-E245B MECHATRO CONTROL SYSTEM 4) High pressure sensor : YN52S00048P1 SPECIFICATION : ECONOSEAL SERIES MARK(+)> 3POLES CAP MATING HOUSING174357-2 PRESSURE RANGE : 0 50 MPa POWER SOURCE VOLTAGE : 5.

if the machine stops with engine trouble. • Swing priority circuit (simultaneous operation of arm in and swing • Easy operation of stable swing speed. • Boom up conflux circuit • Speed up of boom up operation • Arm conflux circuit • Speed up of arm operation • Bucket conflux circuit • For speed-up of bucket operation (digging & dump) • Travel 2-speed change & Auto 1st (low) speed return • 1-2 travel speed change and low speed / high torque at heavy duty • Auto parking brake • Automatic braking when parking • Motor overrun protection • Prevents overrunning of travel motor on the • Travel pilot operation • Prevents hunting by the built in travel • Reverse rotation protective function • Easy positioning to protect it from swinging back when stops swinging.HYDRAULIC SYSTEM E215B-E245B 1. • Pressure draining circuit • To release the main circuit pressure for piping repair work. • Holding valve for boom (Option) • Prevention of boom falling when boom head side piping breaks manual valve for lowering Attachment Micro computer Low fuel consumption Pump • Travel straight at combined operation Mass handling capability • Travel straight • Emergency attachment Others Easy operability and safety Swing Travel Performance • For safety. SUMMARY The hydraulic circuits are built up with the following functions and features in order to achieve easy operability. • 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. swing press digging • Optimum operation by work mode select (H. this valve lowers risen attachment to the ground.A.B) • Efficient operation in all work modes • Automatic swing parking brake • Swing parking brake when operating at on a slope • Auto accel • Reduce fuel consumption and noise by lowering engine speed when control lever is in neutral position. • Main control valve with optional valve • Optional piping and additional work are easy • Switching of return line for N&B machine in the cab (Option) • Switching of return line for N&B machine is able to change with a switch in the cab operating circuit from T2-2-1 . mass volume handling and low fuel consumption. • Line filter. • Hydraulic pilot control system • Light action with operating lever • Pilot safety lock system • Cut out of pilot circuit by safety lock lever. arm slanted leveling. and the pressure in the cylinder of attachment can be released. safety. • Lock valve (boom / arm) • Protect boom and arm from unexpected drop (Natural fall).S. Device Attachment Function Features Performance Device Function Features • Electric flow controlled variable displacement pump • Pump delivery rate control by a current command to the solenoid proportional valve of the variable displacement pump • Positive flow rate control • Flow control by positive pilot control pressure • Hydraulics backup control • Backup control by hydraulic when the electric flow controlled variable displacement pump fails. pilot circuit • To prevent pilot malfunctioning • Return circuit oil filter • To prevent hydraulic oil from contamination • Cooling hydraulic oil by oil cooler • To prevent hydraulic oil from being deteriorated.

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 .E215B-E245B HYDRAULIC SYSTEM 2. HYDRAULIC CIRCUITS AND COMPONENTS HYDRAULIC DIAGRAM READING KEY Item T2-2-2 Component name 1 Hyd.

HYDRAULIC SYSTEM E215B-E245B HYDRAULIC CIRCUIT (MONOBLOCK VERSION) SM0077 T2-2-3 .

W/O: -) . SELECTION Conflux/single flow changeover switch Electromagnetic command signal of selector valve (50) (W:O. T2-2-4 Command signal of solenoid proportional valve (W:O. Adjust overload relief valve (53) of optional port to customize specification ordinary set pressure. according to specification of nibbler installed. 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.E215B-E245B HYDRAULIC SYSTEM 3. W/O: -) Conflux flow of nibbler Conflux “ON” Single flow of nibbler Breaker P1 Pump P2 Pump Travel Straight P1 Unload P2 Unload - O O O O O Conflux “OFF” - - O - - O Conflux “OFF” O - O - - O When using nibbler.

HYDRAULIC SYSTEM E215B-E245B N&B HYDRAULIC CIRCUIT 51 53 52 53 50 SM0078 T2-2-5 .

HYDRAULIC CIRCUIT READING KEY Item T2-2-6 Component name 54 Holding valve for boom cylinders 55 Holding valve for arm cylinder .E215B-E245B HYDRAULIC SYSTEM 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 SYSTEM E215B-E245B HOLDING VALVE FOR BOOM & ARM HYDRAULIC CIRCUIT 54 54 55 SM0079 T2-2-7 .

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 holding valve (57) prevents the positioning falling in case of rod side cylinder piping breaks. 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).E215B-E245B HYDRAULIC SYSTEM 5. 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. T2-2-8 .

HYDRAULIC SYSTEM E215B-E245B POSITIONING CIRCUIT (TRIPLE ARTICULATION VERSION) 57 R POSITIONING CYLINDER H 58 59 56 SM0080 T2-2-9 .

and the values are output to respective pump proportional valve as a command current. the opening of spool sleeve closes gradually.59 MPa (64~86 psi) Purple Secondary pilot pressure. On the regulator attached on the pump.E215B-E245B 6. the limit switch (SW-11) is turned on. Therefore when servo piston moves leftward.59~5 MPa (86~725 psi) Red Primary pilot pressure. the spool (652) through piston (643) is pushed leftward. and consequently the by-pass cut spool is switched to CLOSE side.44 MPa (64 psi) Green Return. the spool (652) is moved leftward by the feedback lever. but the servo piston moves rightward due to the difference of area. resulting in the reduction of tilt angle. 7. As the pump command current value rises. (including proportional vlave) 0. NEUTRAL CIRCUIT 7. and stops at the position where being in proportion to the force of pilot spring (646). With this operation. the delivery pressure P1 usually flows into the large bore of piston through the spool. The tank port connected to the large bore of servo piston (532) opens. HYDRAULIC SYSTEM 7. and this pressure exerts on PBp1 and PBp2 ports. T2-2-10 (2) Principle: The current command I to the pump’s solenoid proportional valve controls the delivery rate of the pump.3 MPa (725~4970 psi) Blue tone At valve operation Red valve When solenoid proportional valve (reducing) is operating Red solenoid In active and exciting Displaying the flow circuit and standby circuit when operating.1 Bypass cut valve and unload valve control 7. 7. And it is switched to OPEN side only when failure occurred on pump proportional valve and mechatro controller. PSV-B) output secondary pressure according to the command output by mechatro controller. P1 pump) By operating any of control levers. resulting in rise of command current value I to the pump proportional solenoid valve and consequently the pump flow rate rises.2 SAFETY LOCK LEVER AND PILOT CIRCUIT (1) Purpose: To protect attachment movement for safety. On the other hand. The servo piston and spool (652) are connected to feedback lever (611). consequently the P1 and P2 unloading valves are switched to OPEN side. 5~34.4 PUMP P-Q CURVE CONTROL OPERATION (1) Type: Electrical flow control type variable pump (2) Principle: Perform an operation of the value from pump high pressure sensor to P-Q curve control value. This is called "Positive Control System". P1 and P2 unloading proportional valves (PSV-D. The operation is maintained until the opening of spool sleeve is closed. the spool (652) also moves rightward by means of feedback lever. The timer relay is actuated one second later which causes the solenoid (SV-4) of the solenoid valve block (13) to be energized and makes the pilot operating circuit to stand by. The by-pass cut spool is usually held on CLOSE side after the engine started. drain circuit less than 0. the secondary pressures output by P1 and P2 unloading proportional valves (PSV-D. With this movement. (3) Operation: If the safety lock lever (red) is pushed forward after the engine starts.3 PUMP POSITIVE FLOW CONTROL This section describes the following. and the rising pressure is transformed to the rise of output voltage corresponding to the pressure input by the low pressure sensor. Mechatro controller signalprocesses this change of voltage. PSV-B) exert on PCb and PCa ports. Regarding the electrical symbols in this manual. select the pump positive control command current value from the low pressure sensor in lower order. and spool (652) is moved rightward by the force of pilot spring (646).2 Safety lock lever and pilot circuit 7. when the servo piston moves rightward. the operating secondary pressure of pilot valve rises. . therefore engine dose not stall. like by-pass cut valve. The mechatro controller converts the voltage output by the high pressure sensor to the P-Q curve control value. 7.3 Pump positive flow control 7. 2) Flow rate reduction operation As the current value I of mechtro controller reduces. (3) Operation: The pump high pressure sensor converts the pressure to the output voltage corresponding to the pump delivery pressure. 1) Flow rate rise operation (Eg. the secondary pressure of solenoid proportional valve reduces. (including proportional vlave) 5 MPa (725 psi) Orange Main pump drive pressure. refer to the electric circuit diagram. The delivery pressure P1 flows in the small bore of servo piston. make up circuit. the pump power is controlled so as not to be exceed the engine power. With the movement of spool. COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS Blue Feed. 0. from unexpected (2) Principle: Cut pressure source of pilot valve for operation. the secondary pressure of proportional solenoid valve also rises. and send a command to the pump solenoid proportional valve. and the piston moves leftward by delivery pressure P1 of the small bore resulting in the increase of tilt angle ( ).4 Pump P-Q (Pressure-Quantity) curve control (1) Type: Electric flow controlled variable displacement pump. 7. and the servo piston stops at the position the opening closed completely.1 OPERATION OF BY-PASS CUT VALVE AND UNLOADING VALVE HOUSED IN CONTROL VALVE (3) Operation: (1) By-pass cut valve On starting engine. Similarly.44~0. (2) Unloading valve On starting engine.

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 .

1 Travel forward pilot simultaneous operation circuit 8. (2) Principle: If the switch is turned. and switches the main circuit. and at the same time the command current is output to P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B). The secondary pressure from proportional valve which has exerted on PCb and PCa ports switches the unloading spool in CLOSE side. the motor’s self pressure pushes the 2nd speed select piston back to the 1st speed. T2-2-12 8. when the main circuit pressure rises above 28 MPa (4060 psi). The secondary pressure from proportional valve which has exerted on PBp1 and PBp2 ports holds the by-pass cut spool on CLOSE side. the secondary pilot proportional pressure comes out of the 3. 5) Travel parking brake. 2) The pilot secondary pressure flows to PAr and PAL ports of the control valve (2). 8. 5) The secondary pressure delivered in P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B) is fed to PBp1. and causes the motor to run in the 2nd speed tilting mode by its self pressure. (3) Operation: If the rabbit marked switch on the gauge cluster is pressed. 5 ports and acts upon the low pressure sensors (SE9) (SE-10).3 Travel main circuit 8.1 TRAVEL FORWARD PILOT SIMULTANEOUS OPERATION CIRCUIT (1) Purpose: Light operating force and shockless operation (2) Mechatronics : 1) If the travel lever with damping mechanism is operated for travel right. 1 ports of P/V (10). 2) Check valve that prevents cavitation of the hydraulic motor. 3) The low pressure sensor output voltage is input into mechatro controller. However.4 TRAVEL MOTOR FUNCTION (1) Function: 1) Prevents the motor from over running on a slope. actuating the pump on the delivery flow rate increase side. PCb.D ports of swivel joint (8) from AL. like the operation in the lever neutral position.E215B-E245B HYDRAULIC SYSTEM 8. The mechatro controller performs signal processing and outputs current corresponding to the increase of flow rate to P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2). The higher of the pressures is selected. PBp2 and PCa ports provided in control valve (2). TRAVEL CIRCUIT This section describes the following. 8. left and forward motions. enters the P port of the travel motor (4).3 TRAVEL MAIN CIRCUIT (1) Operation: The delivery oil from Pump A1 and A2 ports by changing the travel spool with the operation of travel pilot flows in each VA port on the left side of travel motor (4) through C. 8. and rotates the travel motor. 4) High/Low 2 step speed change mechanism and auto 1st speed return at high load. AR ports of C/V. moves the travel spool. Then the solenoid command pressure is issued from port A3. the solenoid (SV-3) of the proportional valve block (13) is excited and changes the proportional valve. It excites the 2-speed travel solenoid which in turn converts the primary pilot pressure and the self pressure to a tilting angle of the variable displacement motor. 3) Shockless relief valve and anti cavitation valve when inertia force stops. . an electric signal is issued. 4) The secondary pressures output by P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2) exert on pump regulator.2 2-SPEED TRAVEL SOLENOID COMMAND CIRCUIT AND AUTO 1st SPEED RETURN FUNCTION 1) Purpose: Change travel motor speed with switch. comes out of the 6. opens the oil passage to the 2nd speed select piston.2 2 speed travel solenoid command circuit and auto 1-speed return function 8.4 Travel motor function 8.

SM0082 T2-2-13 . RH & LH simultaneous operation.HYDRAULIC SYSTEM E215B-E245B TRAVEL CIRCUIT: Travel 2nd speed.

4) The secondary pressure delivered in P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B) is led to PBp1. proportional voltage from low pressure sensor inputs in mechatro controller. (2) Operation: Even if the engine speed specified by acceleration potentiometer is low speed. resulting in single flow of bucket circuit. and then the engine speed returns to the dial set position corresponding to the lever operation. 9. like the operation in the lever neutral position. bucket. making the simultaneous operation of boom up and bucket digging possible. T2-2-14 5) The secondary pressure delivered in travel priority proportional valve (PSV-C) is led to PTb port provided in control valve (2) and shifts the travel priority valve one stage.1 9.5 BUCKET SPOOL STROKE LIMITER (1) Purpose: To secure simultaneous operability of boom and arm on boosting up attachment pressure (Pump flow rate decreases.4 BUCKET DIGGING AND TRAVEL PRIORITY CONFLUENCE (CONFLUX) MAIN CIRCUIT (1) Operation: 1) The oil delivered through A1 port of P1 pump goes into P1 port of C/V (2).2 9. the relation of operation of low pressure sensor to both the increase of pump flow rate and unloading proportional valve is the same. <When lever is operated> When the pressure 0. . P2 unloading valve (PSV-B) and travel priority proportional valve (PSV-C). The secondary pressure from proportional valve which has exerted on PCb and PCa ports switches the unloading spool in CLOSE side. 2) The voltage output by low pressure sensor (SE-1) inputs in mechatro controller. command current value to have the pump delivery rate constant is output. In the following pages. • When the bucket operation and other operation are simultaneously performed. and at the same time the bucket spool is switched. similarly the cavitations can be prevented by actuating the stroke limiter. Therefore the explanation is omitted. pilot primary pressure exerts on PCc port of C/V(2) through attachment booster solenoid valve.3 9. 3) The secondary pressure output by P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2) exerts on pump regulator. swing. the travel priority valve does not actuate. As a result. (2) Operation: <When lever is set to neutral position> In the event where the sensor does not receive signal for 4 seconds or more even though the acceleration dial is set to MAX position.6MPa (87psi) is input to low pressure sensor in STD specification (travel. flows to PAc port. resulting in confluence with travel straight. P1 pump pressure increases. the pilot proportional secondary pressure is delivered through port 1 of the right pilot V (9). confluences with oil from P1 pump through travel priority valve. and goes into bucket spool. the travel priority valve also switches like digging operation. On the other hand.3 FLOW CONTROL IN THE WORK MODE (1) Principle: When the engine speed is intermediate speed or lower.E215B-E245B HYDRAULIC SYSTEM 9. (Confluence of oil from 2 pumps) 3) 3)With the function of pilot circuit. opens load check valve LCc through parallel circuit and enters in bucket spool. the oil flow is switched from bucket spool.) and to prevent cavitations at low engine speed (2) Operation: On boosting up attachment pressure. 9. BUCKET CIRCUIT This section describes the following. 9. the oil delivered through A2 port of P2 pump goes into P2 port of C/V (2).4 9. The secondary pressure from proportional valve which has exerted on PBp1 and PBp2 ports holds the by-pass cut spool on CLOSE side. PBp2 and PCa ports provided in control valve (2). Even though the engine speed is low. 9. 9. the actuator moves earlier than the movement equivalent to the control lever angle rate in light load operation. operates stroke limiter of bucket spool.5 Bucket digging pilot circuit Auto accel operation Flow control in the work mode Bucket digging travel priority main circuit Bucket spool stroke limiter 9. actuating the pump onto the delivery flow increase side. arm). and throttle oil path of spool. The mechatro controller performs signal processing and outputs current corresponding to the increase of pump flow rate to pump proportional valves (PSV-P1) and (PSV-P2) on the P1 and P2 pump sides. and acts on the low pressure sensor (SE-1).1 PILOT CIRCUIT FOR BUCKET DIGGING (1) Mechatronics : 1) When the operation for bucket digging is performed. as the delivery rate corresponds to the intermediate speed. 2) On the other hand. References: • In bucket dumping operation. PCb. and at the same time the command current is output to P1 unloading valve (PSV-D). and is fed into bucket cylinder head side through Ac port of C/V (2). the engine speed should be raised to 1000rpm. the return oil from cylinder rod (R) side is throttled by bucket spool and returns to tank circuit from Bc port of C/V (2).2 AUTO ACCELERATION OPERATION (1) Principle: Auto acceleration actuates according to signals from low pressure sensor.

HYDRAULIC SYSTEM E215B-E245B BUCKET CIRCUIT: Bucket digging (Travel priority conflux). Auto-accelation and Standby flow rate constant control SM0083 T2-2-15 .

and is led into (H) side of boom cylinder through C/V (2) Ab port. 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. pushes the load check valve CCb open from the boom conflux circuit. 10. Since P1 unloading valve is closed.E215B-E245B HYDRAULIC SYSTEM 10. 10. the boom spool is moved and bypass circuit is closed. opens lock valve of boom lock valve CRb. T2-2-16 . At the same time. the oil opens load check valve LCb through parallel circuit and flows into boom spool. 3) Meanwhile. BOOM CIRCUIT This section describes the boom raise conflux operation. the secondary pilot proportional pressure from the right pilot valve (9) gets out of port 4 and acts upon the low pressure sensor (SE3). 2) Then the oil passes through boom spool. The secondary pressure which enters the PB1 port shifts the boom conflux spool. 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.1 Boom up pilot circuit 10. and combines the oil delivered by the P1 pump internally.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. the oil then passes through the parallel circuit and via the restrictor on the circumference of the boom conflux spool. and branches into bypass circuit and parallel circuit.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. 4) The return oil from boom cylinder (R) side flows into tank circuit through boom spool from C/V (2) Bb port.

HYDRAULIC SYSTEM E215B-E245B BOOM CIRCUIT : Boom up operation. SM0084 T2-2-17 . Confluence function.

The oil then passes through the boom spool and goes out of the Bb port. the pressure acts upon the PBb port of C/V (2).3 Boom down pilot circuit 10. is recirculated to the Bb port and is supplied to the rod (R). the selector valve is changed over by the secondary proportional pressure of PBb port. The oil supplied to the boom cylinder rod (R) flows into the A1 port of the P1 pump and the P1 port of C/V. Then the poppet spring chamber of the lock valve CRb gets through the drain line (Dr) and makes the lock valve poppet open. pushes the check valve in the spool open.3 BOOM DOWN PILOT CIRCUIT (1) Operation: 1) If the boom down operation is performed.E215B-E245B HYDRAULIC SYSTEM This section describes boom lower operation. 2) The voltage output of the low pressure sensor (SE-4) enters the mechatro controller and processed in it. 10.5 Constant recirculation function of boom down main circuit 10. the secondary pilot proportional pressure comes out of port 2 of the right pilot valve (9) and acts upon the low pressure sensor (SE4). . At the same time. T2-2-18 10. Thus the boom cylinder is prevented from making a natural fall. 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. (3) Operation: When the oil is supplied to the boom cylinder rod (R) side during boom down operation. the oil returning from the head (H) goes through the recirculation path in the boom spool. When the (R) pressure is larger than the head (H) pressure.5 CONSTANT RECIRCULATION FUNCTION OF BOOM DOWN MAIN CIRCUIT (1) Purpose: Prevention of cavitation during boom lowering motion. the circuit pressure on the rod (R) side is on the negative side. On that occasion.4 Prevention of natural fall by lock valve and actuation at lowering 10. the boom moves faster than it should do in some cases by the self weight of the attachment. On that occasion. (2) Principle: The oil returning from the boom cylinder head (H) is recirculated to the rod (R). 10. the proportionl secondary pressure fed into C/V (2) PBb port and branches off in two lines and switches boom spool and releases boom lock valve. When the boom lever is at neutral. (3) Operation: In the boom down action. the drain line on the lock valve CRb poppet spring chamber is closed which causes the poppet closed. Thereupon.4 PREVENTION OF NATURAL FALL BY LOCK VALVE AND ACTUATION AT LOWERING (1) Purpose: Prevention of natural fall when the lever is neutral (2) Principle: The oil is prevented from returning to the boom spool by the poppet seat of the boom lock valve. the check valve in spool closes. the recirculation is stopped. 3) Then.

SM0085 T2-2-19 .HYDRAULIC SYSTEM E215B-E245B BOOM CIRCUIT: Boom down operation & Prevention of natural boom falling.

(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.E215B-E245B HYDRAULIC SYSTEM 11.3 Swing main circuit 11. the oil pushes the load check valve LCs open through the parallel circuit.4 SWING MOTOR CIRCUIT (1) Anti cavitation circuit at swing deceleration (2) Shockless relief valve that prevents the swing motor from being reversed.1 PILOT CIRCUIT FOR LEFT SWING (1) Operation: 1) When the left swing operation is performed. 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. 2) The voltage output by the low pressure sensor is input in the mechatro controller.2 Swing auto parking brake 11. the secondary pressure led into PBs port of C/V (2) switches the swing spool. 7). 3) Then. . and the secondary pressure acts on PBs port of C/V (2). and rotates the swing motor counterclockwise.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. This causes the mechanical brake to operate. 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. since the bypass line is closed T2-2-20 as the swing spool is shifted. 11. However.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. 11. enters the B port of the swing motor via the Bs port of C/V (2). and simultaneously flows out from Pss port of C/V and acts on low pressure sensor (SE-5). and is signal-processed.4 Swing motor circuit 11. the pilot proportional secondary pressure is delivered through port (1) of left pilot V (9). 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. 11. In the case of arm in operation.1 Swing left pilot circuit 11. SWING CIRCUIT This section describes the following operations. 11.

HYDRAULIC SYSTEM E215B-E245B SWING CIRCUIT: Swing operation (LH) SM0086 T2-2-21 .

it opens the check valve housed-in arm 2 spool and is recirculated in the head (H) side.2 ARM-IN.E215B-E245B HYDRAULIC SYSTEM 12. at light load. and is pilot signal-processed. INTERNAL CONFLUX MAIN CIRCUIT (1) Operation: 1) The P2 pump delivery oil flows in travel left section through P2 port of C/V (2) and is branched off in by-pass circuit and parallel circuit. ARM CIRCUIT This section describes the following operations. LIGHT-LOAD OPERATING PILOT CIRCUIT (1) Purpose: Speed-up and Anticavitation when the arm is at light loaded. causing restriction of passage to tank. LIGHT-LOAD VARIABLE NORMAL RECIRCULATION. changes over the arm spool and the arm lock valve CRar releases. 3) The return oil from arm cylinder (R) side flows in Ba port of C/V (2) and passes through the Ba port because the arm lock valve CRar is open. and is flowed into arm 2 spool through arm 1 spool. Then because arm 2 spool was switched. • Because. the delivery oil opens load check valve LCAT2. and the flows in travel straight section and travel right tandem path. T2-2-22 Reference: In light-load arm-in operation (normal recirculation.2 Arm in. when the attachment to which the circuit in P1 pump side is applied is operated. At the same time. (2) Principle: The oil returning from the arm cylinder rod (R) is recirculated variably to the head (H) at arm 2 spool in C/V. and then is flowed into arm cylinder head (H) side through Aa port of C/V (2). the pressure is branched off in two flows. P2 pump proportional valve (PSV-P1). resulting in cavitations prevention. the delivery oil which goes through parallel circuit opens load check valve LCa and is flowed into arm 1 spool. resulting in the speed up of arm-in operation at light load. which is reduced by arm 2 inverse proportional valve (PSV-A) switches arm 2 spool. (3) Operation: 1) When the arm in operation is performed. 2) On the other hand. but because arm 1 spool is switched. Spool position at arm in. acts upon the PAa1 port and the PLc2 port. light-load variable normal recirculation main circuit / internal conflux main circuit 12. P1 pump delivery oil flows in P1 port of C/V (2). the pressure in cylinder rod (R) side is higher than that in the head (H) side. accordingly the arm 2 spool is switched to neutral (cavitations prevention) position. Position of arm 2 spool Neutral position (Anticavitation position) Normal recirculation position Recirculation From arm out P/V From arm 2 inverse proportional valve SM0195 12. the meter-in path of arm 2 spool is closed. and confluences with P2 pump delivery oil in the valve section. 5) Cavitations prevention control in arm-in operation. light load and combined operation (This position is not shown in hydraulic diagram) Neutral position Arm 2 spool Meter-in passage (Close) Normal recirculation opsition SM0196 . (PSV-P2) and arm 2 inverse proportional valve (PSV-A). Command current is output to arm 2 solenoid proportional valve by signal processing of E/G speed and arm-in pilot pressure. the secondary pilot proportional pressure gets out of port 4 of the left pilot valve (9) and acts upon the low pressure sensor (SE-7). the return oil from arm cylinder (R) side flows into arm cylinder (H) side. light-load operating pilot circuit 12. resulting in single flow operation.1 Arm in. 12. conflux). and is output to P1. 2) The output voltage by the low pressure sensor is input into mechatro controller.1 ARM IN. 3) The secondary pressure from pilot proportional valve. goes through arm 2 spool. 4) Because arm 2 spool is switched to normal recirculation position.

Arm variable recirculation & Anti cavitation function SM0087 T2-2-23 .HYDRAULIC SYSTEM E215B-E245B ARM CIRCUIT: Arm in (Light load) operation.

heavy load operating pilot circuit (recirculation cut) 12. and flows in the arm spool. the return oil goes through arm lock valve CRar and flows in arm 2 spool.4 ARM IN. 2) Left pilot valve actuation due to arm-in operation is equivalent to that at light load operation. Position of arm 2 spool Neutral position 12. When the recirculation is cut.3 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) The return oil from arm cylinder (R) side flows in Ba port of C/V(2) and is flowed to arm lock valve CRar. 12. P1 pump delivery oil flows in P1 port of C/V (2). consequently the current of arm 2 solenoid proportional valve is controlled according to the load pressure and the arm variable recirculation is cut. and confluences with P2 pump delivery oil in the valve section. heavy load operating sequence confluxed main circuit 4) The return oil returns directly into tank circuit because arm 2 spool is switched to recirculation cut position. HEAVY LOAD OPERATING PILOT CIRCUIT (1) Operation: 1) 1)In arm-in operation. Then because arm 2 spool was switched. 12. and is flowed into arm cylinder head (H) side through Aa port of C/V(2).E215B-E245B HYDRAULIC SYSTEM This section describes the following operations. T2-2-24 From arm out P/V Recirculation cut position From arm 2 inverse proportional valve SM0197 .3 ARM IN. the voltage output by P2 pump pressure sensor (SE-23) is converted to signal (signal processing) by mechatro controller. when the heavy loading is applied to arm and the P2 pump pressure increases to the set 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. the delivery oil opens load check valve LCAT2. and flow in travel right tandem passage through travel straight section. internal confluence is held similarly to that in light load operation.4 Arm in. 2) On the other hand. but because the arm lock valve CRar is open. Consequently the arm spool is switched and pushes and opens load check valve LCa through parallel circuit.

Arm confluence & recirculation cut function SM0088 T2-2-25 .HYDRAULIC SYSTEM E215B-E245B ARM CIRCUIT: Arm in (Heavy load) operation.

P2 pump delivery oil flows through arm 1 spool and confluences with P1 delivery oil. (2) Principle: Complete seat of the return circuit against the arm spool of the arm cylinder (R) side circuit. the operating secondary pressure flowed in PBa2 port of C/V (2) switches the arm 2 spool valve. 12.5 ARM OUT PILOT CIRCUIT (1) Operation: 1) When the arm out operation is performed.6 Arm out 2 pumps conflux main circuit 12. 2) The operating proportional secondary pressure flowed in PBa1 port of C/V (2) switches the arm 1 spool. (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.6 ARM OUT 2 PUMPS CONFLUX MAIN CIRCUIT (1) Purpose: Arm out operation speed up. 2) Since the oil flow into the arm spool from the lock valve is shut off completely. 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). the oil is branched off in two flows and act upon the PBa1 and PBa2 ports of C/V (2). 3) Then. acts the back pressure on the lock valve CRar and seats the lock valve.5 Arm out pilot circuit 12. (3) Operation: 1) When the secondary pressure for arm operation disappears and the arm cylinder stops. the return oil from arm cylinder (H) side flows in Aa port. 3) On the other hand. natural fall of the arm due to oil leaks through the arm spool is prevented. At the same time. and returns into tank circuit through arm 1 spool and arm 2 spool.E215B-E245B HYDRAULIC SYSTEM This section describes the following operations.7 Natural fall protection with arm lock valve 12. and acts upon the low pressure sensor (SE8). (2) Principle: The oil delivered by the P1 pump is confluxed with that delivered by the P2 pump in C/V (2). the pressure on the rod (R) side passes through the selector of the lock valve from the Ba port of C/V.7 NATURAL FALL PROTECTION WITH ARM LOCK VALVE (1) Purpose: To prevent the arm from falling naturally by the weight of the arm and bucket. T2-2-26 12. 2) And. . The return line which does not pass through boost check valve is used for this return circuit to reduce the pressure loss. the secondary pilot proportional pressure gets out of port 8 of the left pilot valve (9). 12.

HYDRAULIC SYSTEM E215B-E245B ARM CIRCUIT: Arm out operation. Confluence function SM0089 T2-2-27 .

P2 pump delivery oil exerts on travel operation. 2) The delivery oil flowed into P1 parallel circuit of P1 pump opens check valve CT1 and LCb and flows in boom spool. The speed of attachments like travel. etc.2 Boom up / travel. And the secondary pressure of solenoid valve in short-circuit valve switches spool of short-circuit valve 1 step.2 BOOM UP / TRAVEL. COMBINED CIRCUIT This section describes only the difference in combined operation.) 4) However.1 Boom up / travel. P1 pump delivery oil exerts on operation of attachment. . boom. And the solenoid proportional valve outputs secondary pressure and acts on PTb port and short-circuit valve. 13. is adjusted by the circuit of restriction. The delivery oil flowed into travel priority spool of P1 pump opens check valve CT2 because the travel priority spool is shifted.E215B-E245B HYDRAULIC SYSTEM 13. (2) Principle: The travel action and the attachment action are actuated by separate pumps. 2) Then the pressure of PTb port switches the travel priority valve. which exerts on boom up operation. (In travel straight operation. a portion of the flow is led to the spool of short-circuit valve notch restriction. PILOT CIRCUIT (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 shortcircuit solenoid proportional valve (PSV-R) after signal processing. and flows in boom conflux spool and exerts on boom up operation with the internal oil conflux. The delivery oil flowed into travel priority spool of P2 pump flows in right travel spool T2-2-28 because the travel straight spool is shifted and exerts on the right travel operation. pilot circuit 13. (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. (In travel straight operation.1 BOOM UP / TRAVEL.) 3) The delivery oil flowed into P2 tandem circuit of P2 pump flows in left travel spool to travel leftward. MAIN CIRCUIT (1) Purpose: To insure straight travel movement during travel operation even if the attachment is operated. main circit 13. 13. 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.

HYDRAULIC SYSTEM E215B-E245B COMBINED CIRCUIT: Boom up & Travel forward 1st speed operation. Travel priority function. SM0090 T2-2-29 .

3 Swing / Arm in light load.E215B-E245B HYDRAULIC SYSTEM In this section. and this proportional valve outputs secondary pressure.4 Swing / Arm in. the flow goes to the swing circuit and arm circuit simultaneously because the swing circuit and arm circuit are parallel. 2) PTb port pressure switches the travel priority spool. 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". and give a priority of the delivery of P2 pump to swing operation. But on P2 pump circuit side. 13. the pressure of return oil is raised. PILOT CIRCUIT (1) Operation: 1) On operating swing (left) and arm in motions simultaneously. 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. causing the rise of circuit pressure on the arm cylinder head (H) side. mechatro controller outputs command current to travel priority solenoid proportional valve (PSV-C) and arm 2 solenoid inverse proportional valve according to signal processing. 13.4 SWING / ARM IN. 2) At the same time meter-in of arm 2 spool closes and arm in conflux is therefore cancelled. T2-2-30 Position of arm 2 spool Position of forced recirculation Neutral position From arm out P/V Meter-in passage (Close) From arm 2 inverse proportional valve Arm 2 spool Normal recirculation position SM0198 . the independent operation is omitted and describes difference in combined operation. (3) Operation: 1) The swing main circuit operates with P2 pump flow. pilot circuit 13. 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. which acts on PTb port and PAa2 port of C/V(2). and the PAa2 port pressure switches the arm 2 spool to the forced recirculation position. (2) Principle: Raise the oil pressure flowing to arm cylinder. SWING PRIORITY MAIN CIRCUIT (1) Purpose: Stable swing speed. swing priority main circuit 13.3 SWING / ARM IN LIGHT LOAD.

swing priority function SM0091 T2-2-31 .HYDRAULIC SYSTEM E215B-E245B COMBINED CIRCUIT: Swing / Arm in operation.

press the SELECT switch [ ] 3 times. 14. PRESS. and highlight "ADJUSTING MODE 1". In that case. 3) Stand-by command value to P1.) 3) When "ADJUSTING MODE 1" screen is displayed. Repeat the pressure releasing procedure once again. the oil delivered by each pump is unloaded to the tank passage. When "LANGUAGE/LOGO". turn the starter key ON. PRESSURE DRAINING (RELEASING) CIRCUIT This section describes the following operations. How to switch to "Pressure release mode" 1) Select the service diagnosis mode 1. press [ ] or [ ] switch. the main circuit pressure may be released. PCa ports of C/V(2) and switches the P1." is displayed on the gauge cluster while the mode switch is changed to pressure relieving mode. If the spools are switched by pilot operation. (Keeping pressing of the "BUZZER STOP SWITCH" [ ] on gauge cluster. When right and left operating levers are operated 4 or 5 times to their full stroke. 4) Press "SELECT Switch" and highlight "OFF". i. In this time the intermittent buzzer sounds continuously. pressure is relieved. turn off the starter key and buzzer sound stops. and press [ ] switch to change to "DRAIN HYD. 2) Output "Pressure relief control speed command value" at engine governor motor (M2). After draining pressure is completed. (2) Principle: After the mode is switched to "Pressure Relief Mode" with switch on gauge cluster. P2 unloading valves to OPEN position.) 2) Select the service Adjustment Mode 1.1 Pressure releasing pilot circuit 14. (2) Hydraulics: If the Unloading valves are turned to the pressure release position.e. PRESS. "DRAINING HYD. PSV-P2). mechatro controller outputs the following commands. "ADJUSTING MODE 1" and "PRESET BY FACTORY" are displayed. ON". When the operating lever is shifted to neutral during engine running. 1) Minimum tilting command value to pump proportional valve (PSV-P1. OFF " screen appears. and then press " SELECT Switch" again.2 Pressure releasing main circuit 14. press [ ] or [ ] switch. 2) Unloading proportional valves (PSV-D. (Under the condition that "Screen No.2 PRESSURE RELEASING MAIN CIRCUIT (1) Operation: CAUTION: before to perform the hydraulic pressure releasing. P2 unloading proportional valves. (3) Operation: 1) Pump proportional valve reduces the pump flow rate to the minimum.E215B-E245B HYDRAULIC SYSTEM 14. also the buzzer is not stopped unless the engine key is turned to OFF. . PSV-B) output secondary pressure and the secondary pressure flows in PCb. make sure to place bucket on the ground. keeping pressing of the "BUZZER STOP SWITCH". PRESS" is displayed and the buzzer sounds continuously. PRESS.1 PRESSURE RELEASING PILOT CIRCUIT (1) Purpose: To release the pressure in main circuit for piping repair works. and then press "SELECT Switch" again. T2-2-32 14. SE 23) (or the high pressure sensors are broken) "FAIL DRAIN HYD.1" of "Service diagnosis mode 1" is indicated. the remaining pressure from the actuators may be relieved to the tank circuit. If the pump pressure is determined to be more than 1 MPa (145 psi) by the output value of the high pressure sensor (SE 22. several times and "DRAIN HYD.

HYDRAULIC SYSTEM E215B-E245B PRESSURE DRAINING (RELEASING) CIRCUIT: at pressure release mode 651 652 611 643 646 532 SM0092 T2-2-33 .

E215B-E245B T2-2-34 HYDRAULIC SYSTEM .

AIR CONDITIONER SYSTEM E215B-E245B BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) Air-conditioner is the unit which places evaporator and heater core parallel. • Heater system The heater recycles (circulates) the cooling water in the engine. • Cooler Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit. and then the heated air blows off from grille through duct. The intake air is heated and the heated air blows off from the grille provided on the inside of cab. AIR CYCLE • Heater Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is performed with hot air (heating) at the heater core of air-con unit. and unifies a blower fan and an inside /outside air switching unit. The blow off air temperature is controlled by the temperature control switch on the control panel. And this unit changes hot air to cool air. and then the cooled air blows off from grille through duct. and the hot water delivered by the engine flows in the heater core of air-con unit and then heat exchange is performed. T3-8-1 . and the operation is controlled by air mixing damper on the air-con unit.

E215B-E245B AIR CONDITIONER SYSTEM AUTO AIR CONDITIONER SYSTEM OUTLINE AIR CONDITIONER CONTROL PANEL 25.0℃ COMPRESSOR COMPRESSOR DRIVE SOURCE SOLAR RADIATION SENSOR REFRIGERANT PRESSURE SWITCH AIR MIXED DAMPER SIGNAL AIR-CON AIR OUTLET SWITCHING SIGNAL BLOWER REVOLUTION SIGNAL CONTROLLER INNER AIR SENSOR EVAPORATION SENSOR INNER AIR AND OUTER AIR SWITCHING SIGNAL MOTOR ACTUATOR VENT OUTER AIR INTAKE INNER AIR MOTOR ACTUATOR AIR CONDITIONER UNIT FACE FOOT MOTOR BLOWER ACTUATOR CONTROLLER SM0024 T3-8-2 .

ty 27 Air conditioner assy 1 32 Compressor 1 35-6 D hose 1 27-1 Air conditioner unit 1 33 Pulley 1 35-7 L hose 1 27-2 Hose 2 34 Condenser 1 35-8 L hose: Ø 15.AIR CONDITIONER SYSTEM E215B-E245B COMPONENT AND CONSTRUCTION COMPONENT 27 30 33 27-1 40 32 39 27-6 27-3 27-5 27-2 35 35-6 35-7 35-1 35-5 35-2 35-8 34 35-9 35-10 SM0025 Air conditioner group No. Parts Q. Parts Q.5 1 40 Solar radiation sensor 1 T3-8-3 1 .5 27-6 Tube assy 1 35-2 Bracket 1 39 Filter 1 30 Panel assy 1 35-5 S hose: Ø 24.ty No.ty No. Parts Q.5 1 27-3 Clamp 2 35 Air dryer assy 1 35-9 S tube: Ø 16 1 27-5 Filter 1 35-1 Receiver dryer 1 35-10 L tube: Ø 8.

E215B-E245B AIR CONDITIONER SYSTEM CONSTRUCTION (1) Air conditioner unit 49 48 6 47 46 44 42 31 31 41 50 3 45 F 1 1 43 1 G 32 1 28 39 1 37 38 B 36 27 H 9 40 A I 2 33 SM0022 Air conditioner unit (1/2) T3-8-4 .

AIR CONDITIONER SYSTEM 1 1 1 31 E215B-E245B 14 16 5 15 31 1 3 1 61 1 F 1 C D 4 7 G 1 1 1 26 20 13 59 29 11 21 22 H 23 1 24 B 1 8 60 D 17 18 A I C 10 31 19 12 3 31 1 25 52 SM0021 Air conditioner unit (2/2) T3-8-5 .

ty No. Q.Refrigerant OUTLET A 2 B 2 -M6 1 3 4 5 6 SM0037 T3-8-6 .Filter 6 .Pressure switch 2 .Receiver tank A .ty 1 Screw M5×16 Parts 23 19 Relay Parts 2 40 KK-box lower packing 1 2 Main harness 1 20 Evaporator 1 41 Vent lever 1 3 MA air mix 3 21 Expansion valve 1 42 Face lever 1 4 Blower controller 1 22 O-ring 1 43 Foot joint lever 1 5 Upper casing 1 23 O-ring 1 44 MA mode lever 1 6 Air mix door 1 24 Screw M5×40 2 45 Foot lever 1 7 Air mix lever 1 25 Thermistor 1 46 Face lever cam 1 8 Lower casing 1 26 Thermistor holder 1 47 Vent lever cam 1 9 Air mix door sub 1 27 Heater core 1 48 Face rod 1 10 Air mix lever sub 1 28 Pipe holder 1 49 Vent rod 1 11 Blower 1 29 Thermistor 1 50 Foot rod 1 12 Lever MA air mix 1 31 Screw M4×30 9 52 Inner air filter 1 13 Intake door 1 32 Upper casing 1 55 Screw M6×25 10 14 MA intake lever 1 33 Lower casing 1 56 Screw M8×25 10 15 Intake lever 1 36 Foot door 1 59 Evaporator packing 1 16 Intake rod 1 37 Vent door 1 60 Casing packing A 1 17 Air mix rod 1 38 Face door 1 61 Casing packing B 1 18 Air mix rod sub 1 39 KK box upper packing 1 Receiver dryer 1 .Refrigerant INLET B .ty No.Suction pipe 5 . AIR CONDITIONER SYSTEM Q.Desiccant 4 . Parts Q.Sight glass 3 .E215B-E245B No.

• It is easy to find out leakage. • It is easy to liquefy (condense).14 °C Critical pressure 4. cools down an object. T3-8-7 Specific volume vapor (25 °C) of saturated Latent heat of vaporization (0 °C) Flammability 1206 kg/m3 0. i. • It is free from toxicity. • It is stable chemically and does not corrode and permeate into the circuit parts.) • It is easy to gasify (evaporate).065 MPa Kind of Refrigerant Critical density 511 kg/m3 Many kinds of refrigerants that change in that way are available. (It does not require very high pressure for condensation. always use a designated refrigerant for the cooling unit.) • It has small specific heat. sufficient refrigeration will not be performed or the equipment in which the refrigerant is used may be broken. (It evaporates sufficiently at not too low pressure. The temperature at which condensation begins is unique to each substance (fluid) at a given pressure.0310 m3/kg 197. it begins to condensate at a certain temperature to take a liquid state. • It has small specific volume. ones having characteristics that suit the intended cooling unit are chosen and used. objectionable odor.03 Boiling point –26. the fluid (general term of gas and liquid) has the following qualities: 1. but the following requirements are needed for use in such applications: • Latent heat of vaporization (heat of vaporization) is large.) • It has a high critical temperature and a low solidification point. As a gas under certain pressure is cooled down.19 °C Critical temperature 101. If a refrigerant other that those designated is used. flammability and explosiveness and excels in thermal conductivity and electric insulation. the loss resulting from it must be held down to a minimum. The temperature determined by a given pressure is called saturation temperature. Table shows the principal characteristics of the R134a refrigerant that is used in this machine.e. Out of refrigerants meeting the above-mentioned requirements. the refrigerant that flows through the cooling circuit changes its phases from liquid to gas and vice versa during which process heat is transferred from the low temperature part (compartment) to the high temperature part (outside of the vehicle). Therefore.5 kJ/kg Non flammable Ozone destruction coefficient 0 P (MPa) R134a 4 3 LIQUID 2 GAS 1 0 15 18 35 50 T (°C) SM0038 . Density of saturated liquid (25 °C) CHARACTERISTICS OF REFRIGERANT In general. HFC-134a (R134a) CH2FCF3 Chemical formula Molecular weight 102. (Since the refrigerant itself is cooled by the expansion valve.AIR CONDITIONER SYSTEM E215B-E245B FUNCTION Mechanism of cooling circuit MECHANISM OF COOLING In the cooling process.

while at the temperature and the pressure on the upper lefthand side of the curve. T3-8-8 . the refrigerant must transform (evaporate) from a liquid to a gaseous state at a lower temperature. At the temperature and the pressure on the lower righthand side of the curve in figure.Expansion valve Cooling circuit The figure illustrates the cooling circuit of the car airconditioner. This pressure is called saturation pressure. Let us think of a case where an air-conditioner is operated in the midst of summer. In order to cool the inside of the compartment down to 25 °C.Compressor 5 . (If a refrigerant that requires a pressure below the atmospheric pressure to cool it to a required temperature is used.Inside of the compartment (cab) 2 . cooled air is constantly delivered to the circumference of the evaporator by the blower fan.Blower 4 .Evaporator 3 . it can be seen from the figure that the pressure of the refrigerant in the evaporator must be less than 0. 1 2 3 9 6 4 5 7 8 SM0039 1 . Figure beside illustrates the relationships between the saturation temperature and the saturation pressure in the case of refrigerant R134a used in the air-conditioner.Cooling fan 6 . above. thereby deteriorating the performance of the cooling unit. As the refrigerant evaporates. In this circuit diagram. the refrigerant take a gaseous state. the refrigerant can not absorb evaporation heat from the air unless it evaporates at a temperature lower that 15 °C. Since the part at which vaporization of the refrigerant takes place is the evaporator. Furthermore.Condenser 8 .E215B-E245B 2. the cooling effect deteriorates unless the feed rate of the refrigerant is controlled so that all of the refrigerant supplied to the evaporator vaporizes and turns into dry vapor. it absorbs evaporation heat from the air of the compartment. the refrigerant takes a liquid state. It can be seen from the figure that R134a under a pressure above the atmospheric pressure is capable of cooling the inside of the compartment sufficiently.) In the process in which gaseous refrigerant is brought back to a liquid state. For instance. In the meantime.Inside of engine room 7 . the portion that cools the air of the compartment is the evaporator. air is mixed into the circuits. AIR CONDITIONER SYSTEM Inversely to 1. in order to cool the air to 15 °C.Receiver dryer 9 .51 MPa. when "cooling" effect is attained. For that purpose. the refrigerant is cooled and condensed by the outer air exceeding 35 °C. the pressure at which a gas condenses for a temperature is determined. as seen from the figure. The object air is cooled off by utilizing the fact that the refrigerant takes heat off the surrounding area as evaporation heat as it evaporates in the cooling circuit. liquid refrigerant (slightly wet vaporized refrigerant) is fed into the evaporator. Accordingly the refrigerant is capable of condensing at a pressure exceeding 1 Mpa.

Socket bolt M5 x 40 In order for the evaporator to fulfill its performances. The compressive action of the compressor and the heat exchange (heat radiation) action of the condenser transform the refrigerant in a dry vapor state back to a liquid state.e. In order to attain proper control. the evaporator is equipped with fins on the air side in order to increase the heat transfer area of the air side and thereby perform excellent thermal transfer between the refrigerant and the air. The cooling effect deteriorates if the water drops freeze.Expansion valve 4 . it is necessary to reduce the pressure drop of the refrigerant of the evaporator. Therefore. The feed rate of the refrigerant is controlled by the expansion valve. If the feed rate is too low. but also damages the compressor valves. To that end. unvaporized liquid refrigerant returns to the compressor (liquid back). If the feed rate is too high. Therefore. This not only deteriorates the cooling effect. The humidity in the air condenses as the air cools down and adheres to the outside of the evaporator as water drops. but the pressure in the evaporator is held low by the throttling action of the expansion valve and the suction action of the compressor. the refrigerant completes vaporization early in the evaporator which results in deterioration of the cooling effect. reducing the pressure drop is one element that makes the evaporator attain its full performances. The amount of refrigerant supplied to the evaporator is controlled by the expansion valve which is described in the following.O-ring 3 . a proper amount of low-pressure low-temperature liquid refrigerant must be fed to the evaporator. low-pressure liquid-state refrigerant. so as to decrease the pressure in the evaporator) and that an adequate amount of refrigerant can be fed to the evaporator. EXPANSION VALVE 1 2 3 4 SM0026 1 . it is necessary that satisfactory heat transfer between the object and the refrigerant take place in the evaporator. The compressor acts as a pump that allows the refrigerant to circulate. Component parts EVAPORATOR The evaporator is an important heat exchanger that absorbs the heat of the compartment air (object) by the utilization of the latent vaporization heat of the low-temperature. how to discharge water is an important point.AIR CONDITIONER SYSTEM E215B-E245B Consequently.Evaporator 2 . T3-8-9 . Accordingly. the cooling circuit is so constructed that the evaporator can cool down an object (air in this case) sufficiently (i.

This action is carried out by sensing the refrigerant temperature at the outlet of the evaporator as against the inlet pressure of the evaporator and consequently controlling the feed rate of the refrigerant.E215B-E245B AIR CONDITIONER SYSTEM The expansion valve feeds the flowing highpressure high-temperature liquid refrigerant to the evaporator as low-pressure low-temperature liquid refrigerant (damp vapor of low dryness). The change in the pressure causes the force acting upon the diaphragm to vary accordingly. The expansion valve senses the pressure and the temperature at the outlet of the evaporator and controls the overheating of the refrigerant and the refrigerant supply to the evaporator more securely. part of the refrigerant evaporates by the very heat of the refrigerant and cooled off. the refrigerant is properly overheated (3 ~ 8 degrees) and goes out of the evaporator. the better.Refrigerant inlet 6 . The expansion valve controls the feed rate of the refrigerant at the same time.Refrigerant outlet 4 . On that occasion. The temperature sensing part is provided in the shaft of the expansion valve to directly detect the refrigerant temperature at the outlet of the evaporator.Ball valve 7 . The diaphragm contains R134a in saturated state. it is difficult to control the overheating or the feed rate of the refrigerant.Diaphragm 2 .Evaporator side 3 . The opening of the valve is determined by the equilibrium between the pressure (low) of the evaporator side. The figure beside shows how the block type expansion valve is constructed. the action of the adjust spring and the pressing force of the diaphragm (the temperature of the refrigerant at the outlet of the evaporator to be sensed by the thermowell). The feed rate is controlled automatically so that under the pressure in the evaporator. The result is that lowpressure low-temperature damp refrigerant vapor is fed to the evaporator. The high-pressure high-temperature liquid refrigerant that is fed from the receiver side reduces the pressure abruptly as it passes through the valve (throttling action). For this reason. the smaller the pressure drop of the evaporator.Shaft 5 . The pressure in the diaphragm changes according to the temperature detected by the sensor. This means that if the refrigerant pressure drop in the evaporator is excessive. The air-conditioner of this machine adopts a block type expansion valve.Spring T3-8-10 SM0041 . 1 2 3 4 5 6 7 SM0040 1 .

S Hose 3 . The direction in which heat moves is from the refrigerant to air. as combined with the throttling action. That is to say.Compressor CONDENSER This is a heat exchanger that cools the vaporized refrigerant at high temperature and high pressure by the use of outer air and condenses the refrigerant. The suction action. since the compressive action takes place only for a short period.AIR CONDITIONER SYSTEM E215B-E245B COMPRESSOR The compressor performs the following three functions in the cooling circuit: 1. transforms vaporized refrigerant back to a liquid state again. SM0023 T3-8-11 . 2. However. works to decrease the refrigerant pressure in the evaporator. 1 2 3 SM0042 1 . This enables enables continuous cooling. This permits the refrigerant to vaporize at low temperature in order to perform cooling effect. The condenser then serves to cool down the refrigerant. Suction action 2. the air in the compartment can not be cooled sufficiently by the evaporator. it becomes possible to cool down the refrigerant by the use of an outer air of 35 °C and liquefy it.D Hose 2 . so that the refrigerant discharged by the compressor turns into high-temperature high-pressure vapor and is delivered to the condenser. For that purpose. If the refrigerant is not cooled well by the condenser. Compressive action 1. the refrigerant hardly exchanges heat with outer air. it is necessary to secure ventilation required for the cooling of the refrigerant. the opposite to the case of the evaporator. 3. as combined with the action of the condenser which is mentioned hereunder. it takes a near form of thermally insulated compression. The compressive action. For instance. The saturation temperature gets higher as the pressure increases. The compressive action of the compressor works to turn low pressure vaporized refrigerant to high pressure vapor refrigerant. The pumping action serves to cause all the refrigerant to circulate in the cooling circuit. Pumping action 3. Fins are equipped on the outer air side to improve thermal transfer.

the receiver tank stores extra refrigerant temporarily and supplies it when the cooling circuit needs much refrigerant.14 MPa). The air-conditioner uses a molecular sieve as desiccant suited for the circuit. It is desirable that the amount of water mixed in the refrigerant should be held below a concentration of 30ppm. 6 Sight Glass This is a inspection window with which the refrigerant level in the circuit is determined.Desiccant 6 . The pressure switch protects the circuit by cutting off the power supply to the compressor when high pressure increases abnormally high (more than 3.E215B-E245B AIR CONDITIONER SYSTEM RECEIVER DRYER 1.Receiver tank T3-8-12 . Pressure Switch This machine employs pressure switches of high/low pressure type. 2. Filter 5. the revolution of the compressor varies greatly which causes the proper flow of refrigerant in the cooling circuit to vary. 8 4. 1 2 3 4 Dryer If water is mixed in the cooling circuit.Suction pipe 7 . When the cooling circuit does not need much refrigerant.Filter 8 . corrodes the metallic parts of the circuit or clogs the circuit as the water freezes in the expansion valve.Sight glass 3 . The receiver tank also stores an extra amount of refrigerant to be used for filling balance and supplement small amounts of leakage of the refrigerant through penetration into rubber hoses. 3. the only means of confirming the inside of the circuit visually.Pressure switch 5 . in order to absorb water content that intrudes into the circuit when the dryer is installed or when refrigerant is charged.Refrigerant inlet 2 . Receiver Tank On the air-conditioner. The pressure switch also detects the leakage of refrigerant by cutting the power supply to the compressor when the pressure of the circuit falls below 0.196 MPa.Refrigerant outlet 4 . it deteriorates the compressor valves and oil. It is the receiver tank that receives the variations. 5 7 SM0043 1 .

8~11. M5 1.9 (29~40) REPLACED PARTS AMOUNT TO BE FILLED IN EVAPORATOR 40 cc (2. Tightening Torque 1) Pipe Joints When connecting pipe joints.2cu·in) T3-8-13 . In case SP20 has adhered to such surfaces. 2.2~8.8 (7.8~11.5 (14~18) D hose and condenser 19.2~8.7~11) S hose and air-conditioner unit 29.3 (22~25) Expansion valve 1.6~24. remove the valve at the pipe port immediately before connecting pipes. Special Refrigerator Oil This air-conditioner uses special refrigerator oil SP20 for use with new refrigerant R134a.8~8.) 2) Use care so SP20 does not adhere to the painted surface and resin parts. Unit: N·m (lbf·ft) TIGHTENING TORQUE PIPE FASTENING PART D hose and compressor (M8 bolt) 19. M4 0.7~11) L hose and receiver dyer (M6 bolt) 7.8 (7.5 (14~18) M8 (mounting part of A/C unit) 9.8) Unit: N·m (lbf·ft) TIGHTENING TORQUE SCREW SIZE N4.4cu·in) CONDENSER 40 cc (2.7) L hose and air-conditioner unit 11.7 (8. Oils other than SP20 may not be used. 6.7) M8 (other than those mentioned above) 11. Before performing operation.AIR CONDITIONER SYSTEM E215B-E245B DISASSEMBLY AND ASSEMBLY PRECAUTIONS TO BE EXERCISED IN OPERATION 1.8) M6 (mounting part of L hose joint) 7.8 (5. Once the air-conditioner is operated. If the oil volume is small. If the oil volume is large.45 (1.8~8.85~11. stop the engine and turn off all power supplies to the equipment related to the air-conditioner. If you have removed a pipe joint for repair. confirm that all faults have been repaired completely.5 (14~18) L hose and condenser 11.7) M6 (except mounting part of L hose joint) 9. The receiver dryer is filled with desiccant to absorb moisture in the circuit.18 (0.8~14.D hose joints) 19.4cu·in) COMPRESSOR Drain out the volume of oil left in the compressor to be replaced.96~2.45 (1. coat the O-ring with special oil (SP20) and fasten to the tightening torque indicated in the table.7 (8.7) M8 (mounting part of S.6~24. the cooling ability will be deteriorated.7 (8. the following points must be noted: 1) Do not keep open all pipe connections on a new compressor and the component parts of the installed refrigeration circuit (Remove valves and caps at the pipe openings of the compressor.8~11. just before connecting pipes. adjust the oil level to that of table. part of the oil is dispersed in the refrigeration circuit. using a double spanner.2~53.4~1.58~0.2cu·in) HOSES 20 cc (1. 3.6~24. RECEIVER DRYER 20 cc (1.8~14.78~1. Therefore. T5 machine screw.8 (5.4~34. Since SP20 tends to absorb moisture and may corrode paint and resin.87 N5. wipe it off immediately. seizure at high revolution and shortening of service life will occur.7~12) M10 39. T4 machine screw. put a cap to both ports immediately. Therefore. when replacing the parts in right Table. by operating the air-conditioner. After the operation is over. 2) Screws and Bolts Fasten to the tightening torque indicated in the table 4.96~2. 5.4~1. from the new compressor.8~15.2cu•in) of oil. Amount of Oil for Compressor The compressor SD7H (HD type) is filled with 135cc (8.

2 7 1 SM0027 2. and separate the mode selector box from the unit (2). 3 5 Removing main harness Pull out 3 harness clamps (7) from the unit (2). Removing selector box Remove 6 plus screws (3). 11 12 2b 10 9 2a T3-8-14 SM0029 . Pull out the upper unit casing (2b) upward giving attention to the thermistor harness so as not to be caught by the casing.E215B-E245B AIR CONDITIONER SYSTEM DISASSEMBLY AND ASSEMBLY OF UNIT 1. 3. 2) Remove 12 plus screws (12) which are used to install the upper and lower unit casings (2a). Removing inner air filter Slide the inner air filter (1) leftward and remove it from the unit (2). Removing upper unit case 1) Remove air MIX rod (9) and air MIX rod sub (10) from air MIX lever (11). and disconnect all connected connectors and remove harness (8) on the body from the unit (2). remove connector (4) connected to the mode actuator (5) on mode selector box (6). 8 4 6 2 SM0028 4.

SM0032 and install the evaporator sensor (21) again. 2) Install new blower controller by the reverse procedure of removal. Replacing blower controller 1) Remove 2 plus screws (14) and remove the blower controller (15) from the upper unit casing (2b). 2) Remove evaporator sensor (21) with sensor holder (22) from the removed evaporator (20). and remove pipe clam (18) which is used to secure the heater core and then remove the heater core (16) from the lower unit casing (2a). 3) Install it by the reverse procedure of removal. 8. 16 17 18 20 19 Replacing blower motor 1) Disconnect connector which is connected to the blower motor and remove the blower motor (19) from the lower unit casing (2a). 2) Remove 1 plus screw (17). 7. 3) Insert the sensor holder into the new evaporator at the position shown in Fig. Removing heater core 1) After draining the coolant.11th rows of fin 20 22 105mm (4. * Do not remove the fan from the blower motor. 2a SM0031 2) Install it by the reverse procedure of removal.1 inch) 21 A SM0032 T3-8-15 . remove heater hos e from the heater core (16).AIR CONDITIONER SYSTEM E215B-E245B 5. 2b * Do not disassemble the blower controller. A . Replacing evaporator and expansion valve 1) Take the evaporator (20) with expansion valve off from the lower casing. 14 15 SM0030 6.

c) Remove 3 plus screws (34) and remove the motor actuator (35) with MA lever air MIX (36) from the unit. 5) Fit O-ring (24) (NF O-ring 5/8 and 1/2 one each) to new evaporator. similar careful work is necessary. c) Remove 3 plus screws (31) and remove the motor actuator (27) with lever MA mode from the unit. SM0025) connected with expansion valve (25) is disconnected from expansion valve. 25 23 Replacing motor actuator SM0033 1) Replacing mode actuator a) Remove connector (26) connected to the motor actuator (27). when tube assembly (27-6) (see Pag. 20 A * When assembling again. Moreover. b) Remove rod air MIX (33) which is used to connect the motor actuator (27) and the lever MA air MIX.1lbf•ft) 24 * Do not apply undue force to pipe of evaporator outlet. (Socket bolt M5×40 (2 pcs. This undue stress causes the leak of refrigerant from "A" part of evaporator. d) Remove the lever MA mode from the removed motor actuator. 29 28 30 31 27 SM0034 33 36 32 34 T3-8-16 26 35 SM0035 . fit O-ring paying attention so as not to be caught with others. T3-8-3 Fig.) Tightening torque: 6. and install it on new motor actuator by the reverse procedure of removal.E215B-E245B AIR CONDITIONER SYSTEM 4) Remove 2 socket bolts M5×40 (23) with Allen wrench (4 mm) and remove the expansion valve from the evaporator (20). 2) Replacing air mixing actuator a) Remove connector (32) connected to the motor actuator. b) Remove FACE rod (28) and VENT rod (29) which is used to connect MA mode lever (30) and mode cam from the holder. and install it on new motor actuator by the reverse procedure of removal. 9. d) Remove the MA lever air MIX from the removed motor actuator.9N•m (5.

E215B-E245B 40 39 41 37 38 T3-8-17 SM0036 . c) Remove 3 plus screws and remove the motor actuator (38) with MA intake lever (40) from the unit. d) Remove the MA intake lever (40) from the removed motor actuator. b) Remove intake rod (39) from MA intake lever (40).AIR CONDITIONER SYSTEM 3) Replacing inner and outer air switching actuator a) Disconnect connector (37) connected to the motor actuator (38). and install it on new motor actuator by the reverse procedure of removal.

3) If the can is placed near a fire source. . water and dust are detrimental to the refrigeration cycle. It is for this reason why the can temperature must be kept below 40°C (104°F). do not throw or drop them. choose a cold dark place not exposed to direct sunlight. Install the components of the air-conditioner correctly and speedily. never use them again. the strength of the can will deteriorate. Do not bring the can close to a fire. the pressure of the can may rise sharply. the inside of the trunk room may rise to a dangerous temperature level even in the summer time. . The can may blast as the result. Refrigerant charge operation involves dangers as it handles high pressure gas.) If the can is put in hot water or heated by a direct fire. Always assign a person in charge of handling refrigerant. Always assign a person familiar with how work is done for handling refrigerant. taking the above into account. -26°C (-15°F)]. 6) Store cans beyond the reach of children. Others Reuse of service cans is prohibited by law.) Storage and Transportation 1) Keep the service can (hereinafter called can) less than 40°C (104°F). WARNING • • 2.When transporting. Charging 1) When warming the can in which refrigerant is charged. 3. therefore.E215B-E245B AIR CONDITIONER SYSTEM CHARGING REFRIGERANT PRECAUTIONS TO BE EXERCISED IN OPERATION 1. 2) For storage. loading or unloading cans and packages containing cans. 2) When charging refrigerant while running the engine. Air. Do not allow foreign matter to enter the air-conditioner circuit. (You may get a frostbite if the refrigerant is sprayed over your skin. do not fail to open the service can valve and the low pressure valve of the gauge manifold and warm the can in warm water of 40°C (104°F or below (to an extent that you do not feel hot when you put your hand in the water.) The refrigerant in liquid state is at very low temperature [approx. Wear protective goggles.Do not drop or knock on the can. CAUTION • • Be careful about overcharge of gas Fasten pipes to a specified torque T3-8-18 . This causes the inside pressure to rise and may cause the can to blow out. Pay full attention to the entry of water and dust. do not open the high pressure valve (HI) of the gauge manifold in any case. dents and distortion. Since high pressure gas of R134a is filled in the can in a saturated liguefied state. Do not bring the can into the compartment. 4. it is subject to radiation heat and gets hot. 4) The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the compartment. Therefore. the pressure in the can increases sharply as temperature rises. Use sufficient care. thereby blowing off the can. (You may lose your sight if the refrigerant gets in your eyes. Also. handle it with care. 5) Note that if the can has scratches. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous temperature level.

apply the vacuum and cause the boiling and vaporisation of the moisture. moisture is eliminated from the system.The "gas charging procedure" consists in the filing the circuit with refrigerant. results in an insufficient circulation of lubricant oil in the compressor. On the contrary. An excessive overloading increases considerably the pressure of the system and damages the cooling performance. it is dangerous to handle the gas without complying strictly with the relevant procedures. prior to filling the circuit with refrigerant.1 MPa Check and correct joints SM0194 T3-8-19 . The procedures and the protections described in this manual for the filling of refrigerant gas must be strictly adhered to. for five minutes. In the event even a small quantity of moisture remains in the system. Begin vacuum making Lower than -750m mHg Refrigerant filling operation Leave it as it is. causing the wear of the moving parts of the compressor. with a series of operational troubles. In this manner. This causes a clogging of the circuit or the formation of rust. . Stop vacuum making Check air-tightness Fill in refrigerant Check for gas leak Fill in refrigerant Gauge indicates abnormality Charge refrigerant gas to a gauge pressure of 0.The "vacuum generation procedure" consists in removing moisture from the air conditioner circuit. a too low charging. it would freeze in the small orifices of the expansion valve when in operation. . but it influences also the useful working life of the circuit components. the filling of the gas is not only depending upon the cooling performance of the air conditioner.AIR CONDITIONER SYSTEM E215B-E245B OPERATING PROCEDURE The change of refrigerant in the air conditioner requires a "vacuum generation procedure" and a "gas charging procedure". WARNING The gas filling operation involves the handling of highly compressed gases. after applying a vacuum. Vacuum making operatio More than 30 min.

3. T3-8-20 D S 8 9 SM0017 . Install the pipe firmly until a click noise is heard. 7 SM0016 IMPORTANT: some types of manifold are not equipped with an open/close valve in the central part. 7. Open high pressure valve (3) and low pressure valve (1) of gauge manifold (2). check. If the charging pipe is connected in the opposite direction. 2. 1 3 6 5 4 D S 8 Connect the central valve of the gauge manifold with charging pipe (4) of the vacuum pump (7). 5. 6. NOTE: in the event the pressure gauge moves toward zero. 2 WARNING Never exchange by mistake the high pressure pipe with the low pressure pipe when connecting them. Cut-off the vacuum pump.E215B-E245B AIR CONDITIONER SYSTEM PROCEDURE FOR THE GENERATION OF VACUUM 1. Connect the quick release joint of the charging pipe with the service valve of the compressor. this indicates the presence of a leakage. With the high pressure valve (3) and the low pressure valve (1) closed. Connect the red charging pipe (5) and the blue one (6) to compressor service valves (8) "D" and "S" as described in the figure. At the end of the vacuum phase for the prescribed time (vacuum value: lower than 750 mm Hg) close the high pressure valve (3) and the low pressure valve (1) of the gauge manifold (2). 4. that the pressure gauge dial does not return to zero. verifying that there are no further leakages. after five minutes. Start the vacuum pump and let it operate 30 minutes to generate the vacuum. 8. Close high pressure valve (3) and low pressure valve (1) on gauge manifold (2). mini-valve (9) of the compressor fails to open. Tighten again the connecting joints and apply the vacuum again.

3 1 D WARNING Never start operating the compressor during this work.4 ~ 1. Press central bleeding valve (11) of the side service opening on the low pressure side of the gauge manifold using a screwdriver in order to let out the air in the charging pipe by the pressure of the refrigerant. Open high pressure valve (3) of the gauge manifold and charge the refrigerant to a pressure of 0. always use a tester for R134a. 4. Once the charge is completed. Make sure that high pressure valve (3) and low pressure valve (1) of the manifold and service valve can (10) are closed. 6. Do not use one for flon gas service as it provides poor sensitivity. 5. Activate the air conditioner. exchange charging pipe (4) of the gauge manifold (2). set the discharge pressure of the compressor to 1.AIR CONDITIONER SYSTEM E215B-E245B PROCEDURE FOR THE CHARGING OF THE GAS 1. from the vacuum pump to the service can (9). After applying the vacuum repeatedly. Start the engine running it at 1500 ± 100 rpm and open fully the door and windows of the cab. 2 11 Open the valve of service can (10). 4 10 9 SM0018 3. close high pressure valve (3) of the gauge manifold and service valve (10). 2. T3-8-21 10 S SM0019 . setting it at maximum ventilation speed and at lowest temperature.6 MPa.1 MPa. Retighten and eliminate all points of leakage. 8. 7. The starting of the compressor causes the blowing of the service can. Proceed with this operation until a whistle is heard coming from the bleeder. During the charging of the gas. using a gas leakage tester. Close the high and low pressure valves of the gauge manifold. Check that there are no leakages of gas in the cycle. IMPORTANT: to check for gas leakages.

to a value of 1. Wait for the pressure in the high pressure site to decrease. a. b. Press the quick release coupling of the charging pipe on the low pressure side against the service valve of the compressor so that the refrigerant doers not escape leaking when loosening the connection. indicated on the pressure gauge. the pressure of the system increases abnormally.0 MPa. CAUTION Do not open the high pressure valve of the manifold under any circumstance nor place the service can upside down. close low pressure valve (1) of the gauge manifold and the service valve can (10). IMPORTANT: when the air conditioner operates with an insufficient quantity of refrigerant.E215B-E245B 9. on the contrary. The level of refrigerant is correct only once the air conditioner is activated and through the inspection sight window. 12. Disassemble the manifold disconnecting the charging pipes from the compressor. Once the refrigerant change operation is terminated. afterward. a white colour slightly milky is seen. in the same manner as described for the low pressure. R0115 11. Total quantity of gas to be charged: 900 ± 50 g. the cooling performance is lost. A: Appropriate quantity of refrigerant B: The system is overloaded C: Insufficient quantity of refrigerant T3-8-22 . AIR CONDITIONER SYSTEM Open low pressure valve (1) of the gauge manifold and service valve can (10) and fill with refrigerant until all air bubbles in sight window (12) of the dryer disappear. just a few air bubbles are seen and. when the refrigerant is charged with an excessive quantity. disconnect the charging pipe from the service valve. this has a negative effect on the compressor. 01 10. Disconnect the red charging pipe from the high pressure side. Also. As soon as the nut has been removed. as indicated here below. c.

CCU(Operation Panel + Controller) 2 .Solar radiation Sensor 5 .Motor Actuator (Rec/Fresh) 8 .Motor Actuator (for air mix) 6 .Evaporator Sensor 3 .Compressor 15 .Main Key Switch 14 .Blower Off Relay 12 .Motor Actuator (for Mode) 7 .Compressor Relay 9 .AIR CONDITIONER SYSTEM E215B-E245B ELECTRIC CIRCUIT WIRING DIAGRAM AND CONNECTORS Wiring Diagram 1 (A)(B) 2 (C) 12 (R) 3 (N) 155(BR) (D) 150(BP) FUSE 20A 15 4 85E(WB) (E) 18(RG) 13 25(WG) FUSE 5A 26(RL) FUSE 15A 5 E24(B) FUSE 5A (Q) (M) FUSE BOX (P) (F) (L) 6 11 (K) 14 (G) 10 7 9 (J) (H) 8 SM0044 (I) 1 .Air Inlet Sensor 4 .Light Switch T3-8-23 .Blower AMP 10 .Blower Motor 11 .Pressure Switch 13 .

: 7123-6060-40 TERMINAL : 7116-2871 26 25 85E 150 E24 18 (P) (Q) MAKER : YAZAKI CORP. HOUSING No. HOUSING No. HOUSING No. : 6189-0094 HARNESS SEAL : 7160-8234 TERMINAL : 1500-0110 150 155 SM0045 JAE : JAPAN AVIATION ELECTRONICS INDUSTRY. HOUSING No.E215B-E245B AIR CONDITIONER SYSTEM Connectors (B) (A) JAE HOUSING : IL-AG5-22D-S3C1 TERMINAL : IL-AG5-C1-5000 (C) MAKER : YAZAKI CORP. HOUSING No. 7120-8019 CP3.96MA NIPPON AMP KK 170889-1 170003-5 (R) MAKER : SUMITOMO HOUSING No. HOUSING No. : 7122-6060 REAR HOLDER : 7157-6260-30 TERMINAL : 7114-2871 JAE HOUSING : IL-AG5-14D-S3C1 TERMINAL : IL-AG5-C1-5000 (E) NIPPON AMP KK 174056-2 TERMINAL : 175062-1 (H) JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000 (K) MAKER : YAZAKI CORP. : 7123-2249 TERMINAL : 17111 (D) MAKER : YAZAKI CORP. P W B R Y G L Br Lg O LIGHT PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE T3-8-24 . : 7123-2237 TERMINAL : 17111 (M) MAKER : YAZAKI CORP. : 7123-2228 TERMINAL : 17111 (F) JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000 (G) (I) MAKER : YAZAKI CORP. : 7123-2228 TERMINAL : 17111 JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000 MAKER : YAZAKI CORP. HOUSING No. HOUSING No. LTD. : 7123-6020 TERMINAL : 7116-2871 (N) MAKER : YAZAKI CORP. : 7123-2249 TERMINAL : 17111 (J) (L) MAKER : YAZAKI CORP.

and processes the signal input by each sensor. and the signal input by each switch through control panel with the function of the built-in micro computer. And the self-diagnosis performance is provided to facilitate the trouble shooting. air mix).7 k ±5%) + NOT CONTINUED - CONTINUED (DIODE PARALLEL AND FORWARD DIRECTION FLOW) Lg L In normal operation 1) Disconnect the connector of blower amplifier.AIR CONDITIONER SYSTEM E215B-E245B STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION 1. Blower controller (TKS-B215A1) The power transistor shifts the fan motor into variable speed with base current from the control unit. etc. 1 2 + TESTER + SM0047 CONTINUITY B 3 - CONTINUED (4. 2) Check continuity between terminals on the blower amplifier side. SM0048 T3-8-25 . 㨫 㨫 * The installing position is provided on the left side of air-con unit. TERMINAL NO. Control panel and control unit The control unit is integrated into control panel. 2. and comprehensively controls each actuator (Inner and outer air flow select. fan motor and compressor on the output side.

E215B-E245B 3. When the target air mix door position is determined through the temperature control switch. the contact point is moved. Relay (24-4PE) 2. 5. AIR CONDITIONER SYSTEM Relay Four-electrode relay is used for the blower OFF relay and compressor relay. Then as the motor rotates. The air mix actuator contains potentiometer which is switched by being coupled to the shaft of actuator. and opens and closes air mix damper through the link. 20~30V applied between terminals 1-2: Continued 20~30V not applied between terminals 12: Not continued 4. Inspection: Inspect the continuity between 3 and 4 according to the conditions mentioned below. A A 2) Compressor relay The relay ON—OFF is tripped by the control amplifier and electronic thermostat control. the control unit reads the level of potentiometer of the actuator. T3-8-26 CONTROL AMPLIFIER MOTOR ACTUATOR LIMITER COOL POTENTIO 5V POTENTIO POTENTIO GND HOT SM0050 . Coil resistance: 320 3. Be careful about the coil side of relay because this relay has polarity. When the blower OFF relay turns on. 1) Blower OFF relay The blower OFF relay turns on after receiving the signal from the control amplifier. the motor stops rotating. Specified voltage: DC20V~30V 4. Air mix actuator Air mix actuator is installed at the center of aircon unit. SM0049 3) Relay inspecting items 1. and when the contact point is detached or the output signal of control unit turns OFF. the source voltage is supplied to the blower motor and the blower motor starts running. and determines the rotating direction of motor in either normal rotation or reverse rotation.

AIR CONDITIONER SYSTEM 5. SM0054 T3-8-27 . Evaporator sensor This sensor is used to control the evaporator outlet temperature with the compressor ONOFF to protect the evaporator from freezing.2k Dual pressure switch This dual pressure switch is attached on L-hose and is used to turn OFF the compressor. When the inner and outer damper position is set by the inner and outer switch on the control panel. The actuator for inner and outer air flow select contains position detection switch which is switched with the movement of shaft of the actuator.9psi) 0. Solar radiation sensor This solar radiation sensor. AMPLIFIER E215B-E245B MOTOR ACTUATOR INNER AIR SIDE OUTER AIR SIDE LIMITER SM0051 Evaporator sensor inspecting items (Specification) Terminal resistance: at 0 degree C: 7. which is used to correct the solar radiation to the auto air conditioner detects the strength and solar orientation of sunbeam after transforming them into current by means of photo diode.14MPa 0. and this evaporator sensor functions as a sensor of this control. and opens and closes inner and outer air damper through the link. Inspection: Check for the continuity between terminals. and employs dual type (for high and low pressure control) to protect the cooler cycle from possible failure at the time when abnormal pressure was generated on the high pressure side.02MPa(2. 6. • 7. The actuator for inner and outer The actuator for inner and outer air flow select is installed on the blower intake unit. SM0052 SPECIFICATION OF DUAL PRESSURE SWITCH 0. the control unit reads the signal of the position detection switch in the actuator and determines the rotation direction of motor in either normal rotation or reverse rotation. Then as the motor rotates.20MPa (LOW PRESSURE SIDE) (HIGH PRESSURE SIDE) 8. the position detection switch also rotates and makes it stop at the set position of the inner and outer air damper.59MPa(86psi) SM0053 ON OFF 3.2 k at 25 degree C: 2.

A snow mark ( panel is flashing. Inspect and correct electric circuits. YES If M/A is at stop halfway. falls if temp. NO YES • Connector for air mix M/A is disconnected or in poor contact.4 °F) (COOLMAX) and the blowout mode is changed to vent mode.7N: OK) NO Turn compressor clutch on and off. YES Inspect and correct or replace parts.E215B-E245B AIR CONDITIONER SYSTEM TROUBLESHOOTING Note : M/A is motor actuator * is any of the numbers 0 ~ 9 Air temperature does not fall. eliminate cause. . correct and measure operating force. Cool air flowing into inner air sensor Inspect and correct or replace parts. is set at 18. display of the panel NO YES A snow mark ( ) on the panel is flashing. Inspect and replace. A NO Blowout temp. NO ) on Inspect and correct or replace parts. display of the panel. NO YES • Evaporation sensor connector is disconnected or in poor contact. M/A failed or controller is out of order. See section monitor mode. Inspect and correct or replace parts.*" is shown on the set temp. Refer to Troubleshooting for refrigeration cycle. NO Air mix damper is in COOLMAX. • Both inner air sensor and evaporation sensor are disconnected or shorted. YES • Inspect. If AUTO switch or A/C switch is pushed. Replace. "HL. T3-8-28 YES Inspect duct or eliminate cause for cool air intrusion. correct or replace M/A lever link. • Air mix M/A is failed. • Evaporation sensor is disconnected or shorted. See section monitor mode. NO Controller is faulty or inner air sensor is faulty. • Main harness shows poor continuity. apply grease.0 °C (64. "HL. YES • Inner air sensor or harness is disconnected or shorted • Inner air sensor connector is disconnected or in poor contact. • Controller failed. (less than 14. • After cleaning lever link.E" is indicated on the set temp.

. correct and measure operating force. NO • Inspect. • Clean lever link and apply grease. • Air mix M/A is failed. NO YES Inspect and correct or replace parts.E is shown on the set temp.4 °F) NO Air mix damper is in HOT MAX NO YES Warm air is flowing into inner air sensor.*" is shown on the set temp.AIR CONDITIONER SYSTEM E215B-E245B Air temperature does not rise. correct or replace M/A lever link. NO YES • Connector for air mix M/A is disconnected or in poor contact. eliminate cause. (less than 14. See section monitor mode. NO YES Blowout temp. T3-8-29 Inspect duct or eliminate causes for warm air entry. display of the panel. Replace.7N: OK) NO YES Inspect warm water piping. display of the panel. YES M/A failed or controller is out of order. Note : * is any of the numbers 0 ~ 9 HL. is set at HOT MAX 32. Inspect and correct or replace parts. • Main harness shows poor continuity. Controller or inner air sensor is out of order. "HL. Inspect and replace. rises at blowout mode if temp. YES If M/A action is at stop. NO YES • Inner air sensor or harness is disconnected or shorted • Inner air sensor connector is disconnected or in poor contact.0 °C (64.

YES Inspect and repair harness. Wire harness is faulty. you get continuity. Blower motor rotates if white / red wire and red wire of blower motor relay are direct connected. YES Inspect and correct harness or replace controller. Battery voltage acts across red (+) and body of blower motor.E215B-E245B AIR CONDITIONER SYSTEM Blower motor does not run. Replace. Remove blower amplifier and check for continuity across light green wire and black wires. Replace. Battery voltage acts across white / red wire and body of blower motor relay. NO Replace relay. Note 2) Always turn off air-conditioner. Inspect and correct or replace. Note 1) Measure with connector set. T3-8-30 . NO Eliminate cause and replace blower amplifier. NO YES Blower motor fails. battery voltage acts across both terminals (+) and (-) of blower motor. NO Inspect and repair harness or replace. starter key switch and light switch before work. NO NO YES YES Controller is out of order. Approx. 10V acts across light green wire and grounding of blower amplifier. YES Blower turns if orange wire of blower motor relay is connected with ground. Note 1) At air flow HI. NO Note 2) YES Inspect blower motor relay.

Inspect and correct or replace parts.*" is shown on the set temp. See section monitor mode. T3-8-31 YES See CASE (1). NO Replace blower controller. • Inner air sensor connector is disconnected or in poor contact. CASE (2) Does not blower motor speed change because the setting mode is other face NO Is door or front window open? NO The limiting or control operation is actuated by door switch or front window switch YES See CASE (1).AIR CONDITIONER SYSTEM E215B-E245B Blower motor speed does not change. YES • Inner air sensor or harness is disconnected or shorted. CASE (1) "HL. display of the panel. amplifier Note) * is any of the numbers 0 ~ 9. .

Or M/A failed or main harness failed. YES Remove foreign matter and replace parts. NO YES Voltage acts upon clutch. NO To A On page T8-3-28. Snow mark ( ) lights if A/C switch is pressed. NO YES Inspect air-conditioner harness.E215B-E245B AIR CONDITIONER SYSTEM Magnet clutch does not engage. YES Inspect clutch fuses. NO YES Replace harness. Replace T3-8-32 Inspect or replace. No fault. YES Voltage acts across white / green wire and Ground (Black) connector connected to excavator. Inner air and outer air do not change Inner / outer air mode display on operation panel is flickering. Clutch faulty. Replace controller. Snow mark ( ) flickers and E is shown on panel display. NO YES M/A lever includes foreign matter or is broken. NO M/A failed Connector of inner/outer air M/A is disconnected or in poor contact. Refer to troubleshooting for refrigeration cycle. Voltage is applied to pressure switch harness. . NO Pressure switch is faulty or refrigerant gas is under charged or overcharged.

• Clean cam and apply new grease. NO Mode M/A connector is disconnected or in poor contact or M/A failed or main harness is faulty. YES Repair. it is heavy. T3-8-33 . NO M/A or controller is out of order. Mode display (Mark of person) on operating panel is flickering. YES When rod is removed and cam is operated by hand.6N. Each damper lever does not disengage.AIR CONDITIONER SYSTEM E215B-E245B Modes do not change. • Remove foreign matter or replace parts. Inspect or replace. NO YES M/A rod does not disengage. NO Repair. YES • Cam or damper shaft includes foreign matter or is broken • Erroneous motion occurs due to dirty grease.). (more than 19. Replace.

Air bubbles are seen in sight glass. or replace Low pressure is higher. YES High pressure circuit before receiver is clogged up. YES Condenser is fouled or clogged. YES NO YES Expansion valve is clogged or maladjusted. Expansion valve is maladjusted. Remove clogging replace parts. Adjust or replace expansion valve. NO YES Cooling does not work if run at high speed. High pressure is lower. Make vacuum and refill refrigerant. Air bubbles are seen in sight glass. refill refrigerant and replace receiver. or NO Air bubbles are hard to go out even if water is poured on condenser. Natural leak from hose. Retighten parts. NO Oil comes out from piping and parts. Charge gas. Both high and low pressures are lower. Replace compressor High pressure is lower. Clean condenser. Compressor cylinder does not get hot. Replace expansion valve. (too much open) Compressor does not discharge well.E215B-E245B AIR CONDITIONER SYSTEM Trouble with refrigeration cycle. Gas leaks from pipe joints and parts. Compressor cylinder gets very hot. Expansion valve is frozen or intruded by water. NO High pressure gets lower slowly. T3-8-34 . After making vacuum. NO YES Air bubbles are seen in sight glass. Air is mixed.

Check harness or connector to motor actuator for the air outlet damper for disconnection. if the panel ON/ OFF switch is turned ON. MODE is flickering. it functions. HL. R/F is flickering. SM0055 The error is indicated on 3 digits segment. EXPLANATION OF INDICATION FOR FAILURE. Check harness or connector to motor actuator for the air mix damper for disconnection.E is indicated on 3 digits segment. SM0057 3. POSITION OF INDICATION FOR FAILURE. if the starter switch is not switched from OFF to ON the error indication and flickering are not released.AIR CONDITIONER SYSTEM E215B-E245B SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL The failure of motor actuator and each sensor can be identified on the display of panel. SM0058 Check harness or connector to motor actuator for the inner and outer air damper for disconnection. Failure of Motor Actuator 1. After correction of failure. Note: The above indication and flickering does not function if the harness and connector were disconnected under the condition the panel ON/ OFF switch is ON. T3-8-35 . SM0056 2. After the failure was occured.

**E and mark are flickering. and also connectors for disconnection. and also connectors for disconnection.E215B-E245B AIR CONDITIONER SYSTEM Failures of sensors 1. SM0059 (* is any of the numbers 0 to 9. after correction of failure if the panel ON/OFF switch is switched from OFF to ON. Check the inner air sensor or the harness for disconnection and short circuit. HL. Check the harness of control amplifier and panel for disconnection.* is indicated on 3 digits segment. and connectors for poor connection.) 2.) Check evaporator sensor or the harness for disconnection and short circuit. (** is displayed leaving the present set temperature value. And. the error indication is released. SM0061 T3-8-36 . E is indicated on the only use segment of display. SM0060 Note: The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the condition the panel ON/OFF switch is ON. Communication error of control amplifier and panel 1.

the error display is memorized. short circuit). Notes: . Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing UP or DOWN of blower switch (B) or (C). . The monitor display is terminated by pressing the inner and outer air flow select switch (A) and ON/OFF switch (D) for 1 second again. 4. SEGMENT ASSIGNMENT LIST 0 INNER AIR SENSOR 1 EVAPORATOR SENSOR 2 SOLAR RADIATION SENSOR SM0064 (Excluding above mentioned indications. Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit and 2nd digit of segment in three digits. Press inner and outer air flow select switch (A) and ON/OFF switch (D) simultaneously for 1 second. the mode is switched into monitor mode. Position of monitor mode indication SM0062 3 DIGITS SEGMENT 2. T3-8-37 . 1.) 3. or turning off the main switch of excavator.AIR CONDITIONER SYSTEM E215B-E245B EXPLANATION OF MONITOR MODE When error “failure of sensors” is displayed. and the error display is disappeared. Press AUTO switch (E).The air conditioner is turned off while the monitor mode is in operation. SEGMENT FOR ONLY MONITOR INDICATION Operation of monitor mode A B C E D SM0063 1. 2. The 1st digit is indicated by "H". for example "from 3 to 9 and from B to F" are not used at service work. and the required sensor is selected from the list below.) 5. the monitor mode is available to identify the sensor condition (disconnection. Therefore turn on ON/OFF switch (D) again.Even if each sensor is corrected while the monitor mode is in operation. (After all segments are lit on for 1 second. and all switches are not available for operation and setting until the monitor mode is cancelled.

E215B-E245B 3. since the segment indicates FF. --> The inner air sensor is in normal operating condition. since the segment indicates 00. Example 2 When the segment exclusively used for monitor indicates 1 (displays the evaporator sensor condition). SM0065 2. When the segment exclusively used for monitor indicates 2 (displays the solar radiation sensor condition).the sensor is in short-circuiting condition according to the list of 3 segments. -->The solar radiation sensor is in short-circuiting condition. the sensor is in normal operating condition according to the list of 3 segments. Example 3 SM0067 4. SM0066 3. --> The evaporator sensor is in disconnection condition. List of 3 segments SECOND SEGMENT INNER AIR SENSOR DISCONNECTION EVAPORATOR SENSOR DISCONNECTION THIRD SEGMENT SOLAR RADIATION SENSOR SHORT-CIRCUITING EACH SENSOR IS NORMAL SOLAR RADIATION SENSOR 5V SIDE SHORT-CIRCUITING INNER AIR SENSOR SHORT-CIRCUITING EVAPORATOR SENSOR SHORT-CIRCUITING SM0068 T3-8-38 . since the segment indicates 3F. 1. AIR CONDITIONER SYSTEM Contents of monitor mode display Refer to the list of segment display exclusively used for monitor and the list of segments in three digits. the sensor is in disconnection condition according to the list of 3 segments. Example 1 When the segment exclusively used for monitor indicates 0 (displays the inner air sensor condition).

Model name and serial number 2. History of trouble occurred and additional works. SM0101 Verifying background of trouble occurred HOW TO DIAGNOSE TROUBLE 1. VERIFY BACKGROUND OF TROUBLE OCCURRED 1. This manual describes how to solve the specific phenomenon systematically as early as possible. 3. Verify defective part 2. And the method of using the machines should be explained so that the same kind of trouble does not reoccur. Explain the cause of trouble to clients. or problems on the additional works. For example. and return them. 1. situation of trouble and field. etc. Report methods. surmise causes systematically. For troubleshooting concerning the inside of equipment. refer to troubleshooting for each manual of equipment. into port of hydraulic unit. etc. Confirm the symptoms of the trouble 2. 4. procedure. Where defective parts can not be verified. Operating time by hour-meter 4. and period for repairing to user. SM0103 Diagnosing fail by means troubleshooting T5-1-1 . 5. Make the condition of trouble again 3. Recurrence of past trouble.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B OUTLINE Troubleshooting provides process locating for the cause of trouble in the order that trouble occurred. and notify person of arrival time. JUDGMENT OF ACTUAL THING AT SITE SM0100 GET TO THE SITE AS QUICKLY AS POSSIBLE Attending the field to verify actual thing Verify model. serial number. oil leak through piston is caused by flaws on the piston rod. Verify reasons for surmise 5. Protect them from entry of water. And also use care not to flaw and damage those surfaces. SM0102 EXPLANATION OF THE CAUSE OF TROUBLE 1. Kind of attachment Check that the combination of attachment is proper or that the operating method is not unreasonable. Treatment of damaged parts The damaged parts to be claimed and returned are evidence so they should be handled with care. soils.

valve adjustment (B adjustment) is not adjusted yet or is failed. code after self diagnosis is remained in trouble cancel the data in the history and reproduce the history failed situation or suppose the cause according to the troubleshooting by error code. D063. and then repair it. the following display appears on the gauge cluster. carry out the troubleshooting referring to applicable page in the contents of error codes. E023. D023. T5-1-7 A245 Writing of ROM hour meter data is incorrect. TROUBLESHOOTING BY ERROR CODE When error code was displayed on the gauge cluster with the aid of self-diagnosis display function. THE BLOWN FUSE OF MECHATRO CONTROLLER If the fuse of mechatro controller has blown. (1) The blown fuse of mechatro controller a. T5-1-7 A235 Written data of ROM hour meter data is incorrect. b. Error Code Trouble Described page A015 Engine adjustment (A adjustment) is not adjusted yet or is failed. Classes of failure Troubleshooting A When error code after self-diagnosis is displayed Carry out troubleshooting according to the error on gauge cluster code. T5-1-5 A035 Unload valve adjustment (C adjustment) is not adjusted yet or is failed. E013. No. Blown fuse 20A of mechatro controller The controller functions normally but the power supply applied when the controller drives the solenoid. T5-1-6 A225 Writing of ROM adjustment data is incorrect. CLASSIFICATION OF FAILURE AND TROUBLESHOOTING Classify failures into the following 3 types and carry out the troubleshooting. C When error code after self diagnosis is not • Carry out troubleshooting according to displayed or is not remained in the history instructions in Chapter T5-2 "TROUBLESHOOTING BY TROUBLE". • Carry out troubleshooting according to instructions in Chapter T5-3 "TROUBLE DIAGNOSIS MODE". 3. Blown fuse 5A of mechatro controller : "DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the controller program is not executed. etc. Many error codes are displayed on the gauge cluster. T5-1-8 B012 Incorrect output of boom up pressure sensor T5-1-9 B013 Disconnection of boom up pressure sensor T5-1-9 B014 Short-circuit of boom up pressure sensor T5-1-10 B022 Incorrect output of boom down pressure sensor T5-1-10 T5-1-2 . B When no failure is detected currently but error When it is hard to recreate the failure situation. stops. F021 4. D033. T5-1-8 A255 Writing of proportional valve adjustment data is incorrect. T5-1-6 A215 Written data of ROM adjustment data is incorrect. D013. T5-1-5 A025 Pump propo.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) 2.

TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Error Code Trouble B023 Disconnection of boom down pressure sensor T5-1-11 B024 Short-circuit of boom down pressure sensor T5-1-11 B032 Incorrect output of arm out pressure sensor T5-1-12 B033 Disconnection of arm out pressure sensor T5-1-12 B034 Short-circuit of arm out pressure sensor T5-1-13 B042 Incorrect output of arm in pressure sensor T5-1-13 B043 Disconnection of arm in pressure sensor T5-1-14 B044 Short-circuit of arm in pressure sensor T5-1-15 B052 Incorrect output of bucket digging pressure sensor T5-1-16 B053 Disconnection of bucket digging pressure sensor T5-1-16 B054 Short-circuit of bucket digging pressure sensor T5-1-17 B062 Incorrect output of bucket dump pressure sensor T5-1-17 B063 Disconnection of bucket dump pressure sensor T5-1-18 B064 Short-circuit of bucket dump pressure sensor T5-1-18 B072 Incorrect output of swing pressure sensor T5-1-19 B073 Disconnection of swing pressure sensor T5-1-19 B074 Short-circuit of swing pressure sensor T5-1-20 B092 Incorrect output of travel right pressure sensor T5-1-20 B093 Disconnection of travel right pressure sensor T5-1-21 B094 Short-circuit of travel right pressure sensor T5-1-22 B102 Incorrect output of travel left pressure sensor T5-1-23 B103 Disconnection of travel left pressure sensor T5-1-23 B104 Short-circuit of travel left pressure sensor T5-1-24 B113 Disconnection of pressure sensor of optional selector positioning T5-1-25 B114 Short-circuit of pressure sensor of optional selector positioning T5-1-26 B162 Incorrect output of P1 optional side pressure sensor T5-1-26 B163 Disconnection of P1 side optional pressure sensor T5-1-27 B164 Short-circuit of P1 side optional pressure sensor T5-1-28 B172 Incorrect output of P2 optional side pressure sensor T5-1-28 B173 Disconnection of P2 side optional pressure sensor T5-1-29 B174 Short-circuit of P2 side optional pressure sensor T5-1-29 C012 Incorrect output of P1 pump pressure sensor T5-1-30 C013 Disconnection of P1 pump pressure sensor T5-1-30 C014 Short-circuit of P1 pump pressure sensor T5-1-31 C022 Incorrect output of P2 pump pressure sensor T5-1-31 C023 Disconnection of P2 pump pressure sensor T5-1-32 C024 Short-circuit of P2 pump pressure sensor T5-1-32 C033 Disconnection of boom head pressure sensor T5-1-33 C034 Short-circuit of boom head pressure sensor T5-1-33 D012 Failure of output transistor ON at P1 unload proportional valve T5-1-34 D013 Disconnection of P1 unload proportional valve T5-1-34 D022 Failure of output transistor ON at P2 unload proportional valve T5-1-35 D023 Disconnection of P2 unload proportional valve T5-1-36 D032 Failure of output transistor ON at travel straight proportional valve T5-1-36 D033 Disconnection of travel straight proportional valve T5-1-37 D062 Failure of output transistor ON at arm in high speed proportional valve T5-1-38 T5-1-3 Described page .

E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Error Code Trouble Described page D063 Disconnection of arm in high speed proportional valve T5-1-39 D152 Failure of output transistor ON at short-circuit valve T5-1-39 D153 Disconnection of short-circuit valve T5-1-40 E012 Failure of output transistor ON at P1 pump proportional valve T5-1-40 E013 Disconnection of P1pump proportional valve T5-1-41 E022 Failure of output transistor ON at P2 pump proportional valve T5-1-42 E023 Disconnection of P2 pump proportional valve T5-1-42 F011 Failure of output transistor OFF and GND short of attachment boost SOL valve T5-1-43 F013 Failure of output transistor ON and disconnection of attachment boost SOL valve T5-1-4 F021 Failure of output transistor OFF and GND short of swing parking SOL valve T5-1-45 F023 Failure of output transistor ON and disconnection of swing parking SOL valve T5-1-45 F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve T5-1-46 F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve T5-1-47 F041 Failure of output transistor OFF and GND short of optional selector SOL valve T5-1-47 F043 Failure of output transistor ON and disconnection of optional selector SOL valve T5-1-48 G011 Failure of output transistor ON at governor motor T5-1-48 G013 Disconnection of governor motor T5-1-49 G023 Starting point indexing is impossible T5-1-49 G032 Overrun of speed sensor of direct input Mechatro-controller T5-1-50 G033 Disconnection of speed sensor of direct input Mechatro-controller T5-1-50 H013 Disconnection of acceleration potentio T5-1-51 H014 Power short-circuit of acceleration potentio T5-1-51 H023 Disconnection of boom angle potentio T5-1-52 H024 Power short-circuit of boom angle potentio T5-1-53 H033 Disconnection of arm angle potentio T5-1-54 H034 Power short-circuit of arm angle potentio T5-1-55 H091 Failure of GND short-circuit of fuel sensor T5-1-56 H093 Disconnection of fuel sensor T5-1-56 I313 Received error of cluster communication (time-out error) T5-1-57 K014 Adhesion of battery relay terminal T5-1-58 R014 Failure of arc prevention relay of wiper motor T5-1-59 R024 Failure of normal rotation relay of wiper motor T5-1-60 R034 Failure of reverse rotation relay of wiper motor T5-1-61 R044 Failure of washer motor relay T5-1-62 R134 Failure of swing flasher relay T5-1-63 R144 Failure of swing flasher relay T5-1-64 R154 Failure of travel alarm relay T5-1-65 R164 Failure of auto idling stop relay 2 T5-1-66 R174 Failure of engine forcible stop relay T5-1-67 R184 Failure of lever lock relay T5-1-68 R214 Failure of safety relay T5-1-69 T5-1-4 .

checking screen 2 G-3 SPEED SET Screen No. Checking object Checking contents and remedy 1 • Checking Carry out pump adjustment (B adjustment). 3 Table 2 Error code A025 Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment) Judging condition Pump proportional valve adjustment is missed. Service diagnosis Screen No. Symptom Deviated from the rated output. refer to the section "Adjustment procedure . Service diagnosis Screen No. refer to the section "Adjustment procedure Measures to be taken with the adjustment failed" 2 • Mechatro controller Check that the error is corrected after replacement of controller.Measures to be taken with the adjustment failed" 2 • Mechatro controller Check that the error is corrected after replacement of controller. Symptom Deviated from the reqired value. normal condition Screen No. but no problem in normal operation. 3 T5-1-5 . When "ERROR ENG" was displayed during adjustment. When"ERROR PUMP" was displayed during adjustment. normal condition Screen No. Control in the Rotate with the default engine. checking screen 9 E-1 P1 PUMP 9 E-2 P2 PUMP Screen No. Or it is impossible to set the adjusting value within the adjusting range. Checking object Checking contents and remedy 1 • Checking Carry out engine adjustment (A adjustment). event of failure Returned in The engine adjustment is completed normally. Or it is impossible to set the adjusting value within the adjusting range. but no problem in normal operations. event of failure Returned in The pump proportional valve adjustment is completed normally.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 1 Error code A015 Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment) Judging condition Engine adjustment is missed. Control in the Workable with the default proportional valve output.

3 Table 4 Error code A215 Trouble The data of ROM adjustment is written incorrectly. Control in the Work with the aid of output by default proportional valve. 2 3 T5-1-6 . event of failure Returned in The adjustment of unload valve is completed normally. Screen No. Replace controller. When"ERROR PUMP" was displayed during adjustment. 8 D-2 P2 UN-LOAD (BP-CUT) Screen No. but no problem in normal operation. refer to the section "Adjustment procedure . (Trouble history only) Symptom No affect.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 3 Error code A035 Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment) Judging condition The adjustment of unload valve is missed. event of failure Returned in It does not regain.Measures to be taken with the adjustment failed" 2 • Mechatro controller Check that the error is corrected after replacement of controller. normal condition Screen No. Or the adjusting value can not be set in the adjusting range. Control in the Control at side of correct memory data. Symptom It is not normal output. normal condition Screen No. Service diagnosis Screen checking screen No. Checking object 1 Mechatro controller Checking contents and remedy Check that the error is corrected after replacement of controller. 8 D-1 P1 UN-LOAD (BP-CUT) Service diagnosis Screen checking screen No. Checking object Checking contents and remedy 1 • Checking Carry out adjustment of unload valve (C adjustment). Judging condition Check adjustment data. and judge the content of memory is correct or not.

(Trouble history only) Symptom No affect. Screen No. Judging condition Check hourmeter memory. Symptom It is not normal output. Replace controller. event of failure Returned in It does not regain. and judge the data is correct or not. Control in the Control can be done by default value. and judge the data is correct or not. 2 3 Table 6 Error code A235 Trouble The data of ROM adjustment is written incorrectly. Service diagnosis Screen checking screen No. but no problem in normal operation.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 5 Error code A225 Trouble The data of ROM adjustment is written incorrectly. 2 3 T5-1-7 . Service diagnosis Screen checking screen No. Screen No. Checking object 1 Mechatro controller Checking contents and remedy Check that the error is corrected after replacement of controller. Replace controller. Checking object 1 Mechatro controller Checking contents and remedy Check that the error is corrected after replacement of controller. Judging condition Check adjustment data. normal condition Screen No. normal condition Screen No. Control in the Control at side of correct memory data. event of failure Returned in It does not regain.

Checking object 1 Mechatro controller Checking contents and remedy Check that the error is corrected after replacement of controller. No problem in normal operation. Control in the Normal control is available. Symptom It is not normal output. and judge the data is incorrect. but no problem in normal operation. Control in the Using fixed value of proportional valve correction data. Service diagnosis Screen checking screen No. Service diagnosis Screen checking screen No. 2 3 T5-1-8 .E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 7 Error code A245 Trouble The data of ROM hourmeter is written incorrectly. normal condition Screen No. Screen No. event of failure Returned in It does not regain. Replace controller. Symptom The hourmeter data which was judged as error is taken as 0 Hr. Judging condition Check hourmeter memory. Checking object 1 Mechatro controller Checking contents and remedy Check that the error is corrected after replacement of controller. and judge the data is incorrect. usual control is done. Screen No. Judging condition Check proportional valve adjustment data. Replace controller. 2 3 Table 8 Error code A255 Trouble The data of proportional valve adjustment is written incorrectly. normal condition Screen No. event of failure Returned in It does not regain.

Symptom The boom up speed slows down. T5-1-9 . 2 • Wiring between boom up pressure sensor and controller CN-126F CN-101F When B012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. normal condition Screen No. replace it.4 V or more to less than 4. 5 B-1 BOOM RAISE Service diagnosis Screen checking screen No. Returned in It returns automatically in normal condition. pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-126F and repair it if necessary.7 V.1 V. Control in the Normal control. Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. normal condition Screen No. Checking object Checking contents and remedy 1 • Boom up pressure sensor SE-3 When B013 is cancelled and other error occurs after exchanging the connector with other sensor. CN-101F 3 • Mechatro controller Check that the error is corrected after replacement of controller. Judging condition After starter switch ON and engine does not start yet. replace it. If failure found. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 2 • Wiring between boom up When B013 is displayed after the connector is exchanged with other sensor. Symptom The boom up operability becomes poor. Switch the power OFF once and turns on it again.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 9 Error code B012 Trouble Boom up pressure sensor outputs error. Screen No. Check sensor unit for possible failure. If failure found. (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. And the input voltage from the sensor after starter switch ON is in the range of 1. 5 B-1 BOOM RAISE Service diagnosis Screen checking screen No. (Valve emergency mode). event of failure Returned in Not returned automatically under normal condition. Screen No. Judging condition The input voltage from boom up pressure sensor is less than 0. Check sensor unit for possible failure. Checking object Checking contents and remedy 1 • Boom up pressure sensor SE-3 When B012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Table 10 Error code B013 Trouble Boom up pressure sensor’s wiring disconnects.

5 B-1 BOOM RAISE Service diagnosis Screen checking screen No. Control in the Normal control. Table 12 Error code B022 Trouble Boom down pressure sensor outputs error. Symptom The boom down operability becomes poor. Judging condition The input voltage from boom up pressure sensor is 4. pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-126F and repair it if necessary. Screen No. Check sensor unit for possible failure. (Valve emergency mode). replace it. T5-1-10 . SE-4 Check sensor unit for possible failure. Screen No. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. Set proportional valve output rate of P1 and P2 pumps to 0 mA. Symptom The boom up speed slows down. replace it. Checking object Checking contents and remedy 1 • Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. 5 B-2 BOOM LOWER Service diagnosis Screen checking screen No. event of failure Returned in Not returned automatically under normal condition. If failure found. CN-101F 3 • Mechatro controller Check that the error is corrected after replacement of controller. 2 • Wiring between boom down pressure sensor and controller CN-127F CN-101F When B022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. normal condition Screen No. If failure found.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 11 Error code B014 Trouble Boom up pressure sensor’s power source is shortcut. 3 • Mechatro controller Check that the error is corrected after replacement of controller.4 V or more to less than 4. 2 • Wiring between boom up When B014 is displayed after the connector is exchanged with other sensor. normal condition Screen No.7 V. And the input voltage from the sensor after starter switch ON is in the range of 1. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Switch the power OFF once and turns on it again. Checking object Checking contents and remedy 1 • Boom up pressure sensor SE-3 When B014 is cancelled and other error occurs after exchanging the connector with other sensor. Returned in It returns automatically in normal condition.7 V or more. Judging condition After starter switch ON and engine does not start yet.

T5-1-11 . Checking object Checking contents and remedy 1 • Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the connector with other sensor. Set proportional valve output rate of P1 and P2 pumps to 0 mA. Judging condition The input voltage from boom down pressure sensor is 0. Screen No. Symptom The boom down operability becomes poor. (Valve emergency mode) Returned in It returns automatically in normal condition. SE-4 Check sensor unit for possible failure. Screen No. 2 • Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor. pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-127F and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. If failure found. 5 B-2 BOOM LOWER Service diagnosis Screen checking screen No.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 13 Error code B023 Trouble Boom down pressure sensor’s wiring is disconnecting. Table 14 Error code B024 Trouble Boom down pressure sensor’s power source is shortcut. 2 • Wiring between boom down pressure sensor and controller CN-127F CN-101F When B024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. CN-101F 3 • Mechatro controller Check that the error is corrected after replacement of controller. normal condition Screen No. Set proportional valve output rate of P1 and P2 pumps to 0 mA. If failure found. Checking object Checking contents and remedy 1 • Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. Judging condition The input voltage from boom down pressure sensor is 4. replace it.7 V or more.1 V or less. Symptom The boom down operability becomes poor. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. normal condition Screen No. 5 B-2 BOOM LOWER Service diagnosis Screen checking screen No. SE-4 Check sensor unit for possible failure. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. replace it.

And the input voltage from the sensor after starter switch ON is in the range of 1. Checking object Checking contents and remedy 1 • Arm-out pressure sensor SE-8 When B032 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. 2 • Wiring between arm-out pressure When B033 is displayed after the connector is exchanged with other sensor. If failure found. Returned in It returns automatically in normal condition. Symptom The arm-out operability becomes poor. Screen No. normal condition Screen No. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.4 V or more to less than 4. If failure found. replace it. Set proportional valve output rate of P1 and P2 pumps to 0 mA. normal condition Screen No. replace it. 2 • Wiring between arm-out pressure sensor and controller CN-131F CN-101F When B032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. event of failure Returned in Not returned automatically under normal condition. Symptom Shock at stopping of arm-out is great. sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-131F and repair it if necessary. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. 5 B-3 ARM OUT Service diagnosis Screen checking screen No. Check sensor unit for possible failure. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Control in the Normal control. (Valve emergency mode). T5-1-12 . Table 16 Error code B033 Trouble Arm-out pressure sensor’s wiring is disconnecting. Judging condition The input voltage from arm-out pressure sensor is 0.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 15 Error code B032 Trouble Arm-in pressure sensor outputs error. CN-101F 3 • Mechatro controller Check that the error is corrected after replacement of controller.1 V or less. Check sensor unit for possible failure. Judging condition After starter switch ON and engine does not start yet. Switch the power OFF once and turns on it again.7 V. Checking object Checking contents and remedy 1 • Arm-out pressure sensor SE-8 When B033 is cancelled and other error occurs after exchanging the connector with other sensor. 5 B-3 ARM OUT Service diagnosis Screen checking screen No. Screen No.

2 • Wiring between arm-out pressure sensor and controller CN-131F CN-101F When B034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check sensor unit for possible failure. Control in the Normal control. Check sensor unit for possible failure. If failure found. If failure found. Checking object Checking contents and remedy 1 • Arm-out pressure sensor SE-8 When B034 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Judging condition After starter switch ON and engine does not start yet. replace it. Judging condition The input voltage from arm-out pressure sensor is 4. Symptom The arm-in operability becomes poor. normal condition Screen No. Checking object 1 • Arm-in pressure sensor SE-7 Checking contents and remedy When B042 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. event of failure Returned in Not returned automatically under normal condition. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Symptom Shock at stopping of arm-out is great. Switch the power OFF once and turns on it again. 3 • Mechatro controller Check that the error is corrected after replacement of controller.4V or more to less than 4. normal condition Screen No. replace it. And the input voltage from the arm-in pressure sensor after starter switch ON is in the range of 1. T5-1-13 . Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Set proportional valve output rate of P1 and P2 pumps to 0 mA.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 17 Error code B034 Trouble Arm-out pressure sensor’s power source is shortcut. P2 unload proportional valves to 0 mA. Table 18 Error code B042 Trouble Arm-in pressure sensor outputs error. Screen No. 2 • Wiring between arm-in pressure sensor and controller CN-130F CN-101F When B042 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1.7V. 5 B-3 ARM OUT Service diagnosis Screen checking screen No.7 V or more. (Valve emergency mode) Returned in It returns automatically in normal condition. Screen No. 5 B-4 ARM IN Service diagnosis Screen checking screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller.

2 • Wiring between arm-in pressure When B043 is displayed after the connector is exchanged with other sensor. Set proportional valve output rate of P1 and P2 pumps to 0 mA. CN-101F 3 • Mechatro controller Check that the error is corrected after replacement of controller. Screen No. arm falls first.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 19 Error code B043 Trouble Arm-in pressure sensor’s wiring is disconnecting. Checking object Checking contents and remedy 1 • Arm-in pressure sensor SE-7 When B043 is cancelled and other error occurs after exchanging the connector with other sensor. Returned in It returns automatically in normal condition. (Hydraulic pump emergency mode) Control in the Set output of P1 and P2 unload proportional valve to 0 mA. normal condition Screen No. If failure found. 5 B-4 ARM IN Service diagnosis Screen checking screen No. sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-130F and repair it if necessary.1 V or less. (Valve emergency mode) event of failure Set output of arm 2 arm-in proportional valve to 200 mA. Judging condition The input voltage from arm-in pressure sensor is 0. Check sensor unit for possible failure. replace it. T5-1-14 . Symptom Cavitation occurs at independent work of arm-in. Bucket can drag under the condition that the bucket bottom put on the ground. Arm horizontal arm pulling can be barely done but if attachment is pulled in the air..

Arm horizontal arm pulling can be barely done but if attachment is pulled in the air. If failure found. Returned in It returns automatically in normal condition.7 V or more. replace it. checking screen Screen No. Judging condition The input voltage from arm-in pressure sensor is 4.. Bucket can drag under the condition that the bucket bottom put on the ground. 5 B-4 ARM IN Checking object Checking contents and remedy 1 • Arm-in pressure sensor SE-7 When B044 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. normal condition Screen No. P2 unload proportional valves to 0 mA. (Valve emergency mode) event of failure Set output of arm 2 arm-in proportional valve to 200 mA. Symptom Cavitation occurs at independent work of arm-in. T5-1-15 . 2 • Wiring between arm-in pressure When B044 is displayed after turning the starter switch on after the connector sensor and controller is exchanged with other sensor. arm falls first. CN-130F Check wiring for possible failure according to the wiring checking procedure CN-101F and repair it if necessary. Set proportional valve output rate of P1 and P2 pumps to 0 mA.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 20 Error code B044 Trouble Arm-in pressure sensor’s power source is shortcut. Check sensor unit for possible failure. 3 • Mechatro controller Check that the error is corrected after replacement of controller. (Hydraulic pump emergency mode) Control in the Set output of P1. Service diagnosis Screen No.

Judging condition The input voltage from bucket digging pressure sensor is 0. If failure found. Symptom The bucket digging speed slows down a little. 2 • Wiring between bucket digging pressure sensor and controller CN-124F CN-101F When B052 is displayed after turning the starter switch on after the connector is exchanged with other sensor. replace it. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 3 • Mechatro controller Check that the error is corrected after replacement of controller. normal condition Screen No. If failure found. SE-1 Check sensor unit for possible failure. Symptom The bucket digging operability becomes poor.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 21 Error code B052 Trouble Bucket digging pressure sensor outputs error. Table 22 Error code B053 Trouble Bucket digging pressure sensor’s wiring is disconnected. Checking object Checking contents and remedy 1 • Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. replace it. Screen No. 5 B-5 BUCKET DIG Service diagnosis Screen checking screen No. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 2 • Wiring between bucket digging pressure sensor and controller CN-124F CN-101F When B053 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Switch the power OFF once and turns on it again. Judging condition After starter switch ON and engine does not start yet. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. SE-1 Check sensor unit for possible failure. And the input voltage from the bucket digging pressure sensor after starter switch ON is in the range of 1.7 V. Control in the Normal control.4 V or more to less than 4. Checking object Checking contents and remedy 1 • Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure Returned in Not returned automatically under normal condition. T5-1-16 . normal condition Screen No. Returned in It returns automatically in normal condition. 5 B-5 BUCKET DIG Service diagnosis Screen checking screen No.1 V or less. (Valve emergency mode). Screen No.

If failure found.4 V or more to less than 4. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Judging condition The input voltage from bucket digging pressure sensor is 4. 2 • Wiring between bucket digging pressure sensor and controller CN-125F CN-101F When B062 is displayed after turning the starter switch on after the connector is exchanged with other sensor. replace it. event of failure Returned in Not returned automatically under normal condition. Screen No.7 V. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. normal condition Screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller. T5-1-17 . SE-1 Check sensor unit for possible failure. Symptom The bucket digging speed slows down a little.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 23 Error code B054 Trouble Bucket digging pressure sensor’s power source is shortcut. (Valve emergency mode) Returned in It returns automatically in normal condition. If failure found. Control in the Normal control. 5 B-6 BUCKET DUMP Service diagnosis Screen checking screen No. Symptom The bucket dump operability becomes poor.7 V or more. Screen No. Judging condition After starter switch ON and engine does not start yet. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. replace it. Set proportional valve output rate of P1 and P2 pumps to 0 mA. 5 B-5 BUCKET DIG Service diagnosis Screen checking screen No. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. Table 24 Error code B062 Trouble Bucket dump pressure sensor outputs error. Checking object Checking contents and remedy 1 • Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-2 Check sensor unit for possible failure. 2 • Wiring between bucket digging pressure sensor and controller CN-124F CN-101F When B054 is displayed after turning the starter switch on after the connector is exchanged with other sensor. And the input voltage from the bucket dump pressure sensor after starter switch ON is in the range of 1. Checking object Checking contents and remedy 1 • Bucket digging pressure sensor When B062 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. normal condition Screen No. Switch the power OFF once and turns on it again.

If failure found. Judging condition The input voltage from bucket dump pressure sensor is 0. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. normal condition Screen No. Checking object Checking contents and remedy 1 • Bucket digging pressure sensor When B064 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Set proportional valve output rate of P1 and P2 pumps to 0 mA. Table 26 Error code B064 Trouble Bucket dump pressure sensor’s power source is shortcut. If failure found. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No. (Valve emergency mode). SE-2 Check sensor unit for possible failure. 2 • Wiring between bucket digging pressure sensor and controller CN-125F CN-101F When B063 is displayed after turning the starter switch on after the connector is exchanged with other sensor.7 V or more.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 25 Error code B063 Trouble Bucket dump pressure sensor’s wiring is disconnected. Symptom The bucket dump speed slows down a little. SE-2 Check sensor unit for possible failure. replace it. replace it. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 2 • Wiring between bucket digging pressure sensor and controller CN-125F CN-101F When B064 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Screen No. Set proportional valve output rate of P1 and P2 pumps to 0 mA. Screen No. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Symptom The bucket dump speed slows down a little. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. Returned in It returns automatically in normal condition. 5 B-6 BUCKET DUMP Service diagnosis Screen checking screen No. Checking object Checking contents and remedy 1 • Bucket digging pressure sensor When B063 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Judging condition The input voltage from bucket dump pressure sensor is 4.1 V or less. T5-1-18 . Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. 5 B-6 BUCKET DUMP Service diagnosis Screen checking screen No.

4 V or more to less than 4. normal condition Screen No. Control in the Normal control. normal condition Screen No. Screen No. Symptom The swing operability becomes poor.7 V. Judging condition After starter switch ON and engine does not start yet. Screen No. If failure found. SE-5 2 • Wiring between swing pressure When B072 is displayed after turning the starter switch on after the connector sensor and controller is exchanged with other sensor. CN-103F 3 • Mechatro controller Check that the error is corrected after replacement of controller.1 V or less. Checking object 1 • Swing pressure sensor SE-5 Checking contents and remedy When B073 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. replace it. Switch the power OFF once and turns on it again. Set proportional valve output rate of P1 and P2 pumps to 0 mA. 2 • Wiring between swing pressure When B073 is displayed after turning the starter switch on after the connector sensor and controller is exchanged with other sensor. replace it. 6 B-7 SWING Service diagnosis Screen checking screen No. Control in the (Hydraulic pump emergency mode) event of failure Set output of P2 unload proportional valve to 0 mA. Check wiring for possible failure according to the wiring checking procedure CN-169F and repair it if necessary. And the input voltage from the swing pressure sensor after starter switch ON is in the range of 1. If failure found. Table 28 Error code B073 Trouble Swing pressure sensor’s wiring is disconnected. Judging condition The input voltage from swing pressure sensor is 0. Check sensor unit for possible failure. T5-1-19 . event of failure Returned in Not returned automatically under normal condition. Check sensor unit for possible failure. Check wiring for possible failure according to the wiring checking procedure CN-169F and repair it if necessary. (Valve emergency mode) Returned in It returns automatically in normal condition. 6 B-7 SWING Service diagnosis Screen checking screen No.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 27 Error code B072 Trouble Swing pressure sensor outputs error. Checking object 1 Checking contents and remedy • Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Symptom The swing operability becomes poor. CN-103F 3 • Mechatro controller Check that the error is corrected after replacement of controller.

Screen No. normal condition Screen No. Switch the power OFF once and turns on it again. If failure found.7 V. Judging condition After starter switch ON and engine does not start yet. (Valve emergency mode) Returned in It returns automatically in normal condition. 2 • Wiring between travel right pressure sensor and controller CN-301F CN-102F When B092 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Judging condition The input voltage from swing pressure sensor is 4. Check wiring for possible failure according to the wiring checking procedure CN-169F and repair it if necessary. Symptom The travel right operability becomes poor. Control in the (Hydraulic pump emergency mode) event of failure Set output of P2 unload proportional valve to 0 mA. Checking object 1 • Travel right pressure sensor SE-9 Checking contents and remedy When B092 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. If failure found. Checking object 1 Checking contents and remedy • Swing pressure sensor When B074 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. replace it. T5-1-20 . Symptom The swing operability becomes poor. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Control in the Normal control. replace it. 6 B-9 TRAVEL (R) Service diagnosis Screen checking screen No. Screen No.4 V or more to less than 4. SE-5 2 • Wiring between swing pressure When B074 is displayed after turning the starter switch on after the connector sensor and controller is exchanged with other sensor. Table 30 Error code B092 Trouble Travel right pressure sensor outputs error.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 29 Error code B074 Trouble Swing pressure sensor’s power source is shortcut. 6 B-7 SWING Service diagnosis Screen checking screen No. Check sensor unit for possible failure. Check sensor unit for possible failure. event of failure Returned in Not returned automatically under normal condition.7 V or more. And the input voltage from the travel right pressure sensor after starter switch ON is in the range of 1. Set proportional valve output rate of P1 and P2 pumps to 0 mA. CN-103F 3 • Mechatro controller Check that the error is corrected after replacement of controller. normal condition Screen No.

1 V or less. replace it. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Set output of P2 unload proportional valve to 0 mA. Checking object 1 • Travel right pressure sensor SE-9 Checking contents and remedy When B093 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. T5-1-21 . Check sensor unit for possible failure. If failure found. 2 • Wiring between travel right pressure sensor and controller CN-301F CN-102F When B093 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Control in the (Hydraulic pump emergency mode) event of failure P1. Judging condition The input voltage from Travel right pressure sensor is 0. Screen No. Symptom The Travel right operability becomes poor. Set proportional valve output rate of P1 and P2 pumps to 0 mA.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 31 Error code B093 Trouble Travel right pressure sensor’s wiring is disconnected. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Returned in It returns automatically in normal condition. normal condition Screen No. 6 B-9 TRAVEL (R) Service diagnosis Screen checking screen No. (Valve emergency mode).

Screen No. Set output of P2 unload proportional valve to 0 mA. replace it. Check sensor unit for possible failure. Returned in It returns automatically in normal condition. T5-1-22 . 3 • Mechatro controller Check that the error is corrected after replacement of controller.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 32 Error code B094 Trouble Travel right pressure sensor’s power source is shortcut. If failure found. 2 • Wiring between travel right pressure sensor and controller CN-301F CN-102F When B094 is displayed after turning the starter switch on after the connector is exchanged with other sensor. normal condition Screen No. Symptom The Travel right operability becomes poor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Control in the (Hydraulic pump emergency mode) event of failure P1. Judging condition The input voltage from Travel right pressure sensor is 4.7 V or more. 6 B-9 TRAVEL (R) Service diagnosis Screen checking screen No. Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Valve emergency mode). Checking object 1 • Travel right pressure sensor SE-9 Checking contents and remedy When B094 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor.

replace it.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 33 Error code B102 Trouble Travel left pressure sensor outputs error. normal condition Screen No. Control in the (Hydraulic pump emergency mode) event of failure P1. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Symptom The Travel left operability becomes poor. If failure found. (Valve emergency mode) Returned in It returns automatically in normal condition. 6 B-10 TRAVEL (L) Service diagnosis Screen checking screen No. If failure found. Set proportional valve output rate of P1 and P2 pumps to 0 mA. Screen No. Set output of P2 unload proportional valve to 0 mA. SE-10 2 • Wiring between travel left pressure sensor and controller CN-302F CN-102F When B102 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Judging condition The input voltage from Travel left pressure sensor is 0. Switch the power OFF once and turns on it again. 3 • Mechatro controller Check that the error is corrected after replacement of controller. T5-1-23 . 1 Checking object Checking contents and remedy • Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. normal condition Screen No. 1 Checking object Checking contents and remedy • Travel left pressure sensor When B103 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Table 34 Error code B103 Trouble Travel left pressure sensor’s wiring is disconnected.1 V or less. And the input voltage from the travel left pressure sensor after starter switch ON is in the range of 1. replace it. Symptom The travel left operability becomes poor.4 V or more to less than 4. Screen No. Check sensor unit for possible failure. event of failure Returned in Not returned automatically under normal condition.7 V. Judging condition After starter switch ON and engine does not start yet. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Check sensor unit for possible failure. SE-10 2 • Wiring between travel left pressure sensor and controller CN-302F CN-102F When B103 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Control in the Normal control. 6 B-10 TRAVEL (L) Service diagnosis Screen checking screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller.

3 • Mechatro controller Check that the error is corrected after replacement of controller. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. T5-1-24 . Screen No. 1 Checking object Checking contents and remedy • Travel left pressure sensor When B104 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Set proportional valve output rate of P1 and P2 pumps to 0 mA. Set output of P2 unload proportional valve to 0 mA. 6 B-10 TRAVEL (L) Service diagnosis Screen checking screen No.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 35 Error code B104 Trouble Travel left pressure sensor’s power source is shortcut. Judging condition The input voltage from Travel left pressure sensor is 4. Symptom The Travel left operability becomes poor. Control in the (Hydraulic pump emergency mode) event of failure P1. replace it. Check sensor unit for possible failure.7 V or more. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No. SE-10 2 • Wiring between travel left pressure sensor and controller CN-302F CN-102F When B104 is displayed after turning the starter switch on after the connector is exchanged with other sensor. If failure found.

3 • Mechatro controller Check that the error is corrected after replacement of controller. 16 B-11 Service diagnosis Screen checking screen No. Symptom When B mode is selected.1 V or less. T5-1-25 . Checking object Checking contents and remedy 1 • Option selector position detect When B113 is cancelled and other error occurs by turning starter switch on after pressure sensor exchanging the connector with other sensor. Screen No. normal condition Screen No. option selector valve error is indicated. If failure found. Check sensor unit for possible failure. SE-29 2 • Wiring between option selector position detect pressure sensor and controller CN-162F CN-104F When B113 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Judging condition The input voltage from option selector position detect pressure sensor is 0. Control in the Normal control.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 36 Error code B113 Trouble Option selector position detect pressure sensor’s wiring is disconnected. replace it. event of failure Returned in It returns automatically in normal condition.

replace it. Check sensor unit for possible failure. Service diagnosis Screen checking screen No. normal condition Screen No.7 V or more. Control in the Normal control.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 37 Error code B114 Trouble Option selector position detect pressure sensor’s wiring is disconnected. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Checking object Checking contents and remedy 1 • Option selector position detect When B114 is cancelled and other error occurs by turning starter switch on after pressure sensor exchanging the connector with other sensor. Judging condition After starter switch ON and engine does not start yet.4 V or more to less than 4. And the input voltage from the P1 side option pressure sensor after starter switch ON is in the range of 1. T5-1-26 . Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Switch the power OFF once and turns on it again. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Symptom The P1 side option operability becomes poor. Checking object 1 • P1 side option pressure sensor SE-20 Checking contents and remedy When B162 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Symptom When B mode is selected. Table 38 Error code B162 Trouble P1 side option pressure sensor outputs error. Screen No. SE-29 2 • Wiring between option selector position detect pressure sensor and controller CN-162F CN-104F When B114 is displayed after turning the starter switch on after the connector is exchanged with other sensor. replace it.7 V. option selector valve error is indicated. event of failure Returned in It returns automatically in normal condition. Screen No. 6 B-16 P1 OPT. 16 B-11 Service diagnosis Screen checking screen No. If failure found. Check sensor unit for possible failure. normal condition Screen No. Judging condition The input voltage from selector position detect pressure sensor is 4. If failure found. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 2 • Wiring between P1 side option pressure sensor and controller CN-304F CN-102F When B162 is displayed after turning the starter switch on after the connector is exchanged with other sensor. event of failure Returned in Not returned automatically under normal condition. Control in the Normal control.

replace it. Screen No. Judging condition The input voltage from P1 side option pressure sensor is 0. Check sensor unit for possible failure. Checking object 1 • P1 side option pressure sensor SE-20 Checking contents and remedy When B163 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Service diagnosis Screen checking screen No. 2 • Wiring between P1 side option pressure sensor and controller CN-304F CN-102F When B163 is displayed after turning the starter switch on after the connector is exchanged with other sensor. (Valve emergency mode) But normal control is done when the left control pedal selection is ON. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Set proportional valve output rate of P1 and P2 pumps to 0 mA. 6 B-16 P1 OPT. If failure found. T5-1-27 .1 V or less. Returned in It returns automatically in normal condition.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 39 Error code B163 Trouble P1 side option pressure sensor’s wiring is disconnected. Symptom The P1 side option does not work. normal condition Screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller.

If failure found. 6 B-16 P1 OPT. Returned in It returns automatically in normal condition. Screen No.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 40 Error code B164 Trouble P1 side option pressure sensor’s wiring is disconnected. Table 41 Error code B172 Trouble P2 side option pressure sensor outputs error. event of failure Returned in Not returned automatically under normal condition. 6 B-17 P2 OPT. Check sensor unit for possible failure. And the input voltage from the P2 side option pressure sensor after starter switch ON is in the range of 1. Service diagnosis Screen checking screen No. Screen No. T5-1-28 . normal condition Screen No. Judging condition After starter switch ON and engine does not start yet. replace it. 2 • Wiring between P1 side option pressure sensor and controller CN-304F CN-102F When B164 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Service diagnosis Screen checking screen No.7 or more. Checking object 1 Checking contents and remedy • P1 side option pressure sensor SE-20 When B164 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. 3 • Mechatro controller Check that the error is corrected after replacement of controller. If failure found. Switch the power OFF once and turns on it again. replace it. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Symptom The P1 side option does not work. Symptom The P2 side option operability becomes poor. Judging condition The input voltage from P1 side option pressure sensor is 4. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA.7 V.4 V or more to less than 4. normal condition Screen No. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Set proportional valve output rate of P1 and P2 pumps to 0 mA. Checking object 1 • P2 side option pressure sensor SE-11 Checking contents and remedy When B172 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. (Valve emergency mode) But normal control is done when the left control pedal selection is ON. 2 • Wiring between P2 side option pressure sensor and controller CN-304F CN-102F When B172 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Control in the Normal control.

normal condition Screen No. Service diagnosis Screen checking screen No. If failure found. T5-1-29 . (Valve emergency mode). normal condition Screen No. Screen No.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 42 Error code B173 Trouble P2 side option pressure sensor’s wiring is disconnected. 2 • Wiring between P2 side option pressure sensor and controller CN-303F CN-102F When B174 is displayed after turning the starter switch on after the connector is exchanged with other sensor. 6 B-17 P2 OPT. 2 • Wiring between P2 side option pressure sensor and controller CN-303F CN-102F When B173 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Service diagnosis Screen checking screen No.7 V or more. (Valve emergency mode). Checking object 1 • P2 side option pressure sensor SE-11 Checking contents and remedy When B174 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Symptom The selection of conflux does not work. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Set proportional valve output rate of P1 and P2 pumps to 0 mA. 3 • Mechatro controller Check that the error is corrected after replacement of controller.1 V or less. Table 43 Error code B174 Trouble P2 side option pressure sensor’s wiring is disconnected. Returned in It returns automatically in normal condition. 6 B-17 P2 OPT. Judging condition The input voltage from P2 side option pressure sensor is 0. Checking object 1 Checking contents and remedy • P2 side option pressure sensor SE-11 When B173 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Control in the (Hydraulic pump emergency mode) event of failure Set output of P2 unload proportional valve to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P2 unload proportional valve to 0 mA. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Check sensor unit for possible failure. Check sensor unit for possible failure. If failure found. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Screen No. replace it. Set proportional valve output rate of P1 and P2 pumps to 0 mA. Judging condition The input voltage from P2 side option pressure sensor is 4. replace it. Returned in It returns automatically in normal condition. Symptom The selection of conflux does not work.

4 V or more to less than 4. Check sensor unit for possible failure. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. If failure found.1 V or less.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 44 Error code C012 Trouble P1 pump pressure sensor outputs error.7 V. Check sensor unit for possible failure. event of failure (Hydraulic pump emergency mode) Returned in It returns automatically in normal condition. T5-1-30 . 7 C-1 PUMP P1 Service diagnosis Screen checking screen No. SE-22 2 • Wiring between P1 pump pressure sensor and controller CN-139F CN-103F When C013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. If failure found. Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. normal condition Screen No. Table 45 Error code C013 Trouble P1 pump pressure sensor’s wiring is disconnected. And the input voltage from the P1 pump pressure sensor after starter switch ON is in the range of 1. replace it. 1 Checking object Checking contents and remedy • P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. 7 C-1 PUMP P1 Service diagnosis Screen checking screen No. Judging condition After starter switch ON and engine does not start yet. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Screen No. Symptom The P1 pump operability becomes poor. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 3 • Mechatro controller Check that the error is corrected after replacement of controller. event of failure Returned in Not returned automatically under normal condition. Judging condition The input voltage from P1 pump pressure sensor is 0. Control in the Normal control. SE-22 2 • Wiring between P1 pump pressure sensor and controller CN-139F CN-103F When C012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. replace it. Switch the power OFF once and turns on it again. Screen No. Symptom The delicate operability of P1 pump related attachment becomes poor. normal condition Screen No. 1 Checking object Checking contents and remedy • P1 pump pressure sensor When C013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor.

SE-23 2 • Wiring between P2 pump pressure sensor and controller CN-140F CN-103F When C022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. 1 Checking object Checking contents and remedy • P2 pump pressure sensor When C022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Switch the power OFF once and turns on it again. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Symptom The P2 pump operability becomes poor. Table 47 Error code C022 Trouble P2 pump pressure sensor outputs error. Judging condition After starter switch ON and engine does not start yet. Symptom The delicate operability of P1 pump related attachment becomes poor.4 V or more to less than 4. event of failure Returned in Not returned automatically under normal condition. Check sensor unit for possible failure. 7 C-2 PUMP P2 Service diagnosis Screen checking screen No. Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. replace it. Check sensor unit for possible failure. Screen No. If failure found. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. event of failure (Hydraulic pump emergency mode) Returned in It returns automatically in normal condition. 3 • Mechatro controller Check that the error is corrected after replacement of controller. And the input voltage from the P2 pump pressure sensor after starter switch ON is in the range of 1. T5-1-31 . Judging condition The input voltage from P1 pump pressure sensor is 4. 1 Checking object Checking contents and remedy • P1 pump pressure sensor When C014 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor.7 V or more. normal condition Screen No. SE-22 2 • Wiring between P1 pump pressure sensor and controller CN-139F CN-103F When C014 is displayed after turning the starter switch on after the connector is exchanged with other sensor. replace it. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Control in the Normal control.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 46 Error code C014 Trouble P1 pump pressure sensor’s power source is shortcut. Screen No. 7 C-1 PUMP P1 Service diagnosis Screen checking screen No. normal condition Screen No. If failure found.7 V.

3 • Mechatro controller Check that the error is corrected after replacement of controller. Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure (Hydraulic pump emergency mode) Returned in It returns automatically in normal condition.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 48 Error code C023 Trouble P2 pump pressure sensor’s wiring is disconnected. Symptom The delicate operability of P2 pump related attachment becomes poor. Judging condition The input voltage from P2 pump pressure sensor is 0. replace it. 7 C-2 PUMP P2 Service diagnosis Screen checking screen No. Check sensor unit for possible failure. SE-23 2 • Wiring between P2 pump pressure sensor and controller CN-140F CN-103F When C023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 1 Checking object Checking contents and remedy • P2 pump pressure sensor When C024 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. 3 • Mechatro controller Check that the error is corrected after replacement of controller. normal condition Screen No. Judging condition The input voltage from P2 pump pressure sensor is 4. SE-23 2 • Wiring between P2 pump pressure sensor and controller CN-140F CN-103F When C024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check sensor unit for possible failure. replace it. T5-1-32 . 7 C-2 PUMP P2 Service diagnosis Screen checking screen No. Table 49 Error code C024 Trouble P2 pump pressure sensor’s power source is shortcut. 1 Checking object Checking contents and remedy • P2 pump pressure sensor When C023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. Screen No.7 V or more. event of failure (Hydraulic pump emergency mode) Returned in It returns automatically in normal condition. Screen No. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Symptom The delicate operability of P2 pump related attachment becomes poor.1 V or less. If failure found. normal condition Screen No. If failure found.

Checking object 1 • Boom head pressure sensor SE-24 Checking contents and remedy When C034 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. replace it. Symptom Overload detection is not available. 7 C-3 BOOM-HEAD Service diagnosis Screen checking screen No. event of failure Returned in It returns automatically in normal condition. Judging condition The input voltage from boom head pressure sensor is 4.1 V or less. 2 • Wiring between boom head pressure sensor and controller CN-140F CN-103F When C033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. normal condition Screen No. event of failure Returned in It returns automatically in normal condition. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Table 51 Error code C034 Trouble Boom head pressure sensor’s power source is shortcut. 2 • Wiring between boom head pressure sensor and controller CN-706F CN-104F When C034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Control in the Normal control. overload alarm sounds constantly. If failure found. If failure found. Check sensor unit for possible failure. T5-1-33 . Judging condition The input voltage from boom head pressure sensor is 0. Control in the Normal control.7 V or more. Screen No. Symptom Then overload detection switch is ON. normal condition Screen No. Checking object 1 Checking contents and remedy • Boom head pressure sensor SE-24 When C033 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. replace it.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 50 Error code C033 Trouble Boom head pressure sensor’s wiring is disconnected. 7 C-3 BOOM-HEAD Service diagnosis Screen checking screen No. Check sensor unit for possible failure. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Screen No.

replace it. Check sensor unit for possible failure. replace it. Check sensor unit for possible failure. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 8 D-1 P1 UN-LOAD (BP-CUT) Service diagnosis Screen checking screen No. Checking object 1 Checking contents and remedy • P1 unload proportional valve PSV-D When D012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Screen No. Checking object 1 • P1 unload proportional valve PSV-D Checking contents and remedy When D013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. normal condition Screen No. event of failure Returned in It returns automatically in normal condition. 8 D-1 P1 UN-LOAD (BP-CUT) Service diagnosis Screen checking screen No. Control in the Set output of P1 unload proportional valve to 0mA.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 52 Error code D012 Trouble P1 unload proportional valve and output transistor ON are failure. event of failure Returned in It returns automatically in normal condition. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Judging condition The feed-back value from proportional valve is 1000 mA or more. (Valve emergency mode). 2 • Wiring between P1 unload proportional valve and controller CN-120F CN-105F When D012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. 2 • Wiring between P1 unload proportional valve and controller CN-120F CN-105F When D013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Table 53 Error code D013 Trouble P1 unload proportional valve’s wiring is disconnected. normal condition Screen No. Judging condition The feed-back value from proportional valve is 100 mA or less.) Symptom Option conflux can not be done. (If output is 100 mA or less. Symptom Option conflux can not be done. (Valve emergency mode). judging is not done. Control in the Set output of P1 unload proportional valve to 0 mA. Screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller. T5-1-34 . If failure found. If failure found.

8 D-2 P2 UN-LOAD (BP-CUT) Service diagnosis Screen checking screen No. Control in the Set output of P2 unload proportional valve to 0 mA. replace it. If failure found. Symptom Independent operations of boom up and of bucket digging/dump become slow. Screen No. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. T5-1-35 . normal condition Screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 54 Error code D022 Trouble P2 unload proportional valve and output transistor ON are failure. Judging condition The feed-back value from proportional valve is 1000 mA or more. Check sensor unit for possible failure. (Valve emergency mode) event of failure Returned in It returns automatically in normal condition. Checking object 1 • P2 unload proportional valve PSV-B Checking contents and remedy When D022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. 2 • Wiring between P2 unload proportional valve and controller CN-118F CN-105F When D022 is displayed after turning the starter switch on after the connector is exchanged with other sensor.

Screen No. Check sensor unit for possible failure. Control in the Set Travel straight proportional valve output to 0 mA event of failure Returned in It returns automatically in normal condition. normal condition Screen No. replace it. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Judging condition The feed-back value from proportional valve is 1000 mA or more Symptom Travel deviation occurs by combined operation of travel and attachment. T5-1-36 . Judging condition The feed-back value from proportional valve is 100 mA or less. If failure found. (Valve emergency mode) event of failure Returned in It returns automatically in normal condition. judging is not done. 8 D-3 S-TRAVEL Service diagnosis Screen checking screen No. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. normal condition Screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 2 • Wiring between P2 unload proportional valve and controller CN-118F CN-105F When D023 is displayed after turning the starter switch on after the connector is exchanged with other sensor.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 55 Error code D023 Trouble P2 unload proportional valve’s wiring is disconnected. Screen No. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. PSV-C proportional When D032 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. replace it. 8 D-2 P2 UN-LOAD (BP-CUT) Service diagnosis Screen checking screen No. (If output is 100 mA or less. If failure found. Checking object 1 Checking contents and remedy • P2 unload proportional valve PSV-B When D023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Table 56 Error code D032 Trouble Travel straight proportional valve and output transistor ON are failure. Control in the Set output of P2 unload proportional valve to 0 mA. Check sensor unit for possible failure. Checking object straight Checking contents and remedy 1 • Travel valve 2 • Wiring between Travel straight proportional valve and controller CN-119F CN-105F When D032 is displayed after turning the starter switch on after the connector is exchanged with other sensor.) Symptom Independent operations of boom up and of bucket digging/dump become slow.

Control in the Set Travel straight proportional valve output to 0 mA. Check sensor unit for possible failure. normal condition Screen No. 8 D-3 S-TRAVEL Service diagnosis Screen checking screen No. Judging condition The feed-back value from proportional valve is 100 mA or less. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. PSV-C proportional When D033 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Screen No. T5-1-37 .TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 57 Error code D033 Trouble Travel straight proportional valve’s wiring is disconnected. 3 • Mechatro controller Check that the error is corrected after replacement of controller. (If output is 100 mA or less. Checking object straight Checking contents and remedy 1 • Travel valve 2 • Wiring between Travel straight proportional valve and controller CN-119F CN-105F When D033 is displayed after turning the starter switch on after the connector is exchanged with other sensor.) Symptom Travel deviation occurs by combined operation of travel and attachment. event of failure Returned in It returns automatically in normal condition. If failure found. replace it. judging is not done.

Check sensor unit for possible failure. Checking object Checking contents and remedy 1 • Arm-in spool 2 proportional When D062 is cancelled and other error occurs by turning starter switch on after valve exchanging the connector with other sensor. PSV-A 2 • Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F When D062 is displayed after turning the starter switch on after the connector is exchanged with other sensor. event of failure Returned in It returns automatically in normal condition. Control in the Set Arm-in spool 2 proportional valve output to 0 mA. normal condition Screen No. replace it.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 58 Error code D062 Trouble Arm-in spool 2 proportional valve and output transistor ON are failure. 8 D-4 ARM IN-2-SPEED Service diagnosis Screen checking screen No. T5-1-38 . Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller. If failure found. Screen No. Judging condition The feed-back value from proportional valve is 1000 mA or more Symptom Operability of combined operation with arm-in becomes poor.

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Table 60 Error code D152 Trouble Judging condition Symptom Control in the event of failure Returned in normal condition Screen No. normal condition Screen No. Checking object Checking contents and remedy 1 • Arm-in spool 2 proportional When D063 is cancelled and other error occurs by turning starter switch on after valve exchanging the connector with other sensor. judging is not done. Checking object Checking contents and remedy 1 2 3 • T5-1-39 . replace it. Control in the Set Arm-in spool 2 proportional valve output to 0 mA. event of failure Returned in It returns automatically in normal condition. Screen No. If failure found. Judging condition The feed-back value from proportional valve is 100 mA or less.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 59 Error code D063 Trouble Arm-in spool 2 proportional valve’s wiring is disconnected. (If output is 100 mA or less. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Service diagnosis Screen checking screen No.) Symptom Operability of combined operation with arm-in becomes poor. 8 D-4 ARM IN-2-SPEED Service diagnosis Screen checking screen No. PSV-A 2 • Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F When D063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check sensor unit for possible failure. Screen No.

If failure found. When replacing of connector is executed. Symptom The delicate operability of P2 pump related attachment becomes poor. T5-1-40 .E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 61 Error code D153 Trouble Judging condition Symptom Control in the event of failure Returned in normal condition Screen No. turn off power source once. Judging condition The feed-back value from proportional valve is 1000 mA or more. turn off power source once. Checking object Checking contents and remedy 1 2 3 • Table 62 Error code E012 Trouble P1 pump proportional valve and output transistor ON are failure. Check sensor unit for possible failure. Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. Screen No. PSV-P1 2 • Wiring between P1 pump proportional valve and controller CN-141F CN-105F When E012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. 9 E-1 PUMP P1 Service diagnosis Screen checking screen No. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Service diagnosis Screen checking screen No. Switch the power OFF once and turns on it again. 1 Checking object Checking contents and remedy • P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. replace it. normal condition Screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller. When replacing of connector is executed. event of failure (Hydraulic pump emergency mode) Returned in Not returned automatically under normal condition. Screen No.

Screen No. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Judging condition The feed-back value from proportional valve is 100 mA or less. 1 Checking object Checking contents and remedy • P1 pump proportional valve When E013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. event of failure (Hydraulic pump emergency mode) Returned in Not returned automatically under normal condition. PSV-P1 2 • Wiring between P1 pump proportional valve and controller CN-141F CN-105F When E013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. turn off power source once.) Symptom The delicate operability of P2 pump related attachment becomes poor. When replacing of connector is executed. normal condition Screen No. When replacing of connector is executed. 3 • Mechatro controller Check that the error is corrected after replacement of controller. replace it. If failure found. judging is not done. turn off power source once. Check sensor unit for possible failure.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 63 Error code E013 Trouble P1 pump proportional valve’s wiring is disconnected. Switch the power OFF once and turns on it again. 9 E-1 PUMP P1 Service diagnosis Screen checking screen No. T5-1-41 . (If output is 100mA or less. Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.

replace it. If failure found. turn off power source once. Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 9 E-2 PUMP P2 Service diagnosis Screen checking screen No.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 64 Error code E022 Trouble P2 pump proportional valve and output transistor ON are failure. Screen No. normal condition Screen No. Table 65 Error code E023 Trouble P2 pump proportional valve’s wiring is disconnected. Judging condition The feed-back value from proportional valve is 100 mA or less. turn off power source once. Symptom The delicate operability of P2 pump related attachment becomes poor. replace it. 9 E-2 PUMP P2 Service diagnosis Screen checking screen No. turn off power source once. When replacing of connector is executed. Judging condition The feed-back value from proportional valve is 1000 mA or more. When replacing of connector is executed. T5-1-42 . PSV-P2 2 • Wiring between P2 pump proportional valve and controller CN-142F CN-105F When E023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. 1 Checking object Checking contents and remedy • P2 pump proportional valve When E023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Switch the power OFF once and turns on it again. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. PSV-P2 2 • Wiring between P2 pump proportional valve and controller CN-142F CN-105F When E022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. When replacing of connector is executed. Screen No. Check sensor unit for possible failure. (If output is 100 mA or less. 3 • Mechatro controller Check that the error is corrected after replacement of controller. When replacing of connector is executed. turn off power source once. normal condition Screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller. If failure found.) Symptom The delicate operability of P2 pump related attachment becomes poor. judging is not done. event of failure (Hydraulic pump emergency mode) Returned in Not returned automatically under normal condition. event of failure (Hydraulic pump emergency mode) Returned in Not returned automatically under normal condition. Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. Check sensor unit for possible failure. Switch the power OFF once and turns on it again. 1 Checking object Checking contents and remedy • P2 pump proportional valve When E022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor.

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. normal condition Screen No. Symptom ATT boost is not available. If failure found. SV-2 2 • Wiring between ATT boost solenoid valve and controller CN-117F CN-105F When F011 is displayed after the connector is exchanged with other solenoid valve. T5-1-43 . 3 F-1 POWER BOOST Service diagnosis Screen checking screen No. event of failure Returned in The feed-back signal is 24V level while exciting command is output. 1 Checking object Checking contents and remedy • ATT boost solenoid valve When F011 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Control in the Normal control. 3 • Mechatro controller Check that the error is corrected after replacement of controller.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 66 Error code F011 Trouble ATT boost solenoid valve and output transistor OFF are failure. replace it. Judging condition The feed-back signal is grounding level while exciting command is output. and grounding is short-circuit. Screen No. Check solenoid valve unit for possible failure.

1 Checking object Checking contents and remedy • ATT boost solenoid valve When F013 is cancelled and other error occurs by exchanging the connector for other solenoid valve. 3 F-1 POWER BOOST Service diagnosis Screen checking screen No. normal condition Screen No. If failure found. event of failure Returned in The feed-back signal is grounding level while exciting command is not output. Control in the Normal control. Symptom ATT boost is not available or is leaving available. Judging condition The feed-back signal is 24 V level while exciting command is not output. T5-1-44 . and disconnection. Check solenoid valve unit for possible failure. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 3 • Mechatro controller Check that the error is corrected after replacement of controller.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 67 Error code F013 Trouble ATT boost solenoid valve and output transistor ON are failure. Screen No. replace it. SV-2 2 • Wiring between ATT boost solenoid valve and controller CN-117F CN-105F When F013 is displayed after the connector is exchanged with other solenoid valve.

event of failure Returned in The feed-back signal is 24 V level while exciting command is output. 2 • Wiring between swing parking solenoid valve and controller CN-123F CN-105F When F023 is displayed after the connector is exchanged with other solenoid valve. If failure found. replace it. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. normal condition Screen No. If failure found. 3 F-2 SWING-BRAKE Service diagnosis Screen checking screen No. Screen No. Screen No. Checking object 1 • Swing parking solenoid valve SV-1 Checking contents and remedy When F023 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Symptom Swing parking is not available or is leaving available. replace it. 2 • Wiring between swing parking solenoid valve and controller CN-123F CN-105F When F021 is displayed after the connector is exchanged with other solenoid valve. replace it. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. T5-1-45 . Check solenoid valve unit for possible failure. normal condition Screen No.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 68 Error code F021 Trouble Swing parking solenoid valve and output transistor OFF are failure. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Control in the Normal control. If failure found. Check solenoid valve unit for possible failure. 3 • Mechatro controller Check that the error is corrected after replacement of controller. 3 F-1 POWER BOOST Service diagnosis Screen checking screen No. and disconnection. Symptom Swing parking is not available. Check solenoid valve unit for possible failure. Judging condition The feed-back signal is grounding level while exciting command is output. Control in the Normal control. Checking object 1 Checking contents and remedy • Swing parking solenoid valve SV-1 When F021 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Judging condition The feed-back signal is 24 V level while exciting command is not output. event of failure Returned in The feed-back signal is grounding level while exciting command is output. and grounding is short-circuit. Table 69 Error code F023 Trouble Swing parking solenoid valve and output transistor ON are failure.

event of failure Returned in The feed-back signal is 24 V level while exciting command is output.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 70 Error code F031 Trouble Travel 1. Judging condition The feed-back signal is grounding level while exciting command is output. Symptom Travel 2 speed is not obtainable. SV-3 Check solenoid valve unit for possible failure. 2 • Wiring between travel 1. Control in the Normal control. If failure found. 2 speed solenoid valve and output transistor OFF are failure. 2 speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector for other solenoid valve. normal condition Screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller. replace it. Screen No. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 2 speed solenoid valve and controller CN-123F CN-105F When F031 is displayed after the connector is exchanged with other solenoid valve. and grounding is short-circuit. T5-1-46 . Checking object Checking contents and remedy 1 • Travel 1. 3 F-3 1/2-TRAVEL Service diagnosis Screen checking screen No.

If failure found. 3 F-3 1/2-TRAVEL Service diagnosis Screen checking screen No. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 11 F-4 OPT SELECT Service diagnosis Screen checking screen No. Symptom Option selector valve does not change to breaker side. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Checking object 1 • Option selector solenoid valve SV-13 Checking contents and remedy When F041 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Table 72 Error code F041 Trouble Option selector solenoid valve and output transistor OFF are failure. T5-1-47 .. 2 • Wiring between option selector solenoid valve and controller CN-251F CN-105F When F041 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Control in the Normal control. 2 speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector for other solenoid valve. 2 speed solenoid valve and output transistor ON are failure. and disconnection. 3 • Mechatro controller Check that the error is corrected after replacement of controller. replace it. Screen No. Screen No. Checking object Checking contents and remedy 1 • Travel 1. normal condition Screen No. 2 speed solenoid valve and controller CN-122F CN-105F When F033 is displayed after the connector is exchanged with other solenoid valve. Judging condition The feed-back signal is 24 V level while exciting command is not output. SV-3 Check solenoid valve unit for possible failure. Control in the Normal control. replace it. event of failure Returned in The feed-back signal is grounding level while exciting command is not output. Symptom Travel 2 speed is not obtainable or is keeping 1 speed. If failure found. 2 • Wiring between travel 1. Check solenoid valve unit for possible failure. Judging condition The feed-back signal is grounding level while exciting command is output. event of failure Returned in The feed-back signal is ground level while exciting command is output. normal condition Screen No.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 71 Error code F033 Trouble Travel 1. and grounding is short-circuit.

2 • Wiring between option selector solenoid valve and controller CN-251F CN-105F When F043 is displayed after the connector is exchanged with other solenoid valve. Screen No. event of failure Returned in The feed-back signal is ground level while exciting command is not output. 11 F-4 OPT SELECT Service diagnosis Screen checking screen No. Control in the Normal control. Table 74 Error code G011 Trouble Judging condition Symptom Control in the event of failure Returned in normal condition Screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Screen No. Checking object 1 • Option selector solenoid valve SV-13 Checking contents and remedy When F043 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Service diagnosis Screen checking screen No. and disconnection. replace it. Symptom Option selector valve does not change to breaker side or it does not change from breaker to nibbler. If failure found. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. normal condition Screen No. Judging condition The feed-back signal is 24 V level while exciting command is not output.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 73 Error code F043 Trouble Option selector solenoid valve and output transistor ON are failure. Check solenoid valve unit for possible failure. Checking object Checking contents and remedy 1 2 3 • T5-1-48 .

Screen No. Checking object Checking contents and remedy 1 2 3 • T5-1-49 E215B-E245B .TROUBLESHOOTING (BY ERROR CODES) Table 75 Error code G013 Trouble Judging condition Symptom Control in the event of failure Returned in normal condition Screen No. Service diagnosis Screen checking screen No. Service diagnosis Screen checking screen No. Checking object Checking contents and remedy 1 2 3 • Table 76 Error code G023 Trouble Judging condition Symptom Control in the event of failure Returned in normal condition Screen No. Screen No.

). Normal value: 1. 2 • Wiring between option selector Check wiring for possible failure according to the wiring checking solenoid valve and controller procedure and repair it if necessary. Table 78 Error code G033 Trouble Mechatro controller direct input speed sensor. Check that the error is corrected after replacement of controller. Checking object Checking contents and remedy 1 • Engine speed sensor Measure the resistance between terminals of speed sensor. normal condition Screen No. and speed sensor indicates excess low engine rpm. CN-105F 3 • Mechatro controller SV-13 Normal value: 1. Symptom Operate without problem. 2 G-3 MEAS 2 (receive from engine controller) Screen No. CN-251F Especially check wiring for false disconnection and noise included.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 77 Error code G032 Trouble Mechatro controller direct input speed sensor is overrun. 2 G-3 MEAS 2 (receive from engine controller) Screen No. Symptom Operate without problem. CN-136F CN-106F 3 • Mechatro controller Check that the error is corrected after replacement of controller. event of failure Returned in It returns automatically in normal condition. (Controller is broken by only applying power to grounding of signal. normal condition Screen No. Control in the Receive rpm from engine controller and control the rpm. event of failure Returned in It returns automatically in normal condition.0k . Control in the Receive rpm from engine controller and control the rpm.6~2. Disconnection.6~2. Checking object 1 • Engine speed sensor SE-13 Checking contents and remedy Measure the resistance between terminals of speed sensor. 2 G-3 MEAS 1 (for mechatro controller) Service diagnosis Screen checking screen No. (Only trouble history).0k . 2 • Wiring between engine speed sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. 2 G-3 MEAS 1 (for mechatro controller) Service diagnosis Screen checking screen No. Judging condition Voltage of alternator is 12 V or more. Judging condition Engine rpm input is 3000 rpm or more. T5-1-50 .

T5-1-51 . Checking object 1 Checking contents and remedy • Accel potentiometer Measure the resistance between terminals of speed sensor. CN-402F CN-102F 3 • Mechatro controller Check that the error is corrected after replacement of controller.7 V or more.0k . Turn the potentiometer and measure resistance between signal and GND. event of failure Returned in It returns automatically in normal condition. Checking object 1 • Accel potentiometer SE-16 Checking contents and remedy Measure the resistance between terminals of accel potentiometer. Screen No.1 V or less. CN-402F CN-102F 3 • Mechatro controller Check that the error is corrected after replacement of controller. Service diagnosis Screen checking screen No. Symptom LOW idling is fixed. 1. SE-16 2 • Wiring between accel potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Control in the LOW idling is fixed. normal condition Screen No. 2 • Wiring between accel potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Service diagnosis Screen checking screen No. event of failure Returned in It returns automatically in normal condition. Screen No. normal condition Screen No. 2 H-1 ACCEL VOLT. Judging condition The input voltage from accel potentiometer is 0. 2 H-1 ACCEL VOLT. 1. Judging condition The input voltage from accel potentiometer is 4.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 79 Error code H013 Trouble Accel potentiometer is disconnected.6~2. Table 80 Error code H014 Trouble Accel potentiometer’s power source is shortcut.4k Turn the potentiometer and measure resistance between signal and GND. Control in the LOW idling is fixed.6~2. Symptom LOW idling is fixed.

E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 81 Error code H023 Trouble Boom angle potentiometer’s wiring is disconnected. Screen No. Control in the Normal control.0)k 2 • Wiring between boom angle potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.0~6. Turn the potentiometer and measure resistance between signal and GND. 12 H-2 BOOM Service diagnosis Screen checking screen No. Symptom Indications of rating load and working radius of High-reach crane become abnormal.0k . normal condition Screen No. Checking object 1 • Boom angle potentiometer SE-17 Checking contents and remedy Measure the resistance between terminals of boom angle potentiometer. T5-1-52 . Judging condition The input voltage from boom angle potentiometer is 0. 4.0~6.1 V or less. CN-702F CN-103F 3 • Mechatro controller Check that the error is corrected after replacement of controller. event of failure Returned in It returns automatically in normal condition. Normal value: 0 to all resistance (4.

0k . normal condition Screen No. Normal value: 0 to all resistance (4. T5-1-53 . event of failure Returned in It returns automatically in normal condition. Checking object 1 • Boom angle potentiometer SE-17 Checking contents and remedy Measure the resistance between terminals of boom angle potentiometer. 4.0~6.0~6. Screen No. Control in the Normal control. Judging condition The input voltage from boom angle potentiometer is 0.0)k 2 • Wiring between boom angle potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Turn the potentiometer and measure resistance between signal and GND.1 V or less.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 82 Error code H024 Trouble Boom angle potentiometer’s power source is shortcut. CN-702F CN-103F 3 • Mechatro controller Check that the error is corrected after replacement of controller. Symptom Indications of rating load and working radius of High-reach crane become abnormal. 12 H-2 BOOM Service diagnosis Screen checking screen No.

E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 83 Error code H033 Trouble Arm angle potentiometer’s wiring is disconnected.0~6.0~6. event of failure Returned in It returns automatically in normal condition.0)k 2 • Wiring between arm angle potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Symptom Indications of rating load and working radius of High-reach crane become abnormal. Control in the Normal control. CN-703F CN-103F 3 • Mechatro controller Check that the error is corrected after replacement of controller. Normal value: 0 to all resistance (4. 4. Judging condition The input voltage from arm angle potentiometer is 0.1 V or less. normal condition Screen No. 12 H-3 ARM Service diagnosis Screen checking screen No.0k . Screen No. Turn the potentiometer and measure resistance between signal and GND. T5-1-54 . Checking object 1 • Arm angle potentiometer SE-18 Checking contents and remedy Measure the resistance between terminals of arm angle potentiometer.

Screen No.1 V or less. Normal value: 0 to all resistance (4. event of failure Returned in It returns automatically in normal condition. 12 H-3 ARM Service diagnosis Screen checking screen No.0~6.0)k 2 • Wiring between arm angle potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Judging condition The input voltage from arm angle potentiometer is 0. 4.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 84 Error code H034 Trouble Arm angle potentiometer’s power source is shortcut. Control in the Normal control. normal condition Screen No. Symptom Indications of rating load and working radius of High-reach crane become abnormal. Checking object 1 • Arm angle potentiometer SE-18 Checking contents and remedy Measure the resistance between terminals of arm angle potentiometer.0k . CN-703F CN-103F 3 • Mechatro controller Check that the error is corrected after replacement of controller. Turn the potentiometer and measure resistance between signal and GND. T5-1-55 .0~6.

normal condition Screen No. event of failure Returned in It returns automatically in normal condition.7 V or more. normal condition Screen No.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 85 Error code H091 Trouble Fuel sensor grounding is short-circuited. SE-15 EMPTY 95 .1 V or less. 10 H-9 FUEL LEVEL Service diagnosis Screen checking screen No. SE-15 EMPTY 95 . Symptom Warning for low fuel level is indicated. Screen No. Control in the Fuel level becomes 0%. CN-152F CN-104F 3 • Mechatro controller Check that the error is corrected after replacement of controller. Table 86 Error code H093 Trouble Fuel sensor’s wiring is disconnection. Screen No. event of failure Returned in It returns automatically in normal condition.~ FULL 5 2 • Wiring between fuel sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Judging condition The input voltage from fuel sensor is 4. 1 Checking object Checking contents and remedy • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel sensor. Symptom Warning for low fuel level is indicated.~ FULL 5 2 • Wiring between fuel sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Judging condition The input voltage from fuel sensor is 0. 1 Checking object Checking contents and remedy • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel sensor. CN-152F CN-104F 3 • Mechatro controller Check that the error is corrected after replacement of controller. Control in the Fuel level becomes 0%. T5-1-56 . 10 H-9 FUEL LEVEL Service diagnosis Screen checking screen No.

T5-1-57 . CN-600F CN-101F 2 • Mechatro controller Check that the error is corrected after replacement of controller. Checking object Checking contents and remedy 1 • Wiring between gauge cluster and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. normal condition Screen No.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 87 Error code I313 Trouble Reception of cluster communication is abnormal. event of failure Returned in It returns automatically in normal condition. (Time-out error) Judging condition Reception from gauge cluster can not receive correctly. Screen No. Service diagnosis Screen checking screen No. Symptom Switch operation of gauge cluster can not be done. Control in the Keep the condition after immediately key-on is operated.

Check that no power 24 V is produced on relay (-) line according to the wiring controller checking procedure and replace it if necessary. Screen No. The failure may be occurred in case where the power falls after the relay was removed. remove either auto idling stop relay 2 or alternator relay. 2 • Auto idle stop relay 2 R-24 • Alternator relay Turn off the key switch. check on battery relay for failure and replace it if failed. Checking object Checking contents and remedy 1 • Battery relay R-1 CN-256F Turn key switch off and disconnect the connector (CN-256F) on the battery relay coil. E-1 4 • Mechatro controller Check that the error is corrected after replacement of controller. CN2-1 When no failure found after checking on wiring and K014 is left displayed • Fuse& relay box Replace fuse/relay box. R-28 3 • Wiring between auto idle stop relay/alternator relay and When K014 is left displayed with the relay removed. 4 K-3 KEY SWITCH OFF Screen No. If power of battery relay on secondary side falls. event of failure Returned in Turn key switch ON. and remove the connector (CN-256F) on the battery relay coil side. T5-1-58 . Symptom The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF. Judging condition The power 24 V is continuously supplied to controller for 40 seconds or more while the key switch ON signal turned OFF. CN-109F. If 24 V power lives on battery relay secondary side. and therefore check on the relay unit and replace it with new one if failed. 4 K-1 AIS RELAY 2 Service diagnosis Screen checking screen No. Control in the Normal control with key switch OFF.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 88 Error code K014 Trouble Battery relay contact welded. normal condition Or when the power supply 24 V to mechatro controller is stopped.

Checking object Checking contents and remedy 1 • Wiper motor arc prevention When error is cancelled after removing wiper motor arc prevention relay. 25 PREVENT ARC Service diagnosis Screen checking screen No. it is in abnormal condition. 2 • Wiring between wiper motor arc prevention relay and controller CN-109F. replace it with new one if failed. Symptom Wiper does not move. Judging condition The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the power source. Check that the error is corrected after replacement of controller. normal condition Screen No. Replace fuse/relay box. CN2-1 • Fuse& relay box E-1 3 • Mechatro controller When R014 is left displayed with the relay removed. T5-1-59 . event of failure Returned in When the power is OFF. check relay unit for failure.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 89 Error code R014 Trouble Wiper motor arc prevention relay error. When no failure found after checking on wiring and R014 is left displayed. Control in the Relay output is stopped. Screen No. Check that no power 24 V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. relay R-31 When resistance between relays (1) and (2) is 0 .

event of failure Returned in When the power is OFF. Checking object Checking contents and remedy 1 • Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay. Judging condition The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the power source. Symptom Wiper does not move. 2 • Wiring between wiper motor forward rotation relay and When R024 is left displayed with the relay removed. normal condition Screen No. E-1 3 • Mechatro controller Check that the error is corrected after replacement of controller. replace it with new one if failed. it is in abnormal condition. CN-109F.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 90 Error code R024 Trouble Wiper motor forward rotation relay error. check relay unit for failure. CN2-1 When no failure found after checking on wiring and R024 is left displayed. Check that no power 24 V is produced on relay (-) line according to the wiring controller checking procedure and replace it if necessary. • Fuse& relay box Replace fuse/relay box. Control in the Relay output is stopped. Screen No. 25 CW MOTOR RLY Service diagnosis Screen checking screen No. T5-1-60 . relay R-29 When resistance between relays (1) and (2) is 0 .

Control in the Relay output is stopped. replace it with new one if failed. Judging condition The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the power source. T5-1-61 . CN-109F. it is in abnormal condition. 2 • Wiring between wiper motor forward rotation relay and When R034 is left displayed with the relay removed Check that no power 24 V is produced on relay (-) line according to the wiring controller checking procedure and replace it if necessary. E-1 3 • Mechatro controller Check that the error is corrected after replacement of controller. CN2-1 When no failure found after checking on wiring and R034 is left displayed • Fuse& relay box Replace fuse/relay box. Symptom Wiper does not move after forward rotation. event of failure Returned in When the power is OFF. check relay unit for failure. 25 CCW MOTOR RLY Service diagnosis Screen checking screen No.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 91 Error code R034 Trouble Wiper motor reverse rotation relay error. Checking object Checking contents and remedy 1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay. normal condition Screen No. Screen No. relay R-30 When resistance between relays (1) and (2) is 0 .

E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 92 Error code R044 Trouble Washer motor relay error. E-1 3 • Mechatro controller Check that the error is corrected after replacement of controller. Symptom Washer motor does not move. replace it with new one if failed. it is in abnormal condition. When resistance between relays (1) and (2) is 0 . T5-1-62 . 2 • Wiring between washer motor When R044 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring CN-112F. Screen No. Checking object 1 • Washer motor relay R-32 Checking contents and remedy When error is cancelled after removing washer motor relay. • Fuse& relay box When no failure found after checking on wiring and R044 is left displayed Replace fuse/relay box. normal condition Screen No. check relay unit for failure. Control in the Relay output is stopped. Judging condition The mechatro controller output line to washer motor relay is short-circuited with the power source. 25 MOTOR RELAY Service diagnosis Screen checking screen No. event of failure Returned in When the power is OFF. CN2-1 checking procedure and replace it if necessary.

it is in abnormal 2 • Wiring between swing flasher When R134 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line (as shown right upper CN-74F. normal condition Screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Control in the Relay output is stopped. replace it with new one if failed. Symptom Right swing flasher does not light. Checking object 1 • Swing flasher relay R-19 Checking contents and remedy When error is cancelled after removing connector (CN-74F) of swing flasher relay. . event of failure Returned in When the power is OFF. Judging condition The mechatro controller output line to swing flasher relay is short-circuited with the power source. Screen No. T5-1-63 . 22 D13 Service diagnosis Screen checking screen No.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 93 Error code R134 Trouble Swing flasher relay error. CN-109F figure C) according to the wiring checking procedure and replace it if necessary. check relay unit for failure. When resistance between relays (HB) and (HC) is 0 condition.

CN-109F figure B) according to the wiring checking procedure and replace it if necessary. Screen No. . When resistance between relays (HB) and (HC) is 0 condition. Control in the Relay output is stopped. it is in abnormal 2 • Wiring between swing flasher When R144 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line (as shown right upper CN-74F. T5-1-64 .E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 94 Error code R144 Trouble Swing flasher relay error. 22 D14 Service diagnosis Screen checking screen No. 3 • Mechatro controller Check that the error is corrected after replacement of controller. Symptom Left swing flasher does not light. Checking object 1 • Swing flasher relay R-19 Checking contents and remedy When error is cancelled after removing connector (CN-74F) of swing flasher relay. check relay unit for failure. replace it with new one if failed. Judging condition The mechatro controller output line to swing flasher relay is short-circuited with the power source. normal condition Screen No. event of failure Returned in When the power is OFF.

check relay unit for failure. Replace fuse/relay box. Symptom Travel alarm does not actuate. Control in the Relay output is stopped. 2 • Wiring between travel alarm When R154 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring CN-109F. When resistance between relays (1) and (2) is 0 . Checking object 1 • Travel alarm relay R-8 Checking contents and remedy When error is cancelled after removing of travel alarm relay.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 95 Error code R154 Trouble Travel alarm relay error. 23 D15 Service diagnosis Screen checking screen No. E-1 3 • Mechatro controller Check that the error is corrected after replacement of controller. Screen No. it is in abnormal condition. event of failure Returned in When the power is OFF. Judging condition The mechatro controller output line to travel alarm relay is short-circuited with the power source. T5-1-65 . normal condition Screen No. CN2-2 checking procedure and replace it if necessary. • Fuse & relay box When no failure found after checking on wiring and R154 is left displayed. replace it with new one if failed.

event of failure Returned in When the power is OFF. When resistance between relays (1) and (2) is 0 . replace it with new one if failed. normal condition Screen No. it is in abnormal condition. Control in the Relay output is stopped. 1 Checking object Checking contents and remedy • Auto idle stop relay 2 relay R-24 When error is cancelled after removing of auto idle stop relay 2. Replace fuse/relay box. • Fuse & relay box When no failure found after checking on wiring and R164 is left displayed. Screen No. 4 K-1 AIS RELAY 2 Service diagnosis Screen checking screen No. check relay unit for failure.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 96 Error code R164 Trouble Auto idle stop relay 2 relay error. T5-1-66 . 2 • Wiring between auto idle stop When R164 is left displayed with the relay removed relay 2 and controller Check that no power 24 V is produced on relay (-) line according to the wiring CN-109F. Symptom Power source for mechatro controller often turns off. Auto idle stop relay 2 does not actuate. Judging condition The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source. E-1 3 • Mechatro controller Check that the error is corrected after replacement of controller. CN2-2 checking procedure and replace it if necessary.

2 • Wiring between engine forcibly When R174 is left displayed with the relay removed stop relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring CN-109F. Screen No. CN2-2 checking procedure and replace it if necessary. Symptom When key switch is turned off but engine does not stop. • Fuse & relay box When no failure found after checking on wiring and R174 is left displayed.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 97 Error code R174 Trouble Engine forcibly stop relay error. T5-1-67 . 1 Checking object Checking contents and remedy • Engine forcibly stop relay R-25 When error is cancelled after removing of engine forcibly stop relay. Judging condition The mechatro controller output line to engine forcibly stop is short-circuited with the power source. check relay unit for failure. event of failure Returned in When the power is OFF. E-1 3 • Mechatro controller Check that the error is corrected after replacement of controller. 4 K-3 ENG STOP Service diagnosis Screen checking screen No. replace it with new one if failed. Control in the Relay output is stopped. normal condition Screen No. Engine auto idle stop function does not actuate.. Replace fuse/relay box. When resistance between relays (1) and (2) is 0 . it is in abnormal condition.

replace it with new one if failed. When no failure found after checking on wiring and R184 is left displayed. 4 K-4 LOCK LEVER Service diagnosis Screen checking screen No. Check that the error is corrected after replacement of controller. CN2-2 • Fuse & relay box E-1 3 • Mechatro controller . When R184 is left displayed with the relay removed Check that no power 24 V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. Checking object 1 • Safety lock lever relay R-26 Checking contents and remedy When error R184 is cancelled after removing of safety lock lever relay. check relay unit for failure. Symptom Safety lock lever timer does not actuate.E215B-E245B TROUBLESHOOTING (BY ERROR CODES) Table 98 Error code R184 Trouble Safety lock lever relay error. Control in the Relay output is stopped. event of failure Returned in When the power is OFF. Screen No. it is in abnormal condition. T5-1-68 . When resistance between relays (1) and (2) is 2 • Wiring between safety lock lever relay and controller CN-109F. Judging condition The mechatro controller output line to safety lock lever relay is short-circuited with the power source. normal condition Screen No. Replace fuse/relay box.

check relay unit for failure. replace it with new one if failed. Control in the Relay output is stopped. When R214 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary.TROUBLESHOOTING (BY ERROR CODES) E215B-E245B Table 99 Error code R214 Trouble Safety relay error. When no failure found after checking on wiring and R214 is left displayed. T5-1-69 . it is in abnormal condition. Check that the error is corrected after replacement of controller. event of failure Returned in When the power is OFF. CN2-2 • Fuse & relay box 3 • Mechatro controller E-1 . normal condition Screen No. Symptom Safety relay does not actuate. Replace fuse/relay box. Judging condition The mechatro controller output line to safety relay is short-circuited with the power source. Checking object 1 • Safety lock lever relay R-26 Checking contents and remedy When error R214 is cancelled after removing of safety relay. When resistance between relays (1) and (2) is 0 2 • Wiring between safety lock lever relay and controller CN-109F. 4 K-2 SAFETY RLY Service diagnosis Screen checking screen No. Screen No.

E215B-E245B TROUBLESHOOTING (BY ERROR CODES) [MEMO] T5-1-70 .

Travel 1st/2nd speed not changed 18. HYDRAULIC SYSTEM Preface: The troubleshooting for the failures shown below is explained here. Swing on a slope drifts when control lever is in neutral position 14.TROUBLESHOOTING (BY TROUBLE) E215B-E245B TROUBLESHOOTING BY TROUBLE 1. Poor fine operability 5. Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number. 1. insufficient power for lifting up body 7. Slow arm in. All controls do not function/slow 2. Slow bucket digging 10. 20. Engine down/stalled 3. Travel parking on a slope is not held 19. Option selector valve malfunction: not switched to breaker circuit 22. weak power 21. Swing operation not functioned/slow 12. Move at lever neutral position 4. Slow independent arm out (in the air) 9. Travel deviation 17. Slow bucket dumping 11. Swing drifts when swing operation is stopped 15. Slow travel speed/weak 16. insufficient power 6. Travel does not run straightly when both crawlers and attachment operated simultaneously. insufficient power 8. Slow breaker (crusher) operation. Noise during swing operation 13. Slow boom up. Option selector valve malfunction: not switched to nibbler circuit T5-2-1 . Slow boom down.

Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0. and 4 MPa or more by push it down. Check harness for possible failure. push up and it turns on. TROUBLESHOOTING (BY TROUBLE) All controls do not function/slow No. check on the short-circuited section.2 MPa in boom up full lever and high idling operation • No.19 Travel left full lever & idling T5-2-2 In case where the reading is largely differed from the actually measured value. Replace solenoid valve Pilot line filter Disassemble and check it visually Check filter for clogging Clean filter 8 Pilot gear pump Measure pilot Check that it is 4 MPa or more in high primary pressure at idling gear pump 9 Multi control valve (in Change position case that travel is operable) Since all are blocked due to poor switching performance. Check gear pump and the relief valve for possible failure In case where the reading is largely differed from the actually measured value. Check 5 V power for controller Measure pressure of solenoid A1 port About 0 MPa by pushing the lever up.4 (10 A) If the fuse is blown out. P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block 12 Actual measuring current value of P1/ P2 pump proportional valve Carry out service diagnosis Carry out service diagnosis.1 MPa. check proportional valve and controller for possible failure. or check that the power up and it turns off. No. 0 V by pushing it up 4 Safety lever lock relay Carry out service diagnosis 5 Pilot pressure sensor 6 Solenoid valve for safety lock lever 7 Check solenoid unit for possible failure.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No. voltage is lowered by pushing the lever down. 10 Actual measuring current value of P1/ P2 unload proportional valve • No. others 1 Fuse Check fuse No. 2 Safety lever lock switch Carry out service diagnosis No. check that the lever select pattern is set to the proper position.E215B-E245B 1. check proportional valve and controller for possible failure. push tester.3 Boom up full lever & relief 11 Secondary pressure Measure the of P1. • Stop engine stop and key is on position. Sections Contents/normal value Corrective action.18 Travel right full lever & idling Operation No.5 to 1. 3 Safety lever lock switching Check that the Measure both terminals of solenoid solenoid is switched connector. All pilot low pressure sensors are 0 MPa to 0.4 K-4 switch: Check action of switch by Push down the lever and it turns on. 24 V by pushing the lever correctly down.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.4 K-4 lock lever: Check action of relay by tester Push down the lever and it turns off. .

etc.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No. piston.3 Boom up full lever & relief actually 15 Check set pressure Check that P1 and P2 pump pressures are 32 MPa in boom up full lever. high idling and H mode operation. shaft. free from abnormal Replace resistance against sliding. Replace proportional valve 3 Pressure sensor of P1. inside parts (cylinder Replace block. abnormal damage. Sections Contents/normal value E215B-E245B Corrective action. 17 Pump Visual check When removing. free from abnormal resistance against sliding Free from abnormal damage. etc. damage. etc on outside surface Spring free from breakage. (Ports a3. etc on outside surface Spring free from breakage. piston. others • No. others 13 Secondary pressure Measure the pump of pump proportional proportional valve valve secondary pressure directly in idling operation. T5-2-3 . check proportional valve and controller for possible failure.0 MPa in control lever neutral and high idling operation. Engine down/stalled No. etc.TROUBLESHOOTING (BY TROUBLE) No. Sections 1 Actual measuring current value of P1/ P2 pump proportional valve 2 Contents/normal value Carry out service diagnosis Corrective action. etc. 1 Operation is nil Operation No. valve plate. P2 pump proportional valve proportional valve secondary pressure directly (Ports a3. shaft. inside parts (cylinder block.5 to 1. etc. P2 pump Check pressure • See Service Diagnosis Data List Operation No. 1 Operation is nil In case where the reading is largely differed from the actually measured value. valve plate. Replace 5 Pump Visual check Replace When removing. a4) Check that pump proportional valve Replace proportional valve secondary pressure is 2. Reset or replace 16 Pump regulator Visual check When removing. Free from abnormal damage. abnormal damage. etc. damage. Secondary pressure Measure the pump of P1.) are free from abnormal resistance against sliding. a4) Check that P1/P2 pump proportional valve pressures are within the range of 0.7 MPa or more in right (left) travel full lever and high idling operation Right travel: P1 pump proportional valve Left travel: P2 pump proportional valve 14 Main relief pressure Carry out service diagnosis • See Service Diagnosis Data List Measure the relief pressure Operation No. 2.) are free from abnormal resistance against sliding.3 Boom up full lever & relief Check pressure sensor and replace it if necessary 4 Pump regulator Visual check When removing.

Sections Contents/normal value Corrective action. Seat is free from abnormality Replace 5 Lock valve poppet Check targeted (in case of boom and poppet visually arm) Seat is free from abnormality Replace 6 Lock valve selector Exchange lock (in case of boom and valve selector of arm) boom/arm and boom/arm Check that the trouble is reversed Replace 7 Holding valve spool for boom (in case of boom) Check that smooth sliding of spool in sleeve Free from abnormal resistance against sliding Replace Do not pull spool out of sleeve forcibly. Check that P1/P2 unloads secondary Replace proportional valve pressures is within the range of 2.7 MPa or more in control lever neutral and high idling operation T5-2-4 . others 1 Pressure sensor Carry out service diagnosis • See Service Diagnosis Data List Replace pressure sensor Operation No.E215B-E245B 3. TROUBLESHOOTING (BY TROUBLE) Move at lever neutral position No.1 MPa 2 Actual measuring current value of P1/ P2 unload proportional valve Carry out service diagnosis • No. 8 Holding valve relief valve for boom (in case of boom) Check targeted spool visually Filter free from abnormal contamination Replace 9 Cylinder Check targeted cylinder visually Make sure of no problem of seals by disassembling and investigation 4. 1 Operation is nil • All low pressure sensors are 0MPa to 0. 1 Operation is nil 3 Secondary pressure Measure the of unload proportional valve proportional valve secondary pressure directly at the ports A7 and A8 of 8 sections solenoid block In case where the reading is largely differed from the actually measured value.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No. others 1 Pilot pressure sensor Carry out service diagnosis Check that targeted pilot pressure of sensor is 0MPa in high idling Check remote control valve 2 Remote control valve Check targeted remote control valve Check that spool is free from abnormal damage and spring is free from breakage Replace 3 Main spool Check targeted spool visually Check that spool is free from abnormal damage and spring is free from breakage Replace 4 Over load relief valve Check targeted spool visually Free from dust entered in port relief valve. Sections Contents/normal value Corrective action. check proportional valve and controller for possible failure. Replace cylinder or seals Poor fine operability No.

(G Port) Replace proportional valve. 4 Actual measuring current value of P1/ P2 unload proportional valve Carry out service diagnosis In case where the reading is largely differed from the actually measured value.TROUBLESHOOTING (BY TROUBLE) No. a4) Check that P1/P2 pump proportional valve pressures are within the range of 0. insufficient power No.15 D-15 • See Service Diagnosis Data List Operation No. 1 Operation is nil In case where the reading is largely differed from the actually measured value. Replace (Check on the casing site for damage). others Carry out service diagnosis • No. check proportional valve and controller for possible failure. free from abnormal resistance against free from abnormal damage. valve in short-circuit valve directly. P2 Operation No. Visual check Slow boom up.3 Boom up full lever & relief T5-2-5 .5 -1.0 MPa or more Check remote control valve in boom up full lever and high idling When equipped with multi operation control valve. high idling and of proportional valve secondary pressure secondary pressure is within the range in short-circuit valve.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No. (Ports a3. check proportional valve and controller for possible failure. Sections Contents/normal value Corrective action. 1 Operation is nil. 5.0 MPa. etc. When there is difference between P1 and P2 pump pressures. P2 pump proportional valve proportional valve secondary pressure directly. check it while changing lever pattern 3 Pump pressure sensor Carry out service • See Service Diagnosis Data List diagnosis for P1. When removing.0 MPa in control lever neutral and high idling operation Replace proportional valve Check regulator 6 Command current Carry out service value of short-circuit diagnosis. • No. others 1 Boom up pressure sensor Carry out service diagnosis • See Service Diagnosis Data List Check and replace pressure Operation No. In case where the reading is largely differed from the actually measured value.5 to 1. etc on outside surface Spring is free from breakage. check proportional valve and controller for possible failure. Sections E215B-E245B Contents/normal value Corrective action. 4 Actual measuring current value of P1/ P2 pump proportional valve 5 Secondary pressure Measure the pump of P1. • No. 7 Secondary pressure Measure the Control lever is neutral. check high pressure sensor. 8 Slow return check Visual check valve of pilot line (in case of boom up or arm out) Check that slow return check valve installed on pilot line is free from dust entered Clean and replace 9 Short-circuit valve spool.3 boom up full lever and sensor relief Check remote control valve 2 Remote control valve Measure directly remote control pressure of boom up Check that pressure is 3.4 boom up full lever and pump pressures in in operation operation. of proportional of 0. damage.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.

free from abnormal resistance against sliding Spring is free from breakage. others 5 Secondary pressure Measure the of P1. 7 Secondary pressure Measure the pump of P1.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No. Free from abnormal damage. a4) Check that P1/P2 pump proportional Replace proportional valve valve pressures are within the range of 1. free from abnormal resistance against sliding Free from abnormal damage. free from abnormal resistance against sliding Free from abnormal damage. When removing. etc on outside surface Replace (Check on the casing side for damage) 13 Boom spool <Trouble> Only P1 pressure is high.2 MPa in boom up full lever and high idling operation Replace proportional valve 6 Actual measuring current value of P1/ P2 pump proportional valve • No. P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block Check that P1/P2 unload secondary pressures are within the range of 0.) Clean and replace 9 Remote control valve Check targeted remote control valve Check that spool is free from abnormal damage and spring is free from breakage Replace 10 Lock valve poppet <Trouble> Both P1 and P2 pressures are low. etc on outside surface Replace (Check on the casing side for damage) 12 Holding valve for boom (poppet) <Trouble> Both P1 and P2 pressures are high. Disassembly and investigation Free from abnormal resistance against sliding Spring is free from breakage.E215B-E245B No. free from abnormal resistance against sliding Free from abnormal damage.8 to 3. P2 pump proportional valve proportional valve secondary pressure directly (Ports a3. Replace (Check on the casing side for damage) 14 Check boom spool and recirculation <Trouble> Only P1 pressure is low. etc on outside surface Replace (Check on the casing side for damage) Carry out service diagnosis T5-2-6 . etc on outside surface Replace (Check on the casing side for damage) 11 Conflux check valve Visual check <Trouble> Only P2 pressure is high. Visual check When removing.4 boom up full lever & in operation In case where the reading is largely differed from the actually measured value. Replace spool assembly 15 Conflux spool <Trouble> Only P2 pressure is high. Visual check When removing. free from abnormal resistance against sliding Spring is free from breakage.0 MPa in boom up full lever and high idling operation 8 P2 by-pass cut valve Visual check <Trouble> Only P2 pressure is low.5~1. check proportional valve and controller for possible failure. No problem for sliding ability of main poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port. Sections TROUBLESHOOTING (BY TROUBLE) Contents/normal value Corrective action. Visual check When removing. Visual check When removing.

check it while changing lever pattern. 3 Actual measuring current value of P1 unload proportional valve Carry out service diagnosis 4 Secondary pressure Measure the of P1 unload proportional valve proportional valve secondary pressure directly at the ports A7 of 8 sections solenoid block. others 1 Boom down pressure sensor Carry out service diagnosis Check and replace pressure sensor. others Slow boom down. Sections Contents/normal value Corrective action. check proportional valve and controller for possible failure. & idling check proportional valve Operation No. Visual check (Head Pressure is 32 MPa or more in boom up When only relief pressure of side) full lever and high idling. Seat is free from abnormality 6.19 Travel left full lever & and controller for possible idling failure. a4) Check that P1 pump proportional valve Replace proportional valve pressures are within the range of 2.2 MPa in boom down full lever and high idling operation 5 Actual measuring current value of P1 pump proportional valve • No.5 boom down full lever & in operation P1 unload valve (cut valve) • See Service Diagnosis Data List Operation No. insufficient power for lifting up body No. In case where the reading is largely differed from the actually measured value. Check remote control valve.5 boom down full lever & in operation 6 Secondary pressure Measure the pump of P1 pump proportional valve proportional valve secondary pressure directly (Ports a3. Sections Contents/normal value 16 Main relief valve <Trouble> Relief pressure is low. Check that P1 unload secondary Replace proportional valve pressures are within the range of 0.5 boom down full lever & in operation T5-2-7 In case where the reading is largely differed from the actually measured value. Free from dust boom up is low.0 to 2.5 MPa in boom down full lever and high idling operation 7 Actual measuring current value of travel straight proportional valve Check that the value is not change • Check pressure sensor of regardless of operation travel • See Service Diagnosis Data List • In case where the reading is Operation No.8 to 1.9 E-1 P1 pump • See Service Diagnosis Data List Operation No.0 MPa or more Check remote control valve control pressure of in boom down full lever and high idling When equipped with multi boom down directly operation control valve. check proportional valve and controller for possible failure.18 Travel right full lever actually measured value. Carry out service diagnosis Carry out service diagnosis • See Service Diagnosis Data List Operation No. Check set pressure • See Service Diagnosis Data List Reset or replace Operation No. Corrective action. 1 Operation is nil largely differed from the Operation No.3 boom up full lever and relief 17 Over load relief valve <Trouble> Relief pressure is low.TROUBLESHOOTING (BY TROUBLE) E215B-E245B No. replace valve entered in over load relief valve. . 2 Remote control valve Measure remote Check that pressure is 3.

free from abnormal resistance against sliding Free from abnormal damage. free from abnormal resistance against sliding Free from abnormal damage. Operation No. etc on outside surface Replace (Check on the casing side for damage) 14 Boom spool Visual check <Trouble> Boom down is slow.18 travel right full lever actually measured value.8 MPa or less regardless neutral/operation 9 Actual measuring current value of short-circuit valve. When removing. 1 Operation is nil.19 travel left full check proportional valve lever & idling and controller for possible failure. Check that the value is not change • Check pressure sensor of regardless of operation No 15 D-15 travel. etc on outside surface Replace (Check on the casing side for damage) 13 Holding valve Visual check (poppet) <Trouble> Boom down is slow. free from abnormal resistance against sliding Free from abnormal damage. High idling pressure is 0.8 MPa or less regardless neutral/operation Replace proportional valve 11 Remote control valve Check targeted remote control valve Check that spool is free from abnormal damage and spring is free from breakage Replace 12 Lock valve poppet <Trouble> Boom down is low. (G Port) High idling pressure is 0. others 8 Travel straight Measure directly proportional valve the travel straight secondary pressure proportional valve secondary pressure. Sections TROUBLESHOOTING (BY TROUBLE) Contents/normal value Corrective action. Replace spool assembly 16 short-circuit valve spool. Carry out service diagnosis T5-2-8 Replace proportional valve . free from abnormal resistance against free from abnormal damage. etc on outside surface Spring is free from breakage. When removing. Disassembly and investigation Free from abnormal resistance against sliding Spring is free from breakage. Visual check. Replace (Check on the casing side for damage) 15 Check boom spool and recirculation <Trouble> Machine can not be lifted by supporting with boom. When removing. Visual check When removing. Replace (Check on the casing site for damage). 10 Secondary pressure Measure directly of proportional valve the travel straight in short-circuit valve proportional valve secondary pressure. • See Service Diagnosis Data List • In case where the reading is Operation No. & idling. etc on outside surface Spring is free from breakage.E215B-E245B No. largely differed from the Operation No.

check it while changing lever pattern 3 Pump pressure sensor Carry out service • See Service Diagnosis Data List diagnosis for P1.7 Arm in full lever & in operation Carry out service diagnosis • No. insufficient power Sections Contents/normal value Corrective action. Visual check 7.2 MPa in arm in full lever and high idling operation.5 to 1. Sections Contents/normal value 17 Main relief valve <Trouble> Relief pressure is low.6 Arm in full lever & relief T5-2-9 Check and replace pressure sensor Check remote control valve In case where the reading is largely differed from the actually measured value. Check set pressure • See Service Diagnosis Data List Reset or replace Operation No. check proportional valve and controller for possible failure.0 MPa or more Check remote control valve in arm in full lever and high idling When equipped with multi operation control valve. No. Seat is free from abnormality Replace Slow arm in.3 boom up full lever and relief 18 Over load relief valve <Trouble> Machine can not be lifted by supporting with boom.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No. check high pressure sensor 4 Actual measuring current value of P1/ P2 unload proportional valve Carry out service diagnosis In case where the reading is largely differed from the actually measured value. others Free from dust entered in port relief valve. others 1 Arm in pressure sensor Carry out service diagnosis • See Service Diagnosis Data List Operation No. check proportional valve and controller for possible failure. 5 Secondary pressure Measure the of P1. 6 Actual measuring current value of P1/ P2 pump proportional valve • No. When there is difference between P1 and P2 pump pressures. . P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block. Corrective action.6 arm in full lever and relief 2 Remote control valve pressure Measure directly remote control pressure of arm in Check that pressure is 3.7 arm in full lever and in pump pressures in operation operation. Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0. P2 Operation No.TROUBLESHOOTING (BY TROUBLE) E215B-E245B No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.

19 Travel left full lever & and controller for possible idling failure. 11 Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block 0. Check that secondary pressure of Replace proportional valve proportional valve secondary pressures are within the range of following Lever neutral: 0 MPa Motion in the air: 1.5 MPa or more 10 Actual measuring current value of travel straight proportional valve Check that the value is not change • Check pressure sensor of regardless of operation travel • See Service Diagnosis Data List • In case where the reading is Operation No. Seat is free from abnormality Carry out service diagnosis T5-2-10 In case where the reading is largely differed from the actually measured value. Check set pressure • See Service Diagnosis Data List Reset or replace Operation No.2 MPa Arm in relief: 2. & idling check proportional valve Operation No.E215B-E245B No. 1 Operation is nil largely differed from the Operation No.3 boom up full lever and relief 14 Over load relief valve <Trouble> P1. When only relief pressure of Visual check (Head Pressure is 32 MPa or more in arm in arm in is low.8 MPa or less in high idling operation regardless of neutral/operation Replace proportional valve 12 Remote control valve Check targeted remote control valve Check that spool is free from abnormal damage and spring is free from breakage Replace 13 Main relief valve <Trouble> Relief pressure is low.18 Travel right full lever actually measured value. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action. P2 pressure is low. check proportional valve and controller for possible failure.7 to 2. replace valve side) and relief. others 7 Secondary pressure Measure the pump of P1. Free from dust entered in over load relief valve.0 MPa or more in arm in full lever and high idling operation. (Secondary pressure is affected by oil temperature and attachment weight) 8 Actual measuring Carry out service current value of arm diagnosis in spool 2 proportional valve • See Service Diagnosis Data List Operation No. (Ports a3.6 Arm in full lever & relief Operation No. 1 Operation is nil Operation No. a4) Check that P1/P2 pump proportional Replace proportional valve valve pressures are 2. .7 Arm in full lever & in operation 9 Secondary pressure Measure directly of arm in spool 2 the proportional proportional valve valve secondary pressure at the ports A8 (arm 2 spool) of 8 sections solenoid block. P2 pump proportional valve proportional valve secondary pressure directly.

Visual check When removing. free from abnormal resistance against sliding Free from abnormal damage. Visual check (Rod side) Pressure is 32 MPa or more in arm out When only relief pressure of and relief. etc on outside surface Spring is free from breakage.TROUBLESHOOTING (BY TROUBLE) No. etc on outside surface Replace (Check on the casing side for damage) 8. • No. check it while changing lever pattern 3 Pump pressure sensor Carry out service • See Service Diagnosis Data List diagnosis for P1. arm out is low. etc on outside surface Spring is free from breakage. Visual check When removing. P2 pressures are high.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No. replace valve Free from dust entered in over load relief valve. check proportional valve and controller for possible failure. others 1 Arm out pressure sensor Carry out service diagnosis • See Service Diagnosis Data List Check and replace pressure Operation No.8 arm out full lever and sensor relief Check remote control valve 2 Remote control valve Measure directly Check that pressure is 3. Seat is free from abnormality. check high pressure sensor 4 Actual measuring current value of P1/ P2 unload proportional valve Carry out service diagnosis In case where the reading is largely differed from the actually measured value. P2 pressure is high. P2 pressure is high or low. P2 pressure is low. free from abnormal resistance against sliding Free from abnormal damage.9 arm out full lever and pump pressures in in operation operation. Replace (Check on the casing side for damage) 18 Check arm 2 spool and recirculation <Trouble> Arm in power is poor. P2 Operation No. 16 Arm 1 spool <Trouble> P1. No . others 15 Over load relief valve <Trouble> P1. Slow independent arm out (in the air) Sections Contents/normal value Corrective action. Replace spool assembly 19 Check lock valve poppet <Trouble> Both P1. Disassembly and investigation Free from abnormal resistance against sliding Spring is free from breakage. When there is difference between P1 and P2 pump pressures. Visual check Free from abnormal resistance against sliding Free from abnormal damage. Sections Contents/normal value E215B-E245B Corrective action.0 MPa or more Check remote control valve remote control in arm out full lever and high idling When equipped with multi pressure of arm out operation control valve. Replace (Check on the casing side for damage) 17 Arm 2 spool <Trouble> P1.8 Arm out full lever & relief T5-2-11 .

others 5 Secondary pressure Measure the of P1. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action. P2 pressure is low.3 boom up full lever and relief 12 Over load relief valve <Trouble> P1.9 Arm out full lever & in operation In case where the reading is largely differed from the actually measured value.19 Travel left full lever & and controller for possible idling failure. replace valve Free from dust entered in over load relief valve. Check set pressure • See Service Diagnosis Data List Reset or replace Operation No. etc on outside surface Spring is free from breakage.7 MPa in arm out full lever and high idling operation (Secondary pressure is affected by oil temperature and attachment weight) Replace proportional valve 8 Actual measuring current value of travel straight proportional valve Check that the value is not change • Check pressure sensor of regardless of operation travel • See Service Diagnosis Data List • In case where the reading is Operation No.2 MPa in arm out full lever and high idling operation 6 Actual measuring current value of P1/ P2 pump proportional valve • No.E215B-E245B No .5 to 1. Visual check (Rod side) 13 Visual check Arm 1 spool <Trouble> P2 pressure is high. free from abnormal resistance against sliding Free from abnormal damage. a4) Check that P1/P2 pump proportional valve pressures are within the range of 1. Seat is free from abnormality When removing. check proportional valve and controller for possible failure. 9 Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block 0. 1 Operation is nil largely differed from the Operation No. 7 Secondary pressure Measure the pump of P1. Carry out service diagnosis Carry out service diagnosis Pressure is 32 MPa or more in arm out When only relief pressure of and relief. arm out is low.8 MPa or less in high idling operation regardless of neutral/operation Replace proportional valve 10 Remote control valve Check targeted remote control valve Check that spool is free from abnormal damage and spring is free from breakage Replace 11 Main relief valve <Trouble> Relief pressure is low.18 Travel right full lever actually measured value. P2 pump proportional valve proportional valve secondary pressure directly (Ports a3.5 to 2. T5-2-12 Replace (Check on the casing side for damage) . & idling check proportional valve Operation No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No. P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.

TROUBLESHOOTING (BY TROUBLE)

No
.

Sections

Contents/normal value

E215B-E245B

Corrective action, others

14

Arm 2 spool
Visual check
<Trouble>
P1 pressure is high.

When removing, free from abnormal
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

15

Check arm 2 spool
and recirculation
<Trouble>
Both P1, P2
pressures are low.

Disassembly and
investigation
(spring side)

Free from abnormal resistance against
sliding
Spring is free from breakage.

Replace spool assembly

16

Check lock valve
poppet
<Trouble>
Both P1, P2
pressures are high.

Visual check

Free from abnormal resistance against
sliding
Free from abnormal damage, etc on
outside surface

Replace
(Check on the casing side for
damage)

9.

Slow bucket digging

No. Sections

Contents/normal value

Corrective action, others

1

Bucket digging
pressure sensor

Carry out service
diagnosis

• See Service Diagnosis Data List
Operation No.12 bucket digging full
lever and relief

Check and replace pressure
sensor
Check remote control valve

2

Remote control
valve

Measure directly
remote control
pressure of bucket
digging

Check that pressure is 3.0M Pa or more Check remote control valve
in bucket digging full lever and high
When equipped with multi
idling operation
control valve, check it while
changing lever pattern

3

Pump pressure
sensor

Carry out service
• See Service Diagnosis Data List
diagnosis for P1, P2
Operation No.13 Bucket digging full
pump pressures in
lever and in operation
operation.

When there is difference
between P1 and P2 pump
pressures, check high
pressure sensor

4

Actual measuring
current value of P1/
P2 unload
proportional valve

Carry out service
diagnosis

In case where the reading is
largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

5

Secondary pressure Measure the
of P1, P2 unload
proportional valve
proportional valve
secondary pressure
directly at the ports
A7 and A5 of 8
sections solenoid
block

Check that P1/P2 unload secondary
Replace proportional valve
pressures are within the range of 0.5 to
1.2 MPa in bucket digging full lever and
high idling operation

6

Actual measuring
current value of P1/
P2 pump
proportional valve

• No.9 E-1 P1 pump
E-2 P2 pump
• See Service Diagnosis Data List
Operation No.13 Bucket digging full
lever & in operation

7

Secondary pressure Measure the pump
of P1, P2 pump
proportional valve
proportional valve
secondary pressure
directly (Ports a3,
a4)

Carry out service
diagnosis

• No.8 D-1 P1 unload valve (cut valve)
D-1 P2 unload valve (cut valve)
• See Service Diagnosis Data List
Operation No.12 Bucket digging full
lever & relief

In case where the reading is
largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Check that P1 pump proportional valve Replace proportional valve
pressures is 2.7 MPa or more and P2
pump proportional valve pressure is 1.6
to 2.2 MPa in bucket digging full lever
and high idling operation.

T5-2-13

E215B-E245B

TROUBLESHOOTING (BY TROUBLE)

No. Sections

Contents/normal value

Corrective action, others

8

Attachment boost
solenoid command

Carry out service
diagnosis

No.3 POWER BOOST
Check harness
Bucket digging COMP OFF, MEAS OFF Replace solenoid valve

9

Attachment boost
solenoid secondary
pressure

Measure switching
valve secondary
pressure

Check that pressure is 0 MPa in bucket Replace solenoid valve
digging full lever and high idling
operation

10

Actual measuring
current value of
travel straight
proportional valve

Carry out service
diagnosis

• See Service Diagnosis Data List
Operation No.12 Bucket digging full
lever & relief

In case where the reading is
largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

11

Secondary pressure Measure directly
of travel straight
the proportional
proportional valve
valve secondary
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block

Check that travel straight secondary
pressure is 2.7 MPa or more in bucket
digging full lever and high idling
operation

Replace proportional valve

12

P2 by-pass cut valve Visual check
<Trouble>
Only P2 pressure is
low.

No problem for sliding ability of main
poppet and no contamination on orifice
No problem for sliding ability of internal
piston (Check it through PBp2 port.)

Clean or replace

13

Check stroke limiter Visual check
<Trouble>
Both P1, P2
pressures are high.

When piston is removed from cover, it is Replace
free from abnormal resistance against
(Check on the casing side for
sliding
damage.)
Free from abnormal damage, etc on
outside surface

14

Remote control
valve

Check targeted
remote control
valve

Check that spool is free from abnormal
damage and spring is free from
breakage

15

Main relief valve

Check set pressure • See Service Diagnosis Data List
Reset or replace
Operation No.3 Boom up full lever and
relief

16

Travel straight spool Visual check
<Trouble>
P2 pressure is high.

When removing, free from abnormal
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

17

Bucket spool
<Trouble>
Both P1, P2
pressures are high.

Visual check

When removing, free from abnormal
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

18

Over load relief
valve

Check targeted
spool visually

Free from dust entered in over load relief Replace
valve.
Seat is free from abnormality.

T5-2-14

Replace

TROUBLESHOOTING (BY TROUBLE)

E215B-E245B

10. Slow bucket dump
No.

Sections

Contents/normal value

Corrective action, others

1

Bucket dump
pressure sensor

Carry out service
diagnosis

• See Service Diagnosis Data List
Operation No.14 Bucket dump full
lever and relief

2

Remote control
valve

Measure directly
remote control
pressure of bucket
dump

Check that pressure is 3.0 MPa or more Check remote control valve
in bucket dump full lever and high idling When equipped with multi
operation
control valve, check it while
changing lever pattern

3

Pump pressure
sensor

Carry out service
• See Service Diagnosis Data List
diagnosis for P1, P2
Operation No.15 Bucket dump full
pump pressures in
lever and in operation
operation.

When there is difference
between P1 and P2 pump
pressures, check high
pressure sensor

4

Actual measuring
current value of P1/
P2 unload
proportional valve

Carry out service
diagnosis

• No.8 D-1 P1 unload valve (cut valve)
D-1 P2 unload valve (cut valve)
• See Service Diagnosis Data List
Operation No.14 Bucket dump full
lever & relief

In case where the reading is
largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

5

Secondary pressure Measure the
of P1, P2 unload
proportional valve
proportional valve
secondary pressure
directly at the ports
A7 and A5 of 8
sections solenoid
block

Check that P1/P2 unload secondary
pressures are within the range of
0.5~1.2 MPa in bucket dump full lever
and high idling operation. Replace
proportional valve

Replace proportional valve

6

Actual measuring
current value of P1/
P2 pump
proportional valve.

• No.9 E-1 P1 pump
E-2 P2 pump
• See Service Diagnosis Data List
Operation No.15 Bucket dump full
lever & in operation

In case where the reading is
largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

7

Secondary pressure Measure the pump
of P1, P2 pump
proportional valve
proportional valve
secondary pressure
directly (Ports a3,
a4)

Check that P1 pump proportional valve Replace proportional valve
pressures is 2.7 MPa or more and P2
pump proportional valve pressure is 0.9
to 1.4 MPa in bucket dump full lever and
high idling operation.

8

Actual measuring
current value of
travel straight
proportional valve

• See Service Diagnosis Data List
Operation No.14 Bucket dump full
lever & relief

9

Secondary pressure Measure directly
of travel straight
the proportional
proportional valve
valve secondary
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block

Carry out service
diagnosis

Carry out service
diagnosis

Check and replace pressure
sensor
Check remote control valve

In case where the reading is
largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Check that travel straight secondary
Replace proportional valve
pressure is 2.7 MPa or more in bucket
dump full lever and high idling operation

T5-2-15

E215B-E245B

No.

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value

Corrective action, others

10

P2 by-pass cut valve Visual check
<Trouble>
Only P2 pressure is
low.

No problem for sliding ability of main
poppet and no contamination on orifice
No problem for sliding ability of internal
piston (Check it through PBP2 port.)

Clean and replace

11

Check stroke limiter Visual check
<Trouble>
Pilot pressure is low.

Free from abnormal damage and wear
on outside of piston inside cover

Replace
(Check on the casing side for
damage.)

12

Remote control
valve

Check targeted
remote control
valve

Check that spool is free from abnormal
damage and spring is free from
breakage

Replace

13

Main relief valve
<Trouble>
Relief pressure is
low.

Check set pressure • See Service Diagnosis Data List
Reset or replace
Operation No.3 Boom up full lever and
relief

14

Travel straight spool Visual check
<Trouble>
P2 pressure is high.

When removing, free from abnormal
resistance against sliding
Free from abnormal damage, etc on
outside surface

Replace
(Check on the casing side for
damage)

15

Bucket spool
<Trouble>
Both P1, P2
pressures are high.

Visual check

When removing, free from abnormal
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

16

Over load relief
valve

Check targeted
spool visually

Free from dust entered in over load relief Replace
valve.
Seat is free from abnormality.

11. Swing operation not functioned/slow
No. Sections

Contents/normal value

Corrective action, others

1

Swing pressure
sensor

Carry out service
diagnosis

• See Service Diagnosis Data List
Operation No.11 Swing full lever and
in operation

Check and replace pressure
sensor
Check remote control valve

2

Remote control
valve

Measure directly
remote control
pressure of swing

Check that pressure is 3.0 MPa or more Check remote control valve
in boom up full lever and high idling
When equipped with multi
operation
control valve, check it while
changing lever pattern

3

Swing parking brake Carry out service
solenoid
diagnosis

No.3 F-2 SWING-BRAKE
Lever neutral: COMP ON, MEAS ON
Swing: COMP OFF, MEAS OFF

Check swing pressure sensor
Check harness

4

Swing parking brake Measurement of
solenoid
solenoid valve A2
port

Lever neutral: 0 MPa
In operation: 4 MPa or more

Replace solenoid valve

T5-2-16

TROUBLESHOOTING (BY TROUBLE)

No. Sections

Contents/normal value

E215B-E245B

Corrective action, others

5

Shuttle valve
Visual check
<Trouble>
Pilot pressure is low.

No contamination on spool cover (short Clean or replace
side) and orifice
No damage on spool cover (long side)
and shuttle

6

Pump pressure
sensor

Carry out service
diagnosis for P2
pump pressures in
operation

• See Service Diagnosis Data List
Operation No.11 Swing full lever and
in operation

Check high pressure sensor

7

Actual measuring
current value of P2
unload proportional
valve

Carry out service
diagnosis

• No.8 D-2 P2 unload valve (cut valve)
• See Service Diagnosis Data List
Operation No.11 Swing full lever & in
operation

In case where the reading is
largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

8

Secondary pressure Measure the
of P2 unload
proportional valve
proportional valve
secondary pressure
directly at the ports
A5 of 8 sections
solenoid block

Check that P2 unload secondary
Replace proportional valve
pressures are within the range of 0.5 to
1.2 MPa in swing full lever and high
idling operation

9

Actual measuring
current value of P2
pump proportional
valve

• No.9 E-2 P2 pump
• See Service Diagnosis Data List
Operation No.11 Swing full lever & in
operation

10

Secondary pressure Measure the pump Check that P2 pump proportional valve Replace proportional valve
of P2 pump
proportional valve
pressure is 2.7 MPa or more in swing full
proportional valve
secondary pressure lever and high idling operation
directly (Ports a3,
a4)

11

Actual measuring
current value of
travel straight
proportional valve
(Check this trouble
by only swing
operation)

Carry out service
diagnosis

Check that the value is not change
• Check pressure sensor of
regardless of operation
travel
• See Service Diagnosis Data List
• In case where the reading is
Operation No. 1 Operation is nil
largely differed from the
Operation No.18 Travel right full lever
actually measured value,
& idling
check proportional valve
Operation No.19 Travel left full lever &
and controller for possible
idling
failure.

12

Secondary pressure
of travel straight
proportional valve
(Check this trouble
by only swing
operation)

Measure directly
the proportional
valve secondary
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block

0.8 MPa or less in high idling operation
regardless of neutral/operation

Carry out service
diagnosis

T5-2-17

In case where the reading is
largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Replace proportional valve

E215B-E245B

No. Sections

TROUBLESHOOTING (BY TROUBLE)

Contents/normal value

Corrective action, others

13

Command current
Carry out service
value of short-circuit. diagnosis

Check that the value is not change
• Check pressure sensor of
regardless of operation No 15 D-15
travel.
• See Service Diagnosis Data List
• In case where the reading is
Operation No. 1 Operation is nil.
largely differed from the
Operation No.18 travel right full lever
actually measured value,
& idling. Operation No.19 travel left full
check proportional valve
lever & idling
and controller for possible
failure.

14

Secondary pressure Measure directly
of proportional valve the secondary
in short-circuit valve. pressure of the
proportional valve
in short-circuit
valve. (G Port)

0.8 MPa or less in high idling operation
regardless of neutral/operation.

Replace proportional valve.

15

Remote control
valve

Check that spool is free from abnormal
damage and spring is free from
breakage

Replace

16

Travel straight spool Visual check
<Trouble>
P2 pressure is low.

When removing, free from abnormal
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

17

Swing spool
Visual check
<Trouble>
P2 pressure is high.

When removing, free from abnormal
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

18

Short-circuit valve
spool.

Visual check.

• When removing, free from abnormal Replace (Check on the casing
resistance against free from abnormal site for damage).
damage, etc on outside surface
Spring is free from breakage.

19

Swing relief valve
<Trouble>
Relief pressure is
low.

Check set pressure • See Service Diagnosis Data List
Operation No.10 Swing full lever and
relief

20

Swing motor

Visual check

21

Swing reduction
gear oil

Take sample oil
Sampling oil does not include a lot of
from swing
metal powder.
reduction gear drain

Disassemble and inspect
reduction gear

22

Swing reduction

Visual check

Replace

Check targeted
remote control
valve

Reset or replace

Inner parts (cylinder block, piston, valve Replace
brake etc) are to be free from abnormal
resistance against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)

Tooth surface is not worn abnormally
and is not chipped.

T5-2-18

3 F-2 SWING-BRAKE diagnosis Lever neutral: COMP ON. MEAS OFF Check swing pressure sensor Check harness Measurement of Lever neutral: 0 MPa solenoid valve A2 In operation: 4 MPa or more port Replace solenoid valve Swing parking brake solenoid 2 3 Boost check valve Visual check (Sound of cavitation at stopping) When removing. 7 Swing reduction gear oil Take sample oil from swing reduction gear drain. Noise during swing operation No. Sections Contents/normal value Corrective action. others 1 Carry out service No.3 F-2 SWING-BRAKE solenoid diagnosis Lever neutral: COMP ON. MEAS ON Swing: COMP OFF.TROUBLESHOOTING (BY TROUBLE) E215B-E245B 12.1 MPa. free from abnormal Replace resistance against sliding Spring is free from breakage. free from abnormal Replace resistance against sliding Spring is free from breakage. free from abnormal Replace resistance against sliding Spring is free from breakage. others pressure Carry out service • •Engine stop & starter key ON Check and replace pressure diagnosis All pilot low pressure sensors are sensor within range of 0 to 0. MEAS OFF 4 Corrective action. control Check remote valve targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage Measurement of Lever neutral: 0 MPa solenoid valve A2 In operation: 4 MPa or more port T5-2-19 Check swing pressure sensor Check harness Check parking brake release switch Replace solenoid valve . reduction gear 8 Swing reduction Visual check Tooth surface has no abnormally worn and chipped. MEAS ON Swing: COMP OFF. 4 By-pass check valve (Sound of cavitation at stopping) Visual check When removing. Sampling oil does not include a lot of Disassemble and inspect metal powder. Swing on a slope drifts when control lever is in neutral position No. Replace 13. 5 Swing motor (Brake valve/ friction plate) Visual check Disassemble and inspect abnormal Replace wear and scuffing 6 Swing motor piston Visual check When removing. Sections Contents/normal value 1 Swing sensor 2 Remote valve 3 Swing parking brake Carry out service No.

1 MPa or more Check remote control valve remote control in travel right (left). Sections Contents/normal value 1 Visual check Shuttle valve <Trouble> Pilot pressure is low 2 Swing sensor 3 Swing relief valve Check pressure <Trouble> Relief pressure is low.1 MPa. Replace valve brake etc) are to be free from abnormal resistance against sliding.18 Travel right full lever sensor and idling Check remote control valve Operation No. others 1 Travel right and left Carry out service • See Service Diagnosis Data List Check and replace pressure pressure sensor diagnosis Operation No. abnormal damage and wear. etc on outside surface (brake plate etc) 15. others 5 Swing motor Visual check (Brake valve/friction plate) Disassemble and inspect abnormal Replace wear and scuffing 6 Parking brake Piston and friction plate do not have Replace abnormal resistance against sliding Free from spring damage Visual check 14. Sections Contents/normal value Corrective action. others No contamination on spool cover Clean or replace (short side) and orifice. TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action. Swing drifts when swing operation is stopped No . pressure Carry out service • Engine stop & starter key ON Replace pressure sensor diagnosis All pilot low pressure sensors are within range of 0 to 0.19 Travel left full lever and idling 2 Remote valve control Measure directly Check that pressure is 2. No damage on spool cover (long side) and shuttle. 4 Anti-reaction valve Visual check 5 Remote valve 6 Swing motor Corrective action. control Check remote valve set • See Service Diagnosis Data List Reset or replace Operation No. Slow travel speed/weak No.10 Swing full lever and relief Clean or replace Free from dirt entering Sliding part should be free from foreign matter entering. targeted Check that spool is free from Replace control abnormal damage and spring is free from breakage Visual check Inner parts (cylinder block.E215B-E245B No. forward (reverse) full pressure of travel lever and high idling operation right and left T5-2-20 . piston. Free from abnormal damage.

7 MPa or more directly 0.9 D-1 P1 unload valve (cut valve) current value of P1/ diagnosis D-1 P2 unload valve (cut valve) P2 unload • See Service Diagnosis Data List proportional valve Operation No.0 MPa In case where the reading is largely differed from the actually measured value.7 MPa or more Travel left (P2 pump): 2.9 E-1 P1 pump current value of P1/ diagnosis E-2 P2 pump P2 pump • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No. Operation No. forward (reverse) full lever and high idling operation Travel right (P1 unload): 0. of proportional valve the in short-circuit valve. Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left). Operation No. 1 Operation is nil • In case where the reading is Operation No.18 Travel right full lever largely differed from the & idling actually measured value.19 Travel left full lever & idling In case where the reading is largely differed from the actually measured value. Sections Contents/normal value E215B-E245B Corrective action.19 Travel left full lever & idling 6 Secondary pressure Measure the pump of P1. P2 pump proportional valve proportional valve secondary pressure directly (Ports a3.8 MPa or less in high idling operation Replace proportional valve. pressure of the proportional valve in short-circuit valve. P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block 5 Actual measuring Carry out service • No. 4 Secondary pressure Measure the of P1. • See Service Diagnosis Data List • In case where the reading is Operation No. 10 Secondary pressure Measure secondary regardless of neutral/operation.0 MPa Travel left (P2 unload): 0.5 to 1. forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.19 Travel left full lever & check proportional valve idling and controller for possible failure 8 Secondary pressure Measure directly 0. (G Port) T5-2-21 . check proportional valve and controller for possible failure. Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left). largely differed from the Operation No.18 Travel right full lever & idling Operation No. a4) 7 Actual measuring Carry out service Check that the value is not change • Check voltage of low current value of diagnosis regardless of operation pressure sensor other than travel straight • See Service Diagnosis Data List sensor for travel proportional valve Operation No. check proportional valve and controller for possible failure.5 to 1. 1 Operation is nil. others 3 Actual measuring Carry out service • No. & idling.8 MPa or less in high idling operation Replace proportional valve of travel straight the proportional regardless of neutral/operation proportional valve valve secondary pressure 9 Command current Carry out service Check that the value is not change • Check pressure sensor of value of short-circuit diagnosis regardless of operation No 15 D-15 travel.19 travel left full check proportional valve lever & idling and controller for possible failure.18 travel right full lever actually measured value.TROUBLESHOOTING (BY TROUBLE) No.

reduction gear reduction gear drain 19 Travel reduction Visual check Tooth surface is not worn abnormally Replace and is not chipped. damage. 13 Travel spool Visual check <Trouble> targeted spool Pump pressure is high. etc on damage) outside surface Spring is free from breakage. others If P1 is low. right travel motorÅfs relief valve is failed. free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage. etc on damage) outside surface Spring is free from breakage. of When removing. left travel motorÅfs relief valve is failed.E215B-E245B No. brake valve spool) are to be free from abnormal resistance against sliding. cylinder block. free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage. etc on outside surface Spring is free from breakage 15 Travel motor relief Check set pressure Check P1 and P2 pump pressures are valve 32 MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling 16 Travel motor 17 Parking brake travel motor 18 Travel gear oil Corrective action. If P2 is low. valve Replace plate. free from abnormal Replace resistance against sliding No sticking on friction plate and separator plate reduction Take sample oil Sampling oil does not include a lot of Disassemble and from travel metal powder. valve Visual check. 14 short-circuit spool. T5-2-22 inspect . etc on outside surface (brake plate etc) in Visual check When removing. free from abnormal Replace (Check on the casing resistance against free from abnormal site for damage). When removing. TROUBLESHOOTING (BY TROUBLE) Sections 11 Remote valve Contents/normal value control Check remote valve targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage Check sealing ability of shuttle valve and entry of dust in orifice 12 Travel straight spool Visual check <Trouble> P1 pressure is high. Free from abnormal damage. Visual check Inner parts (piston. When removing.

1 MPa or more Check remote control valve remote control in travel right (left). others 1 Travel right and left Carry out service • See Service Diagnosis Data List Check and replace pressure pressure sensor diagnosis Operation No.9 E-1 P1 pump current value of P1/ diagnosis E-2 P2 pump P2 pump • See Service Diagnosis Data List proportional valve Operation No.0 MPa Travel left (P2 unload): 0.5 to 1.7 MPa or more T5-2-23 .8 D-1 P1 unload valve (cut valve) current value of P1/ diagnosis D-1 P2 unload valve (cut valve) P2 unload • See Service Diagnosis Data List proportional valve Operation No. Travel deviation No.19 Travel left full lever & idling 8 Secondary pressure Measure the pump of P1. check proportional valve and controller for possible failure. forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.19 Travel left full lever and idling 2 Remote valve 3 Actual measuring Carry out service Check that the value is not change • Check voltage of low current value of diagnosis regardless of operation pressure sensor other than travel straight • See Service Diagnosis Data List sensor for travel proportional valve Operation No.18 Travel right full lever & idling Operation No.8 MPa or less in high idling operation Replace proportional valve of travel straight the proportional regardless of neutral/operation proportional valve valve secondary pressure 5 Actual measuring Carry out service • No. forward (reverse) full pressure of travel lever and high idling operation right and left In case where the reading is largely differed from the actually measured value.18 Travel right full lever largely differed from the & idling actually measured value.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling 6 Secondary pressure Measure the of P1. P2 pump proportional valve secondary pressure proportional valve directly (Ports a3. Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left). 1 Operation is nil • In case where the reading is Operation No.19 Travel left full lever & check proportional valve idling and controller for possible failure.18 Travel right full lever sensor and idling Check remote control valve Operation No.TROUBLESHOOTING (BY TROUBLE) E215B-E245B 16. forward (reverse) full lever and high idling operation Travel right (P1 unload): 0. 4 Secondary pressure Measure directly 0. Operation No.0 MPa In case where the reading is largely differed from the actually measured value. Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left).7 MPa or more Travel left (P2 pump): 2. check proportional valve and controller for possible failure. P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block 7 Actual measuring Carry out service • No. a4) control Measure directly Check that pressure is 2. Sections Contents/normal value Corrective action.5 to 1.

valve Replace plate. etc on outside surface Spring free from breakage.) are free from abnormal resistance against sliding. etc. 17 Pump regulator Visual check When removing. valve plate. brake valve spool) are to be free from abnormal resistance against sliding. piston. left travel motorÅfs relief valve is failed.E215B-E245B No. inspect a pump. etc on damage) outside surface Spring is free from breakage 13 Travel motor relief Check set pressure Check P1 and P2 pump pressures are valve 32 MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling 15 Travel gear oil If the direction is changed. free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage. free from abnormal Replace resistance against sliding Free from abnormal damage. abnormal damage. If the direction is not changed. etc. targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage Check sealing ability of shuttle valve and entry of dust in orifice 11 Travel straight spool Visual check <Trouble> P1 pressure is high. 9 TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Exchange P1 for P2 Exchange delivery Check the direction of deviation pipe of P1 for P2 10 Remote valve control Check remote valve 12 Travel spool Visual check <Trouble> targeted spool Pump pressure is high. shaft. free from abnormal Replace (Check on the casing side for resistance against sliding Free from abnormal damage. Free from abnormal damage. T5-2-24 inspect . etc on damage) outside surface Spring is free from breakage of When removing. etc. 14 Travel motor Corrective action. 18 Pump Visual check When removing. inspect a valve and travel unit. right travel motorÅfs relief valve is failed. When removing. reduction gear reduction gear drain 16 Travel reduction Visual check Tooth surface is not worn abnormally Replace and is not chipped. damage. cylinder block. etc on outside surface (brake plate etc) reduction Take sample oil Sampling oil does not include a lot of Disassemble and from travel metal powder. inside parts (cylinder Replace block. Replace as necessary Inner parts (piston. If P2 is low. others Visual check If P1 is low.

8 D-3 S-TRAVEL is should be • Check voltage of low current value of diagnosis COMP 557 mA and MEAS 557±30 mA pressure sensor other than travel straight in both travel full lever and in boom-up travel sensor proportional valve full lever at high idling (Command value • In case where the reading is is changed according to operation. etc. No.TROUBLESHOOTING (BY TROUBLE) E215B-E245B 17. free from abnormal Replace resistance against sliding Spring free from breakage. MEAS OFF Travel operation COMP ON. Travel parking on a slope is not held No. damage. Free from entry of dust Remove dust or replace 19. Sections Contents/normal value 1 Pilot sensor 2 Remote valve 3 Parking brake travel motor 4 Orifice of passage Visual check for parking brake in travel motor Corrective action. boom-up and full lever operation are check proportional valve performed). Travel does not run straightly when both crawlers and attachment operated simultaneously .3 F-3 1/2-TRAVEL Lever neutral COMP OFF.) No. others Actual measuring Carry out service No. largely differed from the Above mentioned values indicate while actually measured value. MEAS ON Check pressure sensor Check harness Check travel 1/2 speed switch on gauge cluster 2 Travel 1/2 speed Measure A3 port Lever neutral: 0 MPa switching solenoid pressure on In operation: 4 MPa or more solenoid valve Replace solenoid valve 3 1/2 speed switching Visual check spool in travel motor Check that spool is free from abnormal Replace damage and spring is free from (Check on the casing side for breakage damage) 4 1/2 speed switching Visual check orifice in travel motor Free from entry of dust 5 Tilting piston travel motor Free from abnormal wear on piston and Replace seal (Check on the casing side for damage) in Visual check Remove dust or replace 18. and controller for possible failure. T5-2-25 . others pressure Carry out service • Engine stop & starter key switch is ON Check pressure sensor and diagnosis Targeted pilot low pressure sensor is replace as necessary in range of 0 to 0. 1 Sections Contents/normal value Corrective action. Sections Contents/normal value Corrective action. the speed may sometimes does not change from 1st to 2nd because this machine equips the function of automatic speed change. Travel 1st/2nd speed notchanged (In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft ground). others 1 Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed switching solenoid diagnosis No.1 MPa Check remote control valve control Check remote valve targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage in Visual check When removing.

6 Short-circuit spool. etc on outside surface Spring is free from breakage. and MEAS 530±30 mA in both travel full pressure sensor other than valve lever and in boom-up full lever at high travel sensor. others 2 Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure 3 Command current Carry out service No 15 D-15 is should be COMP 530 mA • Check voltage of low value short-circuit diagnosis.E215B-E245B No. pressure of the lever and in boom-up full lever at high proportional valve idling. (G Port) 5 Travel straight spool Visual check When removing. check p1 unload/pump and travel straight) No. Sections Contents/normal value Corrective action. Check secondary pressure is within Replace proportional valve range of 1.1 MPa in both travel full lever and in boom-up full lever at high idling. check proportional valve and controller for possible failure. valve Visual check. proportional valve check proportional valve and controller for possible failure. idling • In case where the reading is largely differed from the actually measured value. (Command value is changed according to operation. control Measure directly Check that pressure is 2. Slow breaker (crusher) operation.9 MPa in both travel full in short-circuit valve. etc on damage) outside surface Spring is free from breakage. 20.5 to 1. When removing. free from abnormal Replace (Check on the casing resistance against free from abnormal site for damage). in short-circuit valve. Above mentioned values indicate while boomup and full lever operation are performed). weak power (In case of conflux. others 1 Pressure sensor for Carry out service • See Service Diagnosis Data List Check and replace pressure optional attachment diagnosis Operation No. damage.16 P2 side OPT full largely differed from the P2 unload lever and relief actually measured value. 4 Secondary pressure Measure directly Check secondary pressure is within Replace proportional valve.16 P2 side OPT full sensor lever and relief Check remote control valve 2 Remote valve 3 Actual measuring Carry out service • See Service Diagnosis Data List •In case where the reading is current value of P1/ diagnosis Operation No.1 MPa or more Check remote control valve remote control in optional attachment full lever and high pressure of travel idling operation right and left T5-2-26 . TROUBLESHOOTING (BY TROUBLE) Sections Contents/normal value Corrective action. of proportional valve the secondary range of 1. free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage.7 to 2.

) 8 Relief pressure 9 Remote valve Check set pressure • See Service Diagnosis Data List Reset or replace Operation No. etc on damage) outside surface Spring is free from breakage. 10 Travel straight spool Visual check <Trouble> P1 pressure is high. 12 Over valve load relief Check targeted Free from dust entered in over load relief Replace spool visually valve Seat is free from abnormality.7 MPa or more in optional attachment full lever and high idling operation 7 P1 by-pass cut valve Visual check <Trouble> Only P1 pressure is low. When removing. P2 unload proportional valve pressures are within the range of 0.2 MPa directly at the ports A7 and A5 of 8 sections solenoid block 5 Actual measuring Carry out service • See Service Diagnosis Data List • Check voltage of low current value of diagnosis Operation No. free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage.TROUBLESHOOTING (BY TROUBLE) No. etc on damage) outside surface Spring is free from breakage.5 MPa. 6 Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block Check that travel straight secondary Replace proportional valve pressure is 2. check proportional valve and controller for possible failure. P2 pressures are high.5 to proportional valve secondary pressure 1. free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage. T5-2-27 . 11 Spool for optional Visual check attachment <Trouble> P1. Sections Contents/normal value E215B-E245B Corrective action.) control Check remote valve targeted Check sealing ability of shuttle valve and Replace control entry of dust in orifice. others 4 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve of P1. No problem for sliding ability of main Clean or replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.16 P2 side OPT full pressure sensor other than travel straight lever & relief sensor for optional proportional valve attachment • In case where the reading is largely differed from the actually measured value.16 P2 side OPT full lever and relief (Set value of factory shipment is 24. When removing.

E215B-E245B TROUBLESHOOTING (BY TROUBLE) 21. MEAS ON Spool position BRK Selector switch BRK 4 N&B selector Carry out service • No. For reference. see "Table47-1 Action of optional selector solenoid valve") No. free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage. Option selector valve malfunction: not switched to breaker circuit. MEAS OFF Spool position NIB Selector switch NIB T5-2-28 Check solenoid valve Check harness .0 MPa at A mode for Check that the error indication is Replace solenoid valve disappeared by turning emergency screw Check solenoid valve Check harness 22. others 1 N&B selector spool When removing. etc on damage) outside surface Spring is free from breakage.0 MPa at B mode and 0. For reference. free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage.16 B-11 Check pressure sensor pressure sensor diagnosis Data List Check harness 3. (Indication of failure is displayed.11 F-4 Option selector is B mode diagnosis COMP ON. others When removing. see "Table47-1 Action of optional selector solenoid valve") No.11 F-4 Option selector is A mode diagnosis COMP OFF. selector Carry out service • No. Sections 1 N&B selector spool 2 N&B solenoid Contents/normal value Visual check Corrective action. etc on damage) outside surface Spring is free from breakage 2 N&B solenoid selector Screw emergency 3 N&B solenoid selector Carry out service • No. Sections Contents/normal value Visual check Corrective action. Option selector valve malfunction: not switched to nibbler circuit. (Indication of failure is displayed.

SW's condition input 1 Running ON Safety lock lever relay's output OFF Work mode Optional selector valve COMP.TROUBLESHOOTING (BY TROUBLE) E215B-E245B Table 1 .Action of optional selector solenoid valve Safety Engine lock lever No. MEAS. A OFF Spool position Selector valve detecting pressure sensor Warning display Failure diagnosis display Nibbler Normal — — 2 Running ON OFF A ON Breaker "SELECTOR Normal FAILURE" 3 Running ON OFF A OFF Breaker Normal 4 Running ON OFF A ON Nibbler Normal — [F042] displayed 5 Running ON OFF B ON Breaker Normal — — 6 Running ON OFF B OFF Nibbler Normal "SELECTOR FAILURE" VALVE [F043] displayed simultaneously 7 Running ON OFF B ON N&B Normal "SELECTOR FAILURE" VALVE 8 Running ON OFF B OFF Breaker Normal — [F043] displayed 9 Running ON OFF — — — Failure "SELECTOR FAILURE" VALVE [B113] displayed 10 Stopping "SELECTOR FAILURE" VALVE [F042] displayed simultaneously VALVE — — — — — — — — — — 11 — OFF — — — — — — — 12 — — ON — — — — — — T5-2-29 .

TESTER FRAME BODY GROUNDING SM0106 3. SM0104 JUMPER WIRE TESTER FRAME BODY GROUNDING SM0105 Checking for presence or absence of shortcircuit with machine body Measure the resistance using tester. When the resistance is zero (0). it is in normal condition. it is in normal condition. The resistance is 1 M or more when the terminal on one side is not connected to frame body grounding with jumper wire. and presence or absences of short-circuit with machine body grounding. Pull out opposite connector first. Where the resistance is zero (0). Pull out opposite connector first. presence or absences of short-circuit with other wires. 1. Checking for presence or absence of shortcircuit between wirings. Measure the resistance using tester. it is in normal condition. Pull out opposite connector first. When the resistance is 1 M or more. ELECTRIC SYSTEMS 2. it is in normal condition. if the terminal on one side is connected to frame body grounding with jumper wire. WIRE TESTER (When both ends measurement is difficult because of long distance between connectors) Measure the resistance using tester.1 WIRING CHECKING PROCEDURE Check for continuity between connector terminals. 2. CONNECTOR Checking for disconnection between connectors. When the resistance is 1 M or more.E215B-E245B TROUBLESHOOTING (BY TROUBLE) 2. it is in normal condition. Pull out opposite connector first. TESTER SM0107 T5-2-30 . (When both ends measurement is easy because of short distance between connectors) Measure the resistance using tester.

Pull one electric cable with the about 3kg force.CONTACT RUBBER PLUG SM0109 . If looseness is there. Clean the dirt terminal. When measuring the voltage between frame body grounding and power source. CONTACT PLUG SEALING (is housed in plug) DOUBLE LOCK PLATE FOR PLUG DOUBLE LOCK PLATE FOR CAP CAP TAB. When came out. It may cause loose connection. 5. b.TROUBLESHOOTING (BY TROUBLE) 4. Since the voltage may vary between with connector connected and with connector not connected. c. T5-2-31 RUBBER PLUG RECEPTACLE. When water intruding is found. Check connector for imperfect insertion Check that all top ends form a line on the same position as seen from the connector engaged side. Check the terminal crimped condition. and make sure that the cable does not come out of the terminal. E215B-E245B INSERT MALE TERMINAL FEMALE TERMINAL SM0108 ATTENTION Do not insert the male terminal the thickness differs. Caution which should be paid in measuring voltage When measuring the power supply to electric equipment at connector position with the grounding terminal contained inside of connector. Measure the voltage with each connector connected whenever possible. and then check that the inserting force is equivalent to other female terminals. replace the female terminal with new one. Check connector for intruding of water. 6. push it in further through wire inserting hole. check rubber plug for damage and also that the sealing is fitted properly. measure the voltage between grounding inside of connector and power terminal. the disconnection of wiring to grounding inside of connector cannot be identified. Pull out the connector and check that the inside is free from intruding of water. When moved along. Checking the general view of connector CRIMPED PART a. replace the terminal and crimp it again. Checking connector terminal for contact Insert male terminal into female terminal unit.

Check that variable of display exists or not on the service diagnosis screen while shaking the harness or giving shock by operating the machine.E215B-E245B 7. b. body grounding placed on attaching section of boom working light. Check that variables of resistance and voltage exist or not using tester while shaking the harness. a. 8. horn grounding fixed together with horn. T5-2-32 SM0110 . And also check that there is no loose connection due to corrosion. engine grounding. Turn starter switch on and apply electricity continuously. There are multiple groundings like centralized grounding box shown in the figure and battery grounding. try the following operations. Block of grounding is located under floor plate of cab. c. and check it again after the temperature of wiring and equipment was raised. Checking on body grounding Check attaching bolts of grounding terminal for loosening. TROUBLESHOOTING (BY TROUBLE) When abnormality occurs at intervals When the abnormality situation can not be reoccurred during checking operation.

T5-2-33 E215B-E245B . 2.2 TROUBLE 1. 3. "CPU DATA COMMUNICATION ERROR" is displayed on multi display. Engine does not stop. Auto accel does not actuate.) 5. Wiper does not function.TROUBLESHOOTING (BY TROUBLE) 2. (The engine speed does not automatically slow down.) 4. Auto accel does not actuate. (The engine speed does not automatically speed up.

E215B-E245B 1. No . Sections Contents/normal value Corrective action. No . Sections Contents/normal value Corrective action. No. Voltage between 0 V when starter switch is OFF line No. TROUBLESHOOTING (BY TROUBLE) Engine does not stop. enginestop solenoid and the body grounding Check harness Check diode D-9 between starter switch and auto idling stop relay 1 "CPU DATA COMMUNICATION ERROR" is displayed on multi display. then pull out R-25 engine forcible stop relay and carry out the service diagnosis.) 3 Wiring See “WIRING Transmission circuit line No.4 K-3 Key switch Check on engine forcible OFF at starter key switch OFF stop relay position ON at starter key switch ON position 3 Wiring 2. (Use remote control because the auto accel function is working.62 among starter switch. Check continuity between No. engine forcible stop relay.4 K-3 Key switch OFF at starter key switch OFF terminals of starter switch using tester position ON at starter key switch ON position 2 Engine forcible When ON is stop relay displayed with the starter switch OFF.770 PROCEDURE" from mechatro controller to gauge cluster 4 Gauge cluster Gauge cluster CHECKING Repair wiring Replace gauge cluster T5-2-34 . others 1 Fuse No. others 1 Starter key switch Check signal of starter key switch ON by carrying out service diagnosis.1 fuse (5 A) Not blown fuse Check harness Replace fuse 2 Mechatro controller Accel control Engine speed varies according to Check mechatro controller and replace as necessary accel potentiometer operation.

2 Gauge cluster 3 Low sensor 4. No . T5-2-35 .5 and Check low pressure sensor No. Auto accel does not actuate.2 G-5 WATER TEMP Auto accel does not work in the sensor temperature -15 °C or less.5 and Check low pressure sensor No. (The engine speed does not automatically slow down.1 MPa at control lever neutral position.) Sections Low sensor Contents/normal value Corrective action. (The engine speed does not automatically speed up.6 is raised with control lever operated.6 is in the range of 0~0. others Replace engine coolant No. Auto accel does not actuate. others pressure Service diagnosis Each control pressure of No. No .TROUBLESHOOTING (BY TROUBLE) 3. Warm up and raise the coolant temperature to – 15 °C or more Indication of auto Mark "Display/not display" for auto Replace gauge cluster accel accel switches by auto accel switch operation on gauge cluster. 1 E215B-E245B Corrective action.) Sections Contents/normal value 1 Engine coolant Check engine temperature coolant temperature by carrying out service diagnosis. pressure Service diagnosis Each control pressure of No.

20 Replace fuse 2 SW-19: Wiper interlock switch Service diagnosis No. Wiping range of forward and reverse movements Wiper motor Rise up limit switch's ON range Reverse limit switch's ON range Rise up (storing) position Upper reversing position Lower reversing position SM0111 No. turn OFF all relay's outputs.25 Wiper system built-in wiper motor Reverse limit switch Switch action in operation Check according to "WIRING CHECKING PROCEDURE" Normal condition 4 Rise up limit switch ON OFF OFF Reverse limit switch ON ON OFF R-31: Service diagnosis No. others 1 Fuse Check fuse No.E215B-E245B 5. Check relay & fuse box and replace it if necessary. relay T5-2-36 (STOP) (STOP) (REVERSE) (FORWARD) OFF ON ON ON OFF OFF OFF OFF OFF OFF ON OFF ON ON ON OFF OFF Check that the relay is excited.25 Wiper system Arc prevention relay When started by forward rotation: STOP START R-29: Arc prevention relay OFF ON ON ON ON Forward rotation Forward rotation relay OFF ON ON ON ON Reverse rotation relay OFF OFF OFF OFF OFF relay Check that the relay is worked as shown in the table.19 D125 Check wiper interlock switch Wiper switch display (D125) is OFF with front window closed. TROUBLESHOOTING (BY TROUBLE) Wiper does not function. R-30: * When the limit switch does not change in OFF after 4 seconds Reverse rotation from the wiper startup. Sections Contents/normal value Corrective action. ON . and repair it if necessary Check according to "WIRING CHECKING PROCEDURE" and repair it if necessary 3 Rise up limit switch Service diagnosis No.

4 Go ahead the operation according to the instructions on the screen of cluster gauge. (Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing buzzer stop switch on the service diagnosis screen No.TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) E215B-E245B 1. Function There are two types of trouble diagnosis mode. with the attachment not operated.2 Select Trouble diagnosis mode (Move the cursor to the desired position with screen change switch " ". How to use and flow chart The operation is performed through gauge cluster. and press the select switch. 1.1. T5-3-1 . 1) Trouble diagnosis mode 1: Used to diagnose unload system. and press the select switch.) No. the sensor detects the machine condition and the mechatro controller identifies the normal condition or failed condition of the system. pump system. TROUBLE DIAGNOSIS MODE The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be detected by auto diagnosis function (the trouble can be specified by error code) like disconnection. 2. No.) No. abnormal output.3 Select either "DIAG MODE 1" or "DIAG MODE 2" (Move the cursor to the desired position with screen change switch " ". In any mode. both selector valve and proportional valve are automatically actuated.) No.1 Select service adjustment select screen. travel straight system and engine system. 2) Trouble diagnosis mode 2: Used to diagnose pilot system.

For tthediagnosing Forthe diagnosingitems. T5-3-2 . there is a case no accordance of diagnosis obtained. check each pressure sensor proportional valve and select valve for possible abnormality. Before executing the trouble diagnosis mode. 2.3 8 FAULT DIAG MODE ADJUSTING MODE 1 PRESET BY FACTORY SELECT SWITCH DIAG MODE 1 DIAG MODE 2 BUZZER STOP SWITCH FEED SCREEN CHANGE SWITCH CASE OF DIAG MODE 1 SENSOR CHECK CHECK START ENG ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M E-2 005mA D-2 300mA The other judgments can be confirmed with the feed button. Because the bucket-grounded/bucket-not-grounded can not be automatically identified. When the trouble diagnosis mode is executing. SM0114 Notes: 1.0M PROPO-VALVE E-1 005mA D-1 300mA C-2 00. 1.E215B-E245B No. FEED DIAG MODE 1 RESULT 1 P1 UN-LOAD PSV NG P1 UN-LOAD SPOOL NG DATA END BACK TO No. ENGINE SPEED 0000 rpm PRESSURE C-1 00.3 FEED The data at the time of judgment can be confirmed with the select switch. When desired to see other suspected trouble sections.press pressthe thebuzzer buzzerstop stopswitch switch and andthe theoperation operationisisforcedly forcedlystopped.0M PROPO-VALVE E-1 005mA D-1 300mA C-2 00. lower the attachment and put the bucket on the ground. When the trouble diagnosis mode is operating. The suspected three sections in maximum are displayed. do not fail to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition.0M LOWER BOOM DIAG MODE 1 RELEASE LOCK LEVER TO GROUND About 15 minutes E-2 005mA D-2 300mA Turn engine on manually. If the machine failed. the unexpected touch to the lever may move the attachment and it causes injury or death. operation. For the diagnosis results and the corrective actions to be taken. the error display with self-diagnosis and warning does not appear. examine the presence or absence of trouble referring to the trouble history.0M PROPO-VALVE E-1 005mA D-1 300mA C-2 00. If necessary. 4.see seeTable Table 48-1.1 TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) No.0M E-2 005mA D-2 300mA The suspected trouble sections are displayed in order of possibility. For diagnosis results and corrective actions to be taken. items. 3. BACK TO No. contact our dealer/distributor. Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis. press feed " " button. 1 P1 UNLOAD NG DATA END FEED ENGINE SPEED 0000 rpm PRESSURE C-1 00. When multiple troubles are occurred at the same time. When Whenrequired requiredto tostop stopin indiagnosis diagnosis operation. In this case. The preliminary investigation of electric system makes the time saving and high precision diagnosis possible. stopped. usually occurred troubles are taken as an example. see Table 2. RESULT OF DIAGNOSIS When failed.2 LANGUAGE/LOGO No.3 RESULT OF DIAGNOSIS When not failed. DIAG MODE 1 END In diagnosis operation START ENGINE STOP RESULT OF DETAIL DIAG MODE 1 1 P1 UNLOAD OK O K DATA END Engine stops automatically.

T5-3-3 . Check the troubled section according to indication. When the trouble diagnosis mode is executing.3 MPa In the normal condition. BOOM UP BOOM UP OK PRESSURE 0.5 MPa PRESSURE 3.4 CASE OF DIAG MODE 2 SENSOR CHECK CHECK START ENG ENGINE SPEED 0000 rpm PRESSURE C-1 00. if the pump pressure is generated.0 BACK TO No.0 MPa PRESSURE 1. the error display with self-diagnosis and warning does not appear. examine the presence or absence of trouble referring to the trouble history. the unexpected touch to the lever may move the attachment and it causes injury or death. lower the attachment and put the bucket on the ground. pump pressure is unloaded with unload valve in order not to actuate attachment. If necessary. 3.0M DIAG MODE 2 LOWER BOOM START TO GROUND E-2 005mA D-2 300mA Turn engine on manually. Place the bucket on the ground between both crawlers. When the trouble diagnosis mode is operating. do not fail to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. Because the bucket-grounded/bucket-not-grounded can not be automatically identified. 2. the engine stops and "UNLOAD PSV NG" is displayed. SM0115 SEARCHABLE OPERATION Boom up Boom down Bucket digging Bucket dump Arm in Arm out Swing Travel right Travel left P1 side option P2 side option Notes: 1.TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) E215B-E245B No. If the machine failed. OK is displayed when the control lever is moved to stroke end.0M PROPO-VALVE E-1 005mA D-1 300mA C-2 00. In the case of "DIAG MODE2". When trouble diagnosis is performed. AT CONTROL LEVER IS NEUTRAL Example: Case of boom up WHEN FINISHING OF DIAGNOSIS IS REQUIRED.

and P2 side flow rate is maximum? 13 1 TRAVEL-S Is normal pressure generated in the condition that P1 side flow rate is minimum.Failure diagnosis Mode-1/Diagnosis and Remedy Diagnosis (Display) SENSOR CHECK NG Possible cause Remedy Check each pressure sensor by Disconnection of pressure sensor. and P1 side flow rate is minimum? 4 1 P2 UNLOAD Is normal pressure generated in the condition that the unload valve is in emergency position. Short service diagnosis and replace it if circuit.Failure diagnosis Mode-1/Diagnosis item No. unload valve is emergency position and travel straight is stroked fully? 15 1 P1 ENGINE Is rated engine speed obtained in the condition that P1 side flow rate increases little by little when P1 side flow rate is relieved? 16 2 P2 ENGINE Is rated engine speed obtained in the condition that P2 side flow rate increases little by little when P2 side flow rate is relieved? Table 2 . unload valve is emergency position and travel straight is stroked fully? 14 2 TRAVEL-S Is normal pressure generated in the condition that P2 side flow rate is minimum. Abnormal output necessary Secondary pressure is excessive high against the command Check P1 unload proportional valve P1 UN-LOAD PSV NG Secondary pressure is excessive low and replace it if necessary against the command P1 UN-LOAD SPOOL NG Stuck at full-stroke side Check P1 unload spool and replace it if necessary Stuck at neutral side T5-3-4 . and P2 side flow rate is minimum? 5 2 P2 UNLOAD Is normal pressure generated in the condition that the minimum flow rate is relieved at P2 side? 6 3 P2 UNLOAD Is normal pressure generated in the condition that the unload valve is fully opened.E215B-E245B TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) Table 1 . and P1 side flow rate is minimum? 9 3 P1 PUMP Is normal pressure generated in the condition that the unload valve is in emergency position. Display Contents of diagnosis 1 1 P1 UNLOAD Is normal pressure generated in the condition that the flow rate at P1 side is minimum and the unloading valve is in the emergency position? 2 2 P1 UNLOAD Is normal pressure generated in the condition that the minimum flow rate is relieved at P1 side? 3 3 P1 UNLOAD Is normal pressure generated in the condition that the unload valve is fully opened. and P2 side flow rate is minimum? 12 3 P2 PUMP Is normal pressure generated in the condition that the unload valve is in emergency position. and P1 side flow rate is maximum? 10 1 P2 PUMP Is normal pressure generated in the condition that the flow rate at P2 side is emergency and the unloading valve is in the emergency position? 11 2 P2 PUMP Is normal pressure generated in the condition that the unload valve is emergency. and P2 side flow rate is minimum? 7 1 P1 PUMP Is normal pressure generated in the condition that the flow rate at P1 side is emergency and the unloading valve is in the emergency position? 8 2 P1 PUMP Is normal pressure generated in the condition that the unload valve is emergency.

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

E215B-E245B TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) [MEMO:] T5-3-6 .

REPAIR INSTRUCTIONS M0103 .

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REPAIR INSTRUCTIONS E215B-E245B SECTION AND GROUP CONTENTS Section 1 GENERAL INFORMATION Group 1 Group 2 Precautions for Disassembly and Assembly Tightening Torque Section 2 UPPERSTRUCTURE Group 1 Group 2 Group 3 CCCCC GGGGGGG wwwww Section 3 UNDERCARRIAGE Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8 AAAAAA zzzzzz wwwww zzzzzz AAAAAA zzzzzz wwwww zzzzzz Section 4 FRONT ATTACHMENT Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8 AAAAAA zzzzzz wwwww zzzzzz AAAAAA zzzzzz wwwww zzzzzz .

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.........Tightening Torque Torque Chart .........SECTION 1 E215B-E245B GENERAL INFORMATION CONTENTS Group 1 ............. W1-1-1 Group 2 ........................................ W1-2-4 ............................................... W1-2-1 Piping Joint........Precautions for Disassembly and Assembly Precautions for Disassembly and Assembly ......

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. DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT . 3. repair or replace the parts.Clean the outside surface of equipment. DISASSEMBLING HYDRAULIC EQUIPMENT . .If it is unavoidably necessary to disassemble and modify. .Confirm the position of first-aid kit and fire extinguisher.Before disassembling. . failed parts. . and also where to make contact for emergency measure and ambulance to prepare for accidents and fire. . First check for the cause. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling.Prepare the necessary tools to be used and the area for disassembling work.Removes dirt and water on the surface on which liquid sealant are applied.Remove adhering oil by compressed air. etc.Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from responsibility on the manufacture’s side. 2. and apply gear oil on them before assembling.Wear appropriate clothing. and causes).For common parts.If an abnormality is detected. . don’t fail to use the specified jig and tools. and take out the filter. water or air leaks. . etc. .Check and record the items listed below to prevent problems from occurring in the future. resulting in damage to machine components. assembly and modification without permission are strictly prohibited. REASSEMBLING HYDRAULIC EQUIPMENT . Measure the wear of parts and clearance. . decrease them. Clogging of filters and oil. Loose or damaged parts. never force removal. . . 4. before disassembling. 1. . entry of dust. check that there is no omission of parts.Be sure to thoroughly understand all disassembling/assembling procedures beforehand. machine serial number. and record the measured values. goggles. back-up rings and oil seal with new ones. it should be carried out by experts or personnel qualified through service training.PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY E215B-E245B PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY PREPARATIONS FOR DISASSEMBLY . Capacities and condition of lubricants. and begin a meeting before starting the work. .After completion.Thoroughly wash the machine before bringing it into the shop. . . pay attention to the quantity and places. and apply hydraulic oil or gear oil.Before removing pipes. .During the parts cleaning. and clothes with long sleeves. .Make match mark on parts for reassembling. disassembly.For parts which are required to use jig and tools. or open the cover on the return side to tank.Pipes with plugs or caps to prevent oil leaking.For parts which can not be removed in the specified procedure. and apply liquid sealant on them. and determine if the disassembly and assembly are permitted or not.Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground.Assemble parts matching to the marks.The removed parts should be put in order and tagged so as to install on proper places without confusion. 5. safety shoes. . . W1-1-1 . release the pressure of hydraulic oil tank. to help avoid incorrect disassembling of components as well as personal injury. .Attach "Don’t operate" tag to control lever. and drain hydraulic oil and gear oil before putting them on working. . The machine model. Reason for disassembly (symptoms.Before assembling. bushing and oil seal. read Disassembling Instruction in advance.Replace the removed O-ring. . . remove rust preventives on new parts. ventilate the room.Inspecting parts. as well as decreased efficiency in service work. . and hour meter reading. if any. safety helmet. and then assemble them.Use special tools to fit bearings.

.Air in pilot circuit can be bleed out by only operating digging. W1-1-2 . Removing and attaching hydraulic cylinder IMPORTANT: if hydraulic oil and lubricating oil are not filled and also air bleed is not performed. don’t move it to the stroke end at beginning. and run in low idling. the oil quantity is acceptable. . loosen drain plug on the upper part.E215B-E245B PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY INSTALLING HYDRAULIC EQUIPMENT . Replacement of parts on suction pipe side 3.For air bleed of travel motor and hydraulic cylinder. . swing and travelling motions thoroughly. If the indicator is within level marks. then check the oil level on visual indicator (1) located on the hydraulic oil reservoir. . starts engine and operate it for 10 minutes or more at no-load and low speed.Bleeding Air from Hydraulic System Air release is required in the following cases: 1.Open the hydraulic pump compartment door. IMPORTANT: for cylinder. After completion of comes. . tighten plug securely. Removing and attaching hydraulic pump 4. Removing and attaching swing motor 5. . as indicated in the figure. the hydraulic equipment may be damaged. Move attachments to hydraulic oil check position.Confirm hydraulic oil and lubrication oil.For air bleed of hydraulic pump and swing motor. then bleed air until hydraulic oil is comes out. Removing and attaching travel motor 6.Check hydraulic oil level. start engine. Change of hydraulic oil 2.

to prevent trouble. 3) Check that the O-Ring is not twisted.PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY E215B-E245B Floating Seal Precautions 1. thoroughly dry parts with compressed air. 3) Check O-Ring (B) for tears. rust or dirt. 2) Check the seal ring face (A) for scuffing. 4) After installing the floating seal. After cleaning. deformation or hardening. oil leakage or damage will occur. corrosion. B If incorrectly assembled. scoring. SM0172 1) Clean the floating seal and seal mounting bores with cleaning solvent. and that it is installed correctly on the seal ring. Insert a piece of cardboard to protect surfaces. breaks. RIGHT WRONG SM0173 RIGHT WRONG a A a C B b b a=b W1-1-3 a≠b SM0174 . follow these procedures: A 1) Keep seal rings together as a matched set with seal ring faces together. 2. Be sure to do the following. correct the O-Ring (B) seating. as dust on them tends to enter the floating seal when installing it. Use a wire brush to remove mud. If these distances differ. check that seal ring surface (C) is parallel with mating face (A) by measuring the distances (a) and (b). replace the floating seal with a new one. deformation or uneven wear. If the floating is to be reused. 2) Clean the floating seal and seal mounting bores. as illustrated. In general.

When the fluid has adhered on them. . .Connector should be removed by unlocking while holding the connector.When it has adhered on skin: wash with soap and water. .Engine key off before touching terminals of starter and alternator. .Remove battery grounding terminal before beginning work close to battery and battery relay with tools.When it was swallowed: drink milk or water. take an emergency measure immediately and see a doctor for medical advice. The battery fluid is dilute sulfuric acid. . . W1-1-4 . .Engine key off before removing and connecting connector. . So check the removed waterproofed connector with care to protect it from entry of water.Handle equipment with care so as not to drop it or bump it.Check that connector is connected and locked completely. WARNING Battery fluid is dangerous. . dry it completely before connecting.When it has got in eyes: wash in water for 10 minutes or more immediately. Never stress in tension to the caulked section by pulling wire.Wash machine with care so as not to splash water on electrical equipment and connector.The disassembly of electrical equipment is not allowed.E215B-E245B PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY ELECTRICAL EQUIPMENT . . . skin and clothes.When water has entered in the waterproofed connector. and causes scald and loss of eyesight by adhering on eyes. If moisture adheres on it. the removing of water is not easy.

TIGHTENING TORQUE TORQUE CHART WARNING Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. are used. Bolt Types Tighten nuts or bolts correctly to torque specifications. each made of different material. hexagon bolts T and socket bolt. Wrench Size Hexagon Wrench Size T Bolt. use the correct tools.5 M10 17 8 64 M12 19 10 108 M14 22 12 175 M16 24 14 265 M18 27 14 390 M20 30 17 540 M22 32 17 740 M24 36 19 930 M27 41 19 1370 M30 46 22 1910 M33 50 24 2550 M36 55 27 3140 W1-2-1 E215B-E245B . Two kinds of bolts. Socket bolt (Nm) M18 13 6 29. Avoid bodily injury caused by slipping wrenches. Hexagon T Bolt Socket Bolt SM0175 Specified Tightening Torque Chart Bolt Dia. Make sure to employ the correct bolts and tighten them to specification when assembling the machine or components. For loosening and tightening nuts and bolts.

4. Bolts that are too long cannot be tightened. as the bolt tip comes into contact with the bottom of the bolt hole.3 Tighten from center and diagonally 5 4 2 SM0176 W1-2-2 . Remove dirt or corrosion. if any. 3.4 12 9 4 1 6 7 14 13 8 5 2 3 10 11 3 6 2. to ensure even tightening. 2. Do not use these torques if a different torque is given for a specific application. 5. Apply lubricant (i. Torque tolerance is ± 10%. Bolt Tightening Order When tightening two or more bolts. white zinc B dissolved into spindle oil) to nuts and bolts to stabilize their friction coefficients. Make sure that the nut and bolt threads are clean before installing. Equally tighten upper and lower alternately Tighten diagonally 1 1. Bolts that are too short cannot develop sufficient tightening force. Be sure to use bolts of correct length. e. The torques given in the chart are for general use only. tighten them alternately. as shown.E215B-E245B TIGHTENING TORQUE IMPORTANT 1.

Using an air wrench often causes tightening of one bolt fully before tighten the others. SM0177 WRONG SM0178 Nut and Bolt Lockings • SM0179 Lock Plate IMPORTANT: do not reuse lock plates. 2. resulting in damage to Orings or uneven tightening of bolts. Take care not to file Oring surfaces. 3. • Cotter Pin IMPORTANT: do not reuse cotter pins. Tighten bolts alternately and diagonally. Inspect O-rings for any damage. • WRONG RIGHT Do not bend it round Bend along edge sharply RIGHT RIGHT WRONG Lock Wire IMPORTANT: apply wire to bolts in the bolttightening direction. not in the bolt-loosening direction. Scratches / roughness cause leaks and seal wear. as shown. Loosely assemble split flange halves. not while loosening. Match the holes in the bolt and nut while tightening.TIGHTENING TORQUE E215B-E245B Service Recommendations for Split Flange IMPORTANT 1. use grease to hold it in place. Take care not to pinch the O-ring. Be sure to use only specified O-rings. to ensure even tightening. Do not use air wrenches. When installing an O-ring into a groove. 4. Be sure to clean and inspect sealing surfaces. Do not try to bend the same point twice. Make sure that the split is centrally located and perpendicular to the port. Hand-tighten the bolts to hold the parts in place. Bend along edge sharply RIGHT RIGHT Tighten SM0180 WRONG RIGHT WRONG Loosen SM0181 W1-2-3 . Unevenness causes seal extrusion. 5. replace the component. If defects cannot be polished out.

Excessive force will be applied to metal sealing surfaces (4) and (5). Take care not to damage them when connecting /disconnecting. possibly cracking adaptor (1). Union joints are used to join small-diameter lines.5 36 30. Joint Body SM0182 IMPORTANT 1.6 NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint. Be sure to tighten union nut (3) to specifications. Male Union Joint Female Union Joint SM0183 Type 37° Union Joint Wrench Size Tightening Torque Union Nut Joint Body (Nm) 19 17 29 22 19 39 27 22 78. 37° 37° Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint.E215B-E245B TIGHTENING TORQUE PIPING JOINT Pipe Thread Connection / Union Tightening Torque Specifications Joint 4 1 5 3 2 Union Joint Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. 32 157 41 36 205 50 46 323. 2. W1-2-4 . Do not over-tighten union nut (3).

then tighten union nut (9) after confirming that O-Ring (6) is securely seated in place. Before tightening union nut (9). 4. Tightening union nut (9) with O-Ring (6) displaced will damage O-Ring. Instead. Wrench Size Tightening Torque Union Nut Joint Body (Nm) 19 17 29.4 22 19 68. 7 9 6 IMPORTANT 1. resulting in oil leakage. replace O-Ring (6) with a new one. causing oil leakage.6 27 22 93 30 27 137. do not tighten it to stop the leak.3 36 30 175 41 36 205 50 46 320 W1-2-5 8 10 Joint body SM0184 .TIGHTENING TORQUE E215B-E245B O-Ring Seal Joint O-Ring (6) seats against the end face of adaptor (7) to seal pressure oil. If union nut (9) is found to be loose. Be sure to replace O-Ring (6) with a new one when reconnecting. Take care not to damage O-Ring groove (8) or sealing face (10). confirm that ORing (6) is seated correctly in O-Ring groove (8). Damage to O-Ring (6) will cause oil leakage. 3. 2.

E215B-E245B TIGHTENING TORQUE Screwed-In Connection IMPORTANT: many types of screwed-in connections are used for hose connections. 19 34 22 49 27 93 36. Male Tapered Thread PT PF 30° Male Tapered Thread Wrench Joint Body Tightening Torque (Nm) 17. Be sure to apply just enough seal tape to fill up thread clearances.6 a 0. free of dirt or damage. Wrap seal tape in the same direction as the threads.7 kgf m) SM0188 W1-2-6 SM0189 . SM0187 T-Bolt Type Worm Gear Type T-Bolt Type Band Clamp: 4. Apply seal tape around threads as shown. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.9 Nm (0. See below for correct tightening torque of each type of low-pressure-hose clamp.45 kgf m) Worm Gear Type Band Clamp: 5. so as to prevent any leakage between threads.9 a 6. • Internal Thread Clearance External Thread SM0186 Application Procedure Confirm that the thread surface is clean. 32 157 41 205 50 320 60 410 Male Straight Thread SM0185 Seal Tape Application Seal tape is used to seal clearances between male and female threads. Leave one to two pitch threads uncovered Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp.4 Nm (0. Do not overwrap.

possibly resulting in a fire on the machine. 3. Using hoses other than genuine hoses may cause oil leakage. hose rupture or separation of fitting.TIGHTENING TORQUE E215B-E245B Connecting Hose WARNING 1. Do not install hoses kinked. or an impact to a kinked hose may result in oil leakage. Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked. leading to hose rupture. If hoses rub against each other. 2. Take necessary measures to protect hoses from rubbing against each other. vibration. RIGHT WRONG SM0190 WRONG RIGHT Rubbing Against Each Other SM0191 RIGHT WRONG Clamp Clamp Rubbing SM0192 WRONG RIGHT Rubbing Clamp SM0193 W1-2-7 . Take care that hoses do not come into contact with moving parts or sharp objects. Application of high oil pressure. When replacing hoses. wear to the hoses will result. be sure to use only genuine parts. hose rupture or separation of fitting.

E215B-E245B TIGHTENING TORQUE NOTE: W1-2-8 .