WORKSHOP MANUAL

R0077

All the information and data contained in this manual are based upon most recent information available at the
time of its publication.
FIAT KOBELCO has the right to implement, at any time, any modification without providing any communication.

FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. - ENGINEERING

Print No. 604.13.123
Edition - December 2002
E215-E235
INTRODUCTION
TO THE READER
• This manual is written for an experienced techni-
cian to provide technical information needed to
maintain and repair this machine.
- Be sure to thoroughly read this manual for correct
information concerning the service procedures.
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition
to this service manual:
- Operation and Maintenance Instruction Manual
- Parts Catalog
WORKSHOP MANUAL COMPOSITION
• The Workshop Manual consists of five parts:
- “Safety Precautions”
- “Operational Principle”
- “Operational Performance Test”
- “Troubleshouting”
- “Repair Instructions”
- The “Safety Precaution” part includes the recom-
mended procedures that, if followed, can avoid the
risk of accident for operator and for staff related to
the work and maintenance machine operations.
- The “Operational Principle” part includes the techni-
cal information concerning the operation of main
devices and systems.
IN-1
- If you have any questions or comments, or if you
found any errors regarding the contents of this
manual, please contact:
FIAT KOBELCO
CONSTRUCTION MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 6877357
- The “Operational Performance Test” part includes
the information needed to carry out the machine
operational performance test.
- The “Troubleshooting” part includes the technical
information needed for troubleshooting and mal-
function detection.
- The “Repair Instruction” part includes information
needed for maintenance and repair of the machine,
tools and devices needed for maintenance and
repair, maintenance standards, removal/installa-
tion and assembly/disassembly procedures.
 IN-2 E215-E235

INTRODUCTION

PAGE NUMBER

• Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:

Example: T 1-2-3

Consecutive page number for each group

Group number (if exist)

Section number

T : Technical Manual
W : Workshop Manual

SYMBOLS

In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for
personal injury or machine damage.

This is the safety alert symbol.

When you see this symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed along with the safety alert symbol.
The safety alert symbol is also used to draw attentio in to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy
parts.

UNITS USED

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

MKSA system units and English units are also indicated in parentheses just behinds SI units.

Example: 24.5 MPa (250 kgf/cm2)

A table for conversion from SI units to other system units is shown below for reference purposes.

To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW CV-PS 1.360
Volume L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N.m kgf.m 0.10197 mL/rev cc/rev 1.0
N.m lbf.ft 0.7375
E215-E235 INDEX

INDEX

MANUAL INDEX
SAFETY PRECAUTIONS Pag.
Section 1 GENERALITIES .................................................................... S1
Section 2 SAFETY PRECAUTIONS .................................................. S2
Section 3 SAFETY PLATES ................................................................ S3

OPERATIONAL PRINCIPLE
Section 1 GENERAL
Group 1 Specifications ........................................................................... T1-1
Group 2 Component Layout ................................................................... T1-2

Section 2 SYSTEM
Group 1 Mechatro Control System ........................................................ T2-1
Group 2 Mechatro Controller ................................................................. T2-2
Group 3 Hydraulic System .................................................................... T2-3
Group 4 Electrical System .................................................................... T2-4

Section 3 COMPONENT OPERATION

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

OPERATIONAL PERFORMANCE TEST

Section 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction .............................................................................. T4-1
Group 2 Standard Performances............................................................ T4-2
Group 3 Test Procedures ....................................................................... T4-3
Group 4 Mechatro Controller Adjustment ............................................... T4-4

TROUBLESHOOTING
Section 5 TROUBLESHOOTING
Group 1 Mechatro Control ..................................................................... T5-1
Group 2 Hydraulic System .................................................................... T5-2
Group 3 Electrical System .................................................................... T5-3
INDEX E215-E235

INDEX

REPAIR INSTRUCTIONS

Section 1 GENERAL INFORMATION

Group 1 Precautions for Disassembly and Assembly ......................... W1-1
Group 2 Tightening Torque ................................................................. W1-2

Section 2 UPPERSTRUCTURE
Group 1 Cab ...................................................................................... W2-1
Group 2 Air Conditioner ..................................................................... W2-2
Group 3 Counterweight ...................................................................... W2-3
Group 4 Main Frame .......................................................................... W2-4
Group 5 Pump Device ........................................................................ W2-5
Group 6 Control Valve ........................................................................ W2-6
Group 7 Swing Device ....................................................................... W2-7
Group 8 Pilot Valve ............................................................................. W2-8
Group 9 Solenoid Valve Unit .............................................................. W2-9

Section 3 UNDERCARRIAGE
Group 1 Swing Bearing ...................................................................... W3-1
Group 2 Travel Device ........................................................................ W3-2
Group 3 Swivel Joint .......................................................................... W3-3
Group 4 Track Adjuster ...................................................................... W3-4
Group 5 Front Idler ............................................................................. W3-5
Group 6 Upper and Lower Roller ....................................................... W3-6
Group 7 Tracks ................................................................................... W3-7

Section 4 FRONT ATTACHMENT

Group 1 Front Attachment .................................................................. W4-1
Group 2 Cylinders .............................................................................. W4-2
SAFETY PRECAUTIONS

R0077
E215-E235 W1-1-1
SAFETY PRECAUTIONS E215-E235

INDEX

Section 1 GENERALITIES

Section 2 SAFETY PRECAUTIONS

Section 3 SAFETY PLATES

E215-E235
GENERALITIES
GENERALITIES
Read the Operation and Maintenance Instruction
Manual carefully before starting, operating, maintain-
ing, fuelling or servicing the machine.
Carefully read the explanation to each and all safety
signs in the special section of this Manual before start-
ing, operating, maintaining, fuelling or servicing the
machine.
Machine-mounted safety plates are colour coded yel-
low with black borders when they refer to points where
special ATTENTION must be paid and failure to ob-
serve them may cause a serious DANGER to the in-
tegrity of machine operators. They are white with red
borders and black lettering when they refer to a FOR-
BIDDEN practice.
It is fundamental that all machine operators know very
well the meaning of each safety plate as this consid-
erably decreases operating hazards and accidents.
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, respira-
tors every time the job requires it. Ask your employer
about safety regulations in force and protective equip-
ment.
Always keep the operator’s compartment, step plates,
grab-rails and handles clean and clear of foreign ob-
jects, oil, grease, mud or snow to minimise the dan-
ger of slipping or stumbling. Remove mud or grease
from your shoes before operating the machine.
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 inadvert-
ently moved and cause unexpected movement of the
machine or its attachments.
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 opera-
tor’s compartment at all times to reduce exposure to
external hazards.
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
Do not leave the machine until it has come to a
complete stop.
Always check height, width and weight limitations
which may be encountered in the working site and
ensure the machine does not exceed them.
Assess exact paths of gas ducts, water mains, tel-
ephone lines, sewers, overhead and underground elec-
tric lines and all other possible obstacles.
S1-1
Such paths should be opportunely defined by compe-
tent 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.
Never exceed machine lifting capacity.
Remain within the limits shown in the loading capac-
ity chart which located on the machine.
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 re-
moved. Before starting machine, check that steering
and attachment controls are in the neutral position
and the safety lever is in the LOCK position. Immedi-
ately report any malfunction of parts or systems to
the maintenance managers for proper action.
Prior to starting the engine, check, adjust and lock
the driver’s seat for maximum riding comfort and con-
trol accessibility. Prior to operating the machine and/
or its attachments, check that bystanders are out-
side the machine operating range. Sound the horn.
Obey all hand signals, safety indications and signs.
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.
Ensure that nobody is within the excavator operat-
ing area before starting the machine, swinging the
upper structure or moving in any direction.
Adjust all rear-view mirrors for maximum visibility of
the area behind the machine.
Ensure that engine speed is appropriate to the job to
be carried out.
If any hydraulic control or system exhibits erratic per-
formance or responds abnormally, have the machine
checked for air in the system.
Air in these circuits may cause incorrect movements
with consequent accident hazard. Refer to the Opera-
tion and Maintenance Instruction Manual about cor-
rective action to be taken.
OPERATING
Do not run the engine of this machine in closed
buildings without proper ventilation capable to re-
move harmful exhaust gases which concentrate in
the air.
Keep the operator’s compartment free of foreign ob-
jects, especially if not firmly secured. Never use the
S1-2
GENERALITIES
machine to transport objects, unless proper securing
points are provided.
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.
Make sure that bystanders are clear of the machine
operating range before starting the engine and oper-
ating the attachment. Sound the horn.
Obey all hand signals, safety indications and signs.
When backing, always look to where the machine is
to be moved. Be alert of the position of bystanders.
Should someone enter the work area, stop the ma-
chine.
Maintain a safe distance from other machines or ob-
stacles to ensure required visibility conditions.
Always give way to loaded machines.
Maintain a clear vision of the surroundings of the
travel or work area at all times.
Keep cab windows clean and repaired.
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 prob-
lems 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.
Always wear heavy gloves when handling chains or
cables.
Chains and cables should be securely anchored us-
ing suitable hooks. Anchor points should be strong
enough to withstand the expected load.
Keep anyone clear of anchor points and cables or
chains. Do not pull or tow unless the operator’s
compartments of the machines involved are prop-
erly 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.
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 what-
ever reason under load or at idle, immediately report
this problem to the maintenance managers for proper
action. Do not operate the machine until this condi-
tion is corrected.
Regularly check all exhaust system components, as
exhaust fumes are toxic for the operator.
Operators must know the performance of the ma-
chine 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.
E215-E235
If noise level is high and exceeds 90 dB (A) over 8
hours at the operator’s ear, wear approved ear protec-
tion in compliance with local regulations.
Do not operate the machine if you are extremely tired
or feel ill.
Be especially careful towards the end of the working
shift.
Where removable counterweights are provided, do not
operate the machine if they have been removed.
When operating the machine, keep in mind height lim-
its of overhead doors, arches, overhead cables and
lines as well as width limits of corridors, roads and
narrow passages. Also, get to know load limits of the
ground and paving type of the ramps you are to work
on.
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 ex-
treme care.
Whenever possible, avoid crossing over obstacles
such as very rough terrain, rocks, logs, steps,
ditches, railroad tracks. When obstructions must
be crossed, do so with extreme care and at a
square angle, if possible. Slow down. Ease up to
the break-over point, pass the balance point slowly
and ease down the other side also using the at-
tachment, if necessary.
To overcome deep trenches or sinking ground,
place the machine perpendicular to the obsta-
cle, drastically reduce ground speed and start
crossing using also the attachment if necessary,
only after assessing that ground conditions al-
low the traverse safely and without risks.
The gradient you may attempt to overcome is limited
by factors such as ground conditions, load being han-
dled, machine type and speed, and visibility.
There is no substitute for good judgement and experi-
ence when working on slopes.
Avoid operating the attachment too close to an over-
hang or high wall, either above or below the machine.
Beware of caving edges, falling objects and land-
slides. Remember that such hazards are likely to be
concealed by bushes, undergrowth and such.
Avoid faggots, bushes, logs and rocks. Never drive
over them, nor over any other surface irregularities
that discontinue adherence or traction with the ground,
especially near slopes or drop-offs.
Be alert to avoid changes in adherence conditions
that could cause loss of control. Work with extreme
care on ice or frozen ground and on stepped slopes
or near drop-offs.
The word “bulldozing” generally refers to work in
virgin rough terrain, characterised by the presence
of all the perils and risks listed above. We empha-
sise the danger represented in these conditions by
large tree limbs (possibly falling on the machine)
E215-E235
GENERALITIES
and large roots (which may act as a leverage un-
der the machine when up-rooted and cause the unit
to overturn).
Position the machine dependent upon the loading and
unloading areas in order to swing leftwards to load to
obtain best visibility.
Never use the bucket or attachment as a man lift or
carry riders.Never use the machine as a work platform
or scaffolding. The machine must not be improperly used
for works not consistent with its features (such as push-
ing railway cars, trucks or other machines).
Always pay attention to people within the machine
operating range.
Never move or stop the bucket, other loads or the
attachment above ground personnel or truck cabs.
Ensure the truck driver is in a safe place before load-
ing the truck.
Load trucks from side or rear.
Use only the type of bucket recommended consider-
ing machine type, materials to be handled, material
piling up and loading characteristics, ground type and
other typical conditions of the work to be performed.
When transporting a loaded bucket, keep it as rolled-
back as possible. Keep boom and arm as low as
possible.
Ground speed should be adequate to the load and
ground conditions.
The load must always be properly arranged in the
bucket; move with extreme care when transporting
oversize loads.
Do not lift and move the bucket overhead where per-
sons are standing or working, nor downhill when work-
ing on a slope as this would decrease machine stabil-
ity. Load the bucket from the uphill side.
Loads to be raised using the machine should be ex-
clusively hooked to the hitch specially provided.
The excavator is no lifting and transportation means,
therefore it should not be used to position loads accu-
rately. Should it be exceptionally used to lift and lay
building components, special caution must be taken
as follows:
- The machine must be equipped without failure with
the appropriate variant supplied, upon request, by
FIAT KOBELCO. Also, totally comply with the
safety precautions for the operation of the excava-
tor as a lifting equipment.
- Secure the loads to be raised using cables or chains
fastened with appropriate hooking mechanisms.
- Nobody should be allowed to remain under the raised
load or within the excavator operating range for any
reason whatever.
Never exceed specified loading capacity. Incorrect fas-
tening of slings or chains may cause boom/arm fail-
ure or failure of the lifting means with consequent bodily
injuries and even death.
Always ensure that slings and chains used for lifting
are adequate to the load and in good condition.
All loading capacities are referred to the machine
on a level surface and should be disregarded when
working on a slope.
S1-3
Avoid travelling across slopes. Proceed from uphill
downhill and vice-versa. If machine starts slipping
sideways when on a slope, lower the bucket and thrust
bucket teeth into the ground.
Working on slopes is dangerous. Grade the working
area if possible. Reduce work cycle time if it is not
possible to grade the working area.
Do not move full bucket or a load from uphill downhill
as this would reduce machine stability. Do not work
with the bucket turned to the uphill side.
Do not work with the bucket turned uphill as counter-
weights protruding downhill would reduce machine
stability on the slope and increase risk of overturn-
ing.
We recommend to work on slopes with the bucket
downhill, after checking machine stability with the
bucket empty and attachment retracted, by slowly
swinging the upper structure by 360°.
Position the carriage at a right angle relative to slopes,
hanging walls, etc. to exit the working area easily.
Standard use, provides for the travel controls at the
front and travel motors at the back. Should travel
motors be positioned at the front with regard to the
actual travel direction. Remind relative to travel direc-
tion that controls are reversed.
Always check travel motor position before moving off.
Properly judge ground conditions with particular at-
tention to consistency of the area you are going to
work on.
Keep the machine sufficiently far from the ditch edge.
Never dig under the machine.
Should it be necessary to dig under the machine, al-
ways ensure that digging walls are opportunely
propped up against landslide to prevent the machine
from falling into the trench.
Do not swing the upperstructure, raise the load or
brake abruptly if not required. This may cause acci-
dents.
Prior to beginning the work near gas distribution mains
or other public utilities:
- Contact the company owner of the gas mains or its
nearest branch before starting the work. Look up
the number in the telephone directory.
- Define together which precautions should be taken
to guarantee work safety.
- Decrease work speed. Reaction time could be too
slow and distance evaluation wrong.
- When working near gas mains or other public utili-
ties installations, appoint a person in charge of sig-
nalling duties. This person will have the responsibil-
ity of observing the machine, any part of it and/or
the load approaching the gas mains from a stand-
point more favourable than the Operator’s. This sig-
nal man (flag-man) must be in direct communica-
tion with the Operator and the Operator must pay
undivided attention to the signals supplied.
- The gas distributing Company, if previously advised
and involved in the work, as well as machine Opera-
tor, Owner and/or any natural person or legal entity
having rent or leased the machine or being responsi-
S1-4
GENERALITIES
ble at the time by contract or by law, are liable for the
adoption of the necessary precautions.
Working near electric lines can be very dangerous,
therefore some special precautions must be ob-
served.
Within this Manual, “work near electric lines” means
when the attachment or load raised by the excava-
tor (in any position) may reach the minimum safety
distance established by local or international Safety
Regulations.
To work without risks, keep maximum possible dis-
tance from electric lines and never trespass minimum
safety distance.
- Contact the Company owner of the electric lines or
its nearest branch before starting the work.
Look up the in the telephone directory.
- Define together with the Company representative
which precautions should be taken to guarantee work
safety.
- 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 con-
nected to the ground.
- The Electric Power Company, if previously advised
and involved in the work, as well as machine Op-
erator, Owner and/or any natural person or legal
entity having rent orleased the machine or being
responsible at the time by contract or by law, are
liable for the adoption of the necessary precautions.
- Decrease work speed. Reaction time could be too
slow and distance evaluation wrong.
- Warn all ground personnel to keep clear of the ma-
chine and/or load at all times. If the load has to be
guided down for laying, consult the Electric Power
Company to know which precautions should be
taken.
- Appoint a person in charge of signalling duties.
This person will have the responsibility of observ-
ing the machine, any part of it and/or the load ap-
proaching the electric lines from a standpoint more
favourable than the Operator’s. This signal man (flag-
man) must be in direct communication with the
Operator and the Operator must pay undivided at-
tention to the signals supplied.
When working in or near pits, in ditches or very high
walls, check that the walls are sufficiently propped up
to avoid cave-in hazards.
Pay the utmost attention when working near overhang
walls or where landslides may take place. Make sure
that the support surface is strong enough to prevent
landslides.
When digging, there is the risk of cave-ins and land-
slides.
Always check ground conditions and conditions of the
material to be removed. Support everywhere it is re-
quired to prevent possible cave-ins or landslides when:
- digging near previous trenches filled with material
- digging in bad ground conditions
- digging trenches subject to vibration from railroads,
working machines or highway traffic.
E215-E235
STOPPING
When the machine is to be stopped for whatever reason,
always check that all controls are in the neutral position
and that the safety lever is on the lock position to guaran-
tee risk-free start-up.
Never leave the machine unattended with the engine run-
ning.
Prior to leaving the driver’s seat, and after making
sure that all people are clear of the machine, slowly
lower the attachment until resting it safely to the
ground. Retract possible auxiliary tools to the closed
safety position.
Check that all controls are in the neutral position. Move
engine controls to the shut-down position. Switch off
the key-start switch. Consult the Operation and Main-
tenance Instruction Manual.
Park the machine in a non-operating and no-traffic area.
Park on firm level ground. If this is not possible, posi-
tion the machine at a right angle to the slope, making
sure there is no danger of uncontrolled sliding.
If parking in traffic lanes cannot be avoided, provide
appropriate flags, barriers, flares and other signals as
required to adequately warn the oncoming drivers.
Always switch off the key-start switch before clean-
ing, repairing, or parking the machine to prevent acci-
dental unauthorised start-up.
Never lower the attachment or auxiliary tools other
than from sitting in the operator’s seat. Sound the horn.
Make sure that nobody is within the machine operat-
ing range. Lower the attachment slowly.
Securely block and lock the machine every time you
leave it unattended. Return keys to the safe place
previously agreed upon. Perform all necessary opera-
tions for stopping as detailed in the Operation and
Maintenance Instruction Manual.
Drive the machine far from pits, trenches, rocky hang-
ing walls, areas with overhead electric lines, and slopes
before stopping it at the end of the working day.
Align the upperstructure to the tracks in order to allow
to easily get on and off the driver’s compartment.
Move all controls to the position specified for machine
stopping. Refer the Operation and Maintenance In-
struction Manual.
Never park on an incline without accurately blocking
the machine to prevent unexpected movement.
Follow stopping instructions contained in the Opera-
tion and Maintenance Instruction Manual.
MAINTENANCE
GENERALITIES
Carefully read the Operation and Maintenance Instruc-
tion Manual before starting, operating, maintaining,
fuelling or servicing the machine in any manner.
Read all safety plates mounted on the machine and
E215-E235
GENERALITIES
observe instructions they contain before starting, op-
erating, repairing, fuelling or servicing the machine.
Do not allow unauthorised personnel to repair or serv-
ice the machine.
Follow all recommended maintenance and service
procedures.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get
caught in moving parts. Wear certified safety clothes
such as: hard hat, no-slip footwear, heavy gloves, ear
protection, safety glasses, reflector vests, respirators
when required. Ask your employer about safety regu-
lations in force and protective equipment.
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 inadvert-
ently moved and cause unexpected movement of the
machine or its attachments.
Do not jump on or off the machine. Always keep both
hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Never service the machine with someone sitting in
the driver’s seat, unless this person is an authorised
operator assisting in the maintenance being carried
out.
Keep the operator’s compartment, step plates, grab
rails and handles clear of foreign objects, oil, grease,
mud orsnow to minimise the danger of slipping or stum-
bling.
Clean mud or grease from your shoes before climbing
on the machine or driving it.
Never attempt to operate the machine or its attach-
ments from any position other than sitting in the op-
erator’s seat.
Keep the driver’s seat free from foreign objects, espe-
cially if these are not secured.
Should it be necessary to move the attachment for
maintenance purposes, do not raise or lower the at-
tachment from any other position than sitting in the
operator’s seat. Before starting the machine or mov-
ing its attachment, sound the horn and require that
nobody remains near the machine.
Raise the attachment slowly.
Always lock all moving components or parts of the
machine that must be lifted for maintenance purposes
using adequate external means as required by local
and national regulations. Do not allow anyone to pass
or stay near or below a raised attachment. If you are
not absolutely sure about your safety, do not stay or
walk under a raised attachment.
Do not place head, body, limbs, hands, feet or fingers
near articulated cutting edges deprived of the neces-
sary guards, unless they are suitably and safely
locked.
Never lubricate, repair or adjust the machine with the
engine running, except when this is specifically re-
quired by the Operation and Maintenance Instruction
Manual.
Do not wear loose clothing, jewellery near rotating parts.
S1-5
When service or maintenance require access to ar-
eas that cannot be reached from the ground, use a
ladder or step platform conforming to local or national
regulations to reach the working area. If such means
are not available, use machine grab rails and steps.
Always perform all service or maintenance work with
the greatest care and attention.
Shop and/or field service platforms or ladders should
be manufactured and maintained in accordance with
local or national safety regulations in force.
Disconnect batteries and label all controls to warn that
service work is in progress, according to local and
national safety regulation requirements
Block the machine and all attachments to be raised
according to local and national safety regulation re-
quirements.
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.
The fuel filler pipe nozzle must be constantly kept in
contact with the filler neck and this even before fuel
starts flowing in. Keep this contact from the begin-
ning to the end of the fuelling operation to avoid pos-
sible generation of sparks due to static electricity.
Use a truck or trailer to haul a failed machine. Should
it be necessary to tow it, provide for suitable danger
signals as required by the local norms and regula-
tions and observe recommendations given in the Op-
eration and Maintenance Instruction Manual. Load/
unload the machine on firm level ground providing safe
support to the wheels of the truck or trailer. Use strong
access ramps, with adequate height and angle. Keep
the trailer flatbed free of mud, oil or slippery materi-
als. Tie the machine securely to the trailer and block
carriages and upperstructure.
Never align holes or slots using your fingers;
alwaysuse appropriate aligning tools.
Remove all sharp edges and burrs from re-worked
parts.
Use only approved and effectively grounded auxiliary
power sources for heaters, battery chargers, pumps
and similar equipment to reduce electrical shock haz-
ard.
Lift and handle heavy components using hoisting de-
vices of appropriate capacity. Ensure the parts are
supported by appropriate straps and hooks.
Use lifting eyes provided to this aim.
Pay attention to bystanders near the lifting area.
Never pour gasoline or diesel fuel into open contain-
ers. Never use gasoline, solvents or other flammable
fluids to clean parts. Use proprietary certified non-
flammable, non-toxic solvents only.
When using compressed air to clean parts, wear safety
glasses with side shields. Limit pressure to max. 2
bars, in accordance with local and national safety regu-
lations in force.
Do not run the engine of this machine in closed build-
ings without proper forced ventilation capable to re-
move toxic exhaust gases concentrating in the air.
Do not smoke, nor allow open flames or sparks nearby
S1-6
GENERALITIES
while refuelling the unit or handling highly flammable
materials.
Do not use open flames as light sources to look for
leaks or inspect anywhere on the machine.
Make sure that all mechanical tools provided are in
good condition at all times. Never use tools with mush-
roomed or damaged heads. Always wear eye protec-
tions with side shields.
Move with extreme care when working under, on or
near the machine or its attachments.
In case of attachment tests during which the engine
should be kept running, a qualified operator must sit
in the driver’s seat at all times while the mechanic is
at work.
Keep hands and clothes far OFF moving parts.
Stop the engine and move the safey lever to the lock
position before starting adjusting or repairing an as-
sembly.
Do not carry out any work on the attachment without
prior authorisation. Observe maintenance and repair
procedures.
In case of field service, move the machine to level
ground and block it. If work on an incline cannot be
avoided, securely block the machine and its attach-
ments. Move the machine to level ground as soon as
possible. Do not twist chains and cables. Never use a
twisted chain or cable for lifting or pulling. Always wear
safety gloves to handle chains or cables.
Be sure chains and cables are firmly fastened and
that the anchor point is strong enough to withstand
the expected load. Keep all bystanders clear of the
anchor point, cables or chains. Do not pull or tow
unless the operator’s compartments of the ma-
chines involved are fitted with proper guards
against cable or chain backlash.
Keep the maintenance area clean and dry at all times.
Clean immediately all water and oil spillage.
Do not pile up oily or greasy rags as they represent a
major fire hazard. Always store them in closed metal
containers.
Before starting the machine or its attachment, check,
adjust and lock the operator’s seat. Also ensure that
nobody is within the machine or attachment operating
range before starting or operating the machine and/or
its attachments.
Sound the horn.
Rust inhibitors are volatile and flammable.
Prepare parts in well ventilated areas. Keep open flames
away.
Do not smoke. Store containers in a cool well venti-
lated place where they could not be reached by unau-
thorised people.
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
safety shoes and gloves, safety glasses when splin-
ters or other particles may be ejected.
Wear the appropriate welder’s equipment such as dark
safety glasses or mask, hard hat, protective clothing,
safety gloves and footwear always while welding or
E215-E235
arc-cutting. Wear dark safety glasses when you are
near a welding in progress. Do not look the welding
arc without proper eye protection.
Become acquainted with all your jacking equipment
and their capacity.
Ensure that the jacking point on the machine is ap-
propriate for the load applied. Also, be sure the sup-
ports under the jack and between the jack and the
machine are appropriate and stable.
Any equipment supported by a jack represents a pos-
sible hazard. Always support the load onto appropri-
ate blocking means as a safety measure before pro-
ceeding with service or maintenance work, in compli-
ance with local or national safety regulations.
Metal cables produce steel splinters. Always wear
certified protection clothes such as safety gloves and
glasses while handling them.
Do not use makeshift jacks to adjust track sag. Fol-
low instructions given in the Repair Manual.
Handle all parts carefully. Keep hands and fingers
away from gaps, gears, and similar. Always use and
wear certified safety clothes such as safety glasses,
gloves and footwear.
The attachment is kept constantly in position by an
oil column trapped into the high pressure circuit. Lower
the attachment to the ground and relieve pressure from
all circuits prior to carrying out any type of mainte-
nance or repair work.
Do not service or repair the machine if it is parked
downhill. If this is unavoidable, in case of emergency,
block the carriages to prevent unexpected movement,
particularly if the work is to be carried out on the final
reduction units or travel motors.
Consult the Operation and Maintenance Instruction
Manual for correct maintenance procedure.
Areas near articulated cutting edges where mechani-
cal parts are in motion are where personal injuries are
most likely to occur. Pay attention to prevent possible
part movements by means of blocks or by keeping
clear of such zones when motion may take place dur-
ing maintenance or repair.
Move the hydraulic system lock safety lever to the
lock position when stopping the machine for what-
ever reason.
Always install the safety stays for the hood and other
hinged covers before performing any maintenance or
repair work in the engine compartment.
TRANSFERS AND TRANSPORTATION
Before moving or transporting the machine, block
upperstructure swing to prevent accidental move-
ment.
Pay particular attention during transfer on inclines,
both uphill and downhill. Keep the bucket in a posi-
tion to provide a possible anchor point into the
ground in case of slipping.
E215-E235
GENERALITIES
During transfers on inclines, both uphill and downhill,
keep the upperstructure aligned with the carriages.
Do not travel across the slope.
Never transfer the machine in the working site, in a
crowded area, or near people without having at least
one person charged with hand-signals who could guide
the Operator.
Sound the horn to inform that you are about to move off.
It is necessary to know load limits of bridges and di-
mensional limits of tunnels. Such limits must never
be exceeded. You should also know machine height,
width, and weight. Have a signal-man help you when
clearances are limited.
Check distance between boom/arm and dimensional
limits during transfer or transportation.
Rough terrain may cause the machine to sway and
roll to such an extent that boom/arm could get to con-
tact electric lines or other obstacles. Cross obstacles
at a right angle at low speed. Pay attention to ma-
chine shaking when the centre of gravity overcomes
the obstacle.
Keep the bucket down at all times during transfers.
Drive with the lights on and use appropriate signals
and flags.
Get to know and respect local and national regula-
tions.
Consider boom/arm and upperstructure dimensions
while turning.
Use a ramp to load the machine on a trailer. If a ramp
is not available, fabricate one using blocks. The ramp
should be sufficiently strong to support machine
weight. Always load and unload on level surface.
Tow the machine following the instructions contained
in the Operation and Maintenance Instruction Manual.
ENGINE
Do not run the engine in closed buildings without proper
ventilation capable to remove harmful exhaust fumes.
Do not place head, body, limbs, feet, hands or fingers
near rotating fans or belts. Be especially careful near
blower fans.
Loosen the radiator cap very slowly to relieve system
pressure before removing it. Always top-up coolant
level with the engine off or idling if hot. See the Op-
eration and Maintenance Instruction Manual.
Keep the exhaust manifold and tube free from com-
bustible matters. Fit the machine with shields and
guards when working in the presence of combustible
matter free in the air.
Do not refuel with the engine running, especially if
hot, as this increases fire hazard in case of fuel spill-
age.
Never attempt to check or adjust fan belt tensions
when the engine is running.
Do not adjust the fuel injection pump when the ma-
chine is operating.
S1-7
Do not lubricate the machine with the engine running.
Do not run the engine with the air intakes open and
not protected. If this cannot be avoided for service
reasons, place protection meshes on all intakes be-
fore servicing the engine.
ELECTRICAL SYSTEM
Pay attention to connect connecting cables to cor-
rect poles (+ to +) and (- to -) at both ends. Do not
short-circuit terminals. Thoroughly follow instruc-
tions given in Operation and Maintenance Instruc-
tion Manual.
Always move the key-start switch in the lock posi-
tion before servicing or repairing the machine.
Batteries contain SULPHURIC ACID. Protect the
eyes when working near the batteries against pos-
sible sprays of the acid solution. Should acid con-
tact skin, eyes, or clothes, RINSE IMMEDIATELY
IN WATER FOR AT LEAST 15 MINUTES. Immedi-
ately seek medical attention.
Battery released gas is highly flammable. Leave
the battery compartment cover open during recharg-
ing to improve ventilation. Never check battery
charge by placing metal objects across the posts.
Keep sparks or open flames away from batteries.
Do not smoke near the battery to prevent explo-
sion hazard.
Before any maintenance or repair, make sure that
there are no fuel or electrolyte leaks from the bat-
teries. If any, correct prior to proceeding with fur-
ther work. Do not recharge batteries in confined
spaces. Ensure proper ventilation is provided to
avoid accidental explosions due to build-up of ex-
plosive gas released during charging.
Disconnect batteries before working on the electri-
cal system or carrying out any other type of work.
HYDRAULIC SYSTEM
Pressure fluid escaping from a very small hole can
be almost invisible and still have sufficient force to
penetrate the skin. Always check any suspected
pressure leaks using a piece of cardboard or wood.
Do not use hands. If injured by escaping fluid, ob-
tain medical attention immediately or serious in-
fection or reaction may develop.Stop the engine
and ensure pressure is relieved from all systems
before removing side panels, housings, guards and
covers. See the Operation and Maintenance In-
struction Manual.
Always use gauges of adequate capacity for pres-
sure testing. Refer to the Operation and Mainte-
nance Instruction Manual or Repair Manual.
S1-8
GENERALITIES
TOOLS
Always keep head, body, limbs, feet, hands, and fin-
gers away from the bucket and attachments, when in
the raised position.
Prior to any maintenance or repair work, install all
supports necessary to this aim according to local and
national safety regulations.
In case the attachment is to be operated for mainte-
nance or repair purposes, do so exclusively while sit-
E215-E235
ting in the driver’s seat. Sound the horn before start-
ing the machine or moving the attachment. Require
that nobody remain near the machine. Raise the at-
tachment slowly.
Do not use the machine to transport loose objects,
unless proper securing devices are provided.
Never use gases other than nitrogen to charge the
accumulators.
Refer to the Operation and Maintenance Instruction
Manual.
E215-E235 S2-1

SAFETY PRECAUTIONS

RECOGNISE SAFETY INFORMATION

• This is your SAFETY ALERT SYMBOL.

- When you see this symbol on your machine or in

this Manual, be alert of the potential for personal
injury.
- Follow recommended precautions and safe oper-
ating practices.

S0021

UNDERSTAND SIGNAL WORDS

• In this Manual you will find the following words:

- DANGER;
- WARNING;
- CAUTION.
Referring to different hazard risks. DANGER
These words are always accompanied by the safety
alert symbol.

DANGER: Indicates an imminent hazardous situation

WARNING
which, if not avoided, will result in death or serious
injury.
CAUTION
WARNING: Indicated a potential hazardous situation
which, if not avoided, could result in death or serious
injury.
IMPORTANT
CAUTION: Indicates a potential hazardous situation
which, if not avoided, may result in minor or moderate
injury. NOTE
IMPORTANT: Indicates a situation which, if not
avoided, may cause damage to the machine.

NOTE: Indicates an additional explanation for informa-

tion purposes.

ENVIRONMENTAL PROTECTION

• This Manual also contains this symbol accompany-

ing instructions for correct behaviour as regards
environmental protection.

S0024
S2-2 E215-E235

SAFETY PRECAUTIONS

FOLLOW SAFETY PRECAUTIONS

• Carefully read and observe all safety signs on the

machine and read all safety precautions in this
Manual.
• Safety signs should be installed, maintained, and
replaced when necessary.
- If a safety sign or this Manual are damaged or
missing, obtain a replacement from your FIAT
KOBELCO Dealer in the same way you order a
spare part (be sure to detail machine model and
serial number upon ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorised personnel to S0022
operate the machine.
• Keep the machine in proper working conditions.
- Unauthorised changes to the machine may impair
function and/or safety and affect machine life.
• Safety messages in this Chapter “SAFETY PRE-
CAUTIONS”, are intended to illustrate basic safety
procedures of the machine. However, it is impossi-
ble for these safety messages to cover every
hazardous situation you may encounter. If you have
any doubts, consult your direct supervisor prior to
operating or servicing the machine.

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or an accident occurs.

- Keep the first-aid kit and fire extinguisher on hand.
- Thoroughly read and understand the label at-
tached to the fire extinguisher to use it properly.
- Establish emergency priority procedures to cope
with fires and accidents.
- Keep emergency numbers for doctors, ambulance
service, hospitals and fire department posted near
the telephone.

S0023
E215-E235 S2-3

SAFETY PRECAUTIONS

WEAR PROTECTIVE CLOTHING

• Wear close-fitting clothing and safety equipment

appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask.
Be sure to correctly wear equipment and clothing for
the job.
- Do not take any chances. S0025

- Avoid wearing loose clothing, jewellery, or other

items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full atten-
tion of the operator. Do not wear radio or music
headphones while operating the machine.

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impair-

ment or loss of hearing.
- Wear a suitable hearing protection such as ear-
muffs or earplugs to protect objectionable or un-
comfortably loud noise.

S0026

INSPECT THE MACHINE

• Inspect the machine carefully every day or work-

shift by an attentive visual inspection of machine
outside prior to starting it to prevent damages and
personal injuries.

- In the walk-around inspection, be sure to cover all

points detailed in the Chapter "MAINTENANCE",
paragraph "EXTERNAL VISUAL INSPECTION"
of the OPERATION AND MAINTENANCE IN- S0027
STRUCTION MANUAL.
S2-4 E215-E235

SAFETY PRECAUTIONS

USE HAND HOLDS AND STEPS

• Falling is one of the major causes of personal injury.

- When you get on and off the machine, always face

the machine and maintain a three-point contact
with the steps and handrails.

- Do not use any control as a handhold.

- Never jump off the machine. Never get on and off

a moving machine.

S0028
- Be careful of slippery conditions of platforms,
steps, and handrails when leaving the machine.

ADJUST THE OPERATOR'S SEAT

• A seat poorly adjusted for operator or work require-

ments may quickly fatigue the operator leading to
improper operations.

- The seat should be adjusted whenever machine

operator changes.

- The operator should be able to fully press the

pedals and correctly move the control levers with
his back resting against the seat back.

- If not, move the seat fore and aft, and check again.

S0029
E215-E235 S2-5

SAFETY PRECAUTIONS

FASTEN SEAT BELT

• Should the machine overturn, the operator may

become injured and/or thrown from the cab. Not
only, the operator may be crushed by the overturning
machine resulting in serious injury or even death.

- Prior to operating the machine, thoroughly

examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn, replace
the seat belt or component before operating the
machine.
S0030
- Be sure to remain seated with the seat belt
securely fastened at all times when the machine
is in operation to minimise injury hazard in case of
accident.

- After a significant accident, replace the seat belts

even though they do not look damaged.

MOVE AND OPERATE

MACHINE SAFELY

• Bystanders can be run over.

- Pay the utmost attention not to run over bystand-

ers.

- Be sure and aware of the location of bystanders

before moving, swinging or operating the machine.

- If fitted, keep the travel alarm and horn sounding

to warn people that the machine is about to move.

- When operating, swinging, or moving the machine S0031

in a congested area use a signal man.

- Co-ordinate hand signals before starting the

machine.
S2-6 E215-E235

SAFETY PRECAUTIONS

OPERATE ONLY FROM

THE DRIVER'S SEAT

• Inappropriate engine starting procedures may cause

the machine unexpected movement, possibly
resulting in serious injury and even death.
- Start the engine only from the operator’s seat.
- NEVER start the engine while standing on the
track or on the ground.
- Do not start the engine by shorting across starter
motor terminals.
- Before starting the engine, ensure that all control
levers are in the neutral position.
S0032

KEEP RIDERS OFF THE MACHINE

• Riders on the machine are subject to injuries such as

being struck by foreign objects and being thrown off
the machine.

- Only machine operator is allowed on the machine.

Keep riders off.

- Riders also obstruct the operator’s visibility,

resulting in the machine being operated unsafely.

S0033

CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN

• Incorrect travel controls operation may result in

serious injury and even death.

- Before driving the machine, be aware of the

undercarriage position relative to the operator’s
position. If travel motors are located at the front of
the cab, the machine will move reverse when travel
controls are moved towards cab front.
S0037
E215-E235 S2-7

SAFETY PRECAUTIONS

AVOID INJURY FROM BACK-OVER

AND SWING ACCIDENTS

• If any person is present near the machine when

backing or swinging the upperstructure, the machine
may hit or run over that person, resulting in serious
injury or death.

• To avoid back-over and swing accidents:

- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.

- Keep the travel alarm in working condition (if

equipped).

- ALWAYS BE ALERT FOR BYSTANDERS S0042

MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.

- USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.

- Use hand signals, which conform to your local

regulations, when work conditions require a signal
person.
S0043
- No machine motions shall be made unless signals
are clearly understood by both signalman and
operator.

- Learn the meanings of all flags, signs, and

markings used on the job and confirm with the
person in charge of signalling.

- Keep windows, mirrors, and lights clean and in

good condition.

- Dust, heavy rain, fog, etc., can reduce visibility.

As visibility decreases, reduce speed and use
proper lighting.

- Read and understand all operating instructions in

the OPERATION AND MAINTENANCE IN-
STRUCTION MANUAL.
S2-8 E215-E235

SAFETY PRECAUTIONS

DRIVE MACHINE SAFELY

• Before starting the machine carefully read the OP-

ERATION AND MAINTENANCE INSTRUCTION
MANUAL. (Refer to the OPERATING INSTRUC-
TIONS chapter).

• Before moving the machine, confirm which way to

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

- Pushing down on the front of the travel pedals or

S0038
pushing the levers forward moves the machine
towards the idlers. (Refer to the OPERATION
AND MAINTENANCE INSTRUCTION MANUAL).

• Traveling on a grade may cause the machine to slip

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

- When traveling up or down a grade, keep the

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

- If machine starts to skid or becomes unstable,

lower the bucket immediately.
S0039

- Traveling across the face of a slope may cause

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

- Turning on an incline may cause the machine to tip

over. If turning on an incline is absolutely unavoid-
able, do so at a place where the slope is gentle and S0004

the surface is firm.

- When operating on a grade and the fuel reserve

indicator light lights, immediately refuel.

WRONG
S0005
E215-E235 S2-9

SAFETY PRECAUTIONS

AVOID OVERTURNING

• The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death.

• To avoid tipping:
- Be extra careful before operating on a grade.
- Prepare machine operating area flat by grading.
- Keep the bucket low to the ground and close to the
machine.
- Reduce machine operating speed to avoid tipping
or slipping.
- Avoid changing direction when travelling on
S0002
grades.
- NEVER attempt to travel across a grade steeper
than 15 degrees.
- Reduce swing speed as necessary when swinging
loads.

• Be careful when working on frozen ground.

- Temperature increases will cause the ground to
become soft and make ground travel unstable.

S0047

PARK MACHINE SAFELY

• To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Turn auto-idle (A/I) switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Pull the safety lever (pilot-control shut-off lever) to
the LOCK position.
- Close windows, roof window, and cab door.
- Lock all access doors and compartments. S0049
S2-10 E215-E235

SAFETY PRECAUTIONS

AVOID INJURY FROM UNEXPECTED

MACHINE MOVEMENT

• Death or serious injury may result if you attempt to

get on or off a moving machine.

• To avoid roll-aways:
- Select level ground when possible to park
machine.
- Do not park the machine on a grade.
- Lower the bucket and/or other work tools to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
- Turn the auto-idle switch off.
- Run the engine at slow idle speed without load for
S0040
5 minutes to cool down the engine.
- Stop the engine and remove the key from the key
switch.
- Pull the pilot shut-off lever to LOCK position.
- Block both tracks.
- Position the machine to prevent overturning.
- Park a reasonable distance from other machines.

S0041

PROVIDE SIGNALS FOR JOBS

INVOLVING A NUMBER OF MACHINES

• For jobs involving several machines, provide signals

commonly known by all personnel involved. Also,
appoint a signal person to co-ordinate the job site.
Make sure that all personnel obey the signal per-
son’s directions.

S0036
E215-E235 S2-11

SAFETY PRECAUTIONS

INVESTIGATE JOB SITE

BEFORE HAND

• When working at the edge of an excavation or on a

road shoulder, the machine could overturn, possibly
resulting in serious injury or death.
- Investigate the configuration and ground condi-
tions of the job site beforehand to prevent the
machine from overturning and prevent the ground,
stockpiles, or banks from collapsing.
- Make a work plan. Use machines appropriate to
the work and job site.
- Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
- When working on an incline or road shoulder, S0034
employ a signal person as required.
Confirm that your machine is equipped with a
F.O.P.S. (Falling Object Protective Structure)
cab before working in areas where there is the
possibility of falling stones or landslides.
- When footing is weak, reinforce the ground before
starting the work.
- When working on frozen ground, be extremely
alert. As ambient temperature rises, footing be-
comes loose and slipped.

PROTECT AGAINST FALLING STONES

AND LANDSLIDES

• Confirm that your machine is equipped with a

F.O.P.S. (Falling Object Protective Structure) cab
before working in areas where there is the possibility
of falling stones.

S0035
S2-12 E215-E235

SAFETY PRECAUTIONS

DIG WITH CAUTION

• Accidental severing of underground cables or gas

lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
- Before digging, check the location of cables, gas
lines, and water lines.
- Keep the minimum distance required by law from
cables, gas lines, and water lines. If a fiber optic
cable should be accidentally severed, do not look
into the end. Doing so may result in serious eye
injury.
- Contact local authorities and/or the utility compa-
nies directly (electric power, gas, telephone, wa-
ter, sewers, telecommunications, etc.) to obtain
information about underground utility lines. S0009

OPERATE WITH CAUTION

• If the front attachment or any other part of the

machine hits against an overhead obstacle, such as
a bridge, both the machine and the overhead
obstacle will be damaged, and personal injury may
results as well.
- Take care to avoid hitting overhead obstacles with
the boom or arm.

S0008

AVOID ELECTRIC LINES

• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines. L
- When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m plus twice the line insulator length (L).
- Check and comply with any local regulations that
may apply.
- Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
- Keep all bystanders or co-workers away from the
site.

S0205
E215-E235 S2-13

SAFETY PRECAUTIONS

KEEP PERSONNEL CLEAR FROM

WORKING AREA

• A person may be hit severely by the swinging front

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

- Keep all persons clear from the area of operation

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

S0044

NEVER MOVE THE BUCKET OVER

ANY ONE

• Never lift, move, or swing bucket above anyone or a

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

S0045

AVOID UNDERCUTTING

• In order to retreat from the edge of an excavation if

the footing should collapse, always position the
undercarriage perpendicular to the edge of the exca-
vation with the travel motors at the rear.

- If the footing starts to collapse and if sufficient

retreat is not possible, do not panic. Often, the
machine can be secured by lowering the front
attachment, in such cases.

S0011
S2-14 E215-E235

SAFETY PRECAUTIONS

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur

causing serious injury or death.

S0048

SAFETY LOADS MOVING

• The excavator is no lifting and transportation means,

therefore it should not be used to position loads
accurately. Should it be exceptionally used to lift and
lay building components, special caution must be
taken as follows:
- The machine must be equipped without failure with
the appropriate variant supplied, upon request, by
FIAT KOBELCO. Also, totally comply with the
safety precautions for the operation of the excava-
tor as a lifting equipment.
- Secure the loads to be raised using cables or
chains fastened with appropriate hooking mecha-
nisms.
- Never hook cables or chains to the bucket teeth.
- Nobody should be allowed to remain under the
raised load or within the excavator operating range
for any reason whatever.
- Never exceed specified loading capacity. Incor-
rect fastening of slings or chains may cause
boom/arm failure or failure of the lifting means with
consequent bodily injuries and even death.
S0165
- Always ensure that slings and chains used for
lifting are adequate to the load and in good condi-
tion.
- All loading capacities are referred to the ma-
chine on a level surface and should be disre-
garded when working on a slope.
E215-E235 S2-15

SAFETY PRECAUTIONS

SAFETY TRANSPORTING

• The danger of tipping is present when loading/

unloading the machine onto/from a truck or trailer
bed.
- Be sure to observe local regulations when
transporting the machine on public roads.
- Provide an appropriate truck or trailer for
transporting the machine.

• Take the following precautions when loading/

unloading the machine:
1. Select firm level ground.
2. Be sure to use a loading dock or ramp.
3. Be sure to have a signal person when loading/ S0052

unloading the machine.

4. Always turn the auto-idle (A/I) switch OFF when
loading or unloading the machine, to avoid
unexpected speed increase due to unintention-
al operation of a control lever.
5. Always select the slow speed mode with the
travel speed selector. In the high speed mode,
travel speed may automatically increase.
6. Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify travelling direction, and begin to
drive again.
7. Do not operate any levers besides the travel
levers when driving up or down the ramp.
8. The top end of the ramp where it meets the
flatbed is a sudden jolt. Take care when
traveling over it.
9. Prevent possible injury from machine tipping
while the upperstructure is rotating.
10. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11. Securely fasten machine frame using chains or
cables. Refer to “TRANSPORT” chapter in the
OPERATION AND MAINTENANCE IN-
STRUCTION MANUAL for details.
S2-16 E215-E235

SAFETY PRECAUTIONS

SAFE MAINTENANCE
• To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Kepp the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it is
in motion.
- Kepp hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Switch off the Auto-Idle (A/I).
4. Let the engine idle with no load for at least five
minutes until it has cooled down.
5. Move the key-start switch to the OFF position
to stop the engine.
S0053
6. Remove the ignition key from the start switch.
7. Apply the "Maintenance in progress" tag .
This tag can be applied o the left-hand control
lever, safety lever or cab door.
8. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
9. Let the engine cool down.

- Do not leave the machine unattended if servicing

requires the engine running .
- If the machine is to be raised, place boom and arm
at an angle 90 to 110°. Lock machine components
which should be raised for maintenance or repair
using suitable supporting means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or S0054
replace as necessary.
Refer to the OPERATION AND MAINTENANCE
INSTRUCTION MANUAL.
- Keep all components in good condition and properly
install. Immediately repair any fault.
- Immediately repair any damage.Replace worn or
failed components. Remove grease, oil, debris
build-ups.
- Disconnect the negative cable (-) from the battery
before carry out any work on the electrical system or
arc-welding on the machine.
E215-E235 S2-17

SAFETY PRECAUTIONS

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious

injury.

- Before performing any work on the machine,

attach a maintenance in progress tag. This tag can
be applied o the left-hand control lever, safety
lever or cab door.

S0055

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without

securing the machine first.

- Always lower the attachment or tool to the ground

before working on the machine.
- If you must work on a lifted machine or attach-
ment, securely support the machine or attach-
ment.
- Do not support the machine on cinder blocks,
bollow tires, or props that may crumble under
continuous load.
- Do not work under a machine that is supported S0054
solely by a jack.

STAY CLEAR OF MOVING PARTS

• Entanglements in moving parts can cause serious

injury.

• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair do
not become entangled when working near rotating
parts.

S0056
S2-18 E215-E235

SAFETY PRECAUTIONS

DISPOSE OF WASTE IN THE

APPROPRIATE MANNER

• Waste improperly disposed of represents a danger

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

- Used sealed containers when discharging fluids.

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

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

water beds.
S0064

- Obtain information about the correct methods to

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

WORK IN A CLEAN AREA

• Before starting an operation, clean the working area.

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

S0166

PROPERLY LIGHT THE WORKING AREA

• Properly and safely light the working area.

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

S0167
E215-E235 S2-19

SAFETY PRECAUTIONS

REGULARLY WASH THE MACHINE

• Remove all the traces of grease, oil and deposits,

in order to avoid people accidents or damages to
things.
- Do not spray water or steam in the cab.

S0153

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic

breakers and blades can fall and cause serious injury
or death.
- Securely store attachments and implements to
prevent falling.
- Keep bystanders away from storage areas.

S0058

PREVENT ACID SCALDS

• The sulphuric acid, contained in the battery, is
poisonous.
It is strong enough to scald the skin, corrode clothes
and cause blindness, if it is sprayed into the eyes.
To avoid dangers:
- Fill the batteries in airy areas.
- Wear eye protections and rubber gloves.
- Avoid breathing the electrolyte vapours when
topping up.
- Avoid spilling or dripping the electrolyte.
- Use proper emergency starting techniques.
If you are touched with acid sprays:
- Rinse your skin well with water.
- Put on your skin sodium bicarbonate or clay to S0168
help the acid neutralization.
- Rinse your eyes with water for 10-15 minutes.
- Immediately see a doctor.
If you have swallowed the acid:
- Drink a big quantity of water or milk, swallow milk
of magnesia, scrabbled ‘eggs or vegetal oil.
- Immediately see a doctor.
S2-20 E215-E235

SAFETY PRECAUTIONS

STARTING THE ENGINE WITH

BOOSTER BATTERIES

• Battery gas may explode causing serious damages

and injuries.
- If the engine is to be started using booster
batteries, ensure to comply with all procedures
detailed in the chapter “OPERATING
INSTRUCTIONS” of the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL.
- The operator should be sitting in the driver’s seat
to keep the machine under control when the engine
starts. Starting the engine with booster batteries
is a two man operation.
S0001
- Do not use batteries that have been stored in the
cold for a long time.
- Mistakes in following procedures detailed for
starting the engine with slave batteries may cause
the batteries to explode or machine to move
unexpectedly.

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

- Keep sparks, lighted matches, and flames away

from the top of battery.

- Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.

- Do not charge a frozen battery; it may explode.

Warm battery to 16 °C.

• Battery electrolyte is poisonous. If the battery S0001

should explode, battery electrolyte may be splashed
into eyes, possibly resulting in blindness.

- Be sure to wear eye protection when checking

electrolyte specific gravity.
E215-E235 S2-21

SAFETY PRECAUTIONS

PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.

- To prevent possible injury from hot spraying

water. Do not remove the radiator cap until the
engine is cool. When opening, turn the cap slowly
to the stop. Allow all pressure to be released
before removing the cap.
S0019

- The hydraulic oil tank is pressurized. Again, be

sure to release all pressure before removing the
cap.

Hot fluids and surfaces:

• Engine oil, reduction gear oil and hydraulic oil also

become hot during operation.
The engine, hoses, lines and other parts become
hot as well.

- Wait for the oil and components to cool down

before starting any maintenance or inspection
work.
S0059

KEEP CLEAN THE MACHINE

Keep clean the engine compartment, radiator,

batteries, hydraulic pipes, fuel tank and operator's
position.
The engine compartment temperature can quickly
rise, after stopping the engine.
IN THESE CASES, BE CAREFUL TO POSSIBLE
FIRES.
Open the access doors in order to quicken the engine
cooling process and clean the compartment.

S0177
S2-22 E215-E235

SAFETY PRECAUTIONS

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under

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

- Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
SA0016

- Tighten all connections before applying pressure.

- Search for leaks with a piece of cardboard; take

care to protect hands and body from high-pressure
fluids. Wear a face shield or goggles for eye
protection.

- In an accident occurs, see a doctor familiar with

SA0017
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.

SA0018

PREVENT PARTS FROM FLYING OFF

• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.

- NEVER attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
- As pieces may fly off, be sure to keep body and
face away from valve.

• Travel reduction gears are under pressure.

S0178
- As pieces may fly off, be sure to keep body and
face away from air release plug to avoid injury.
reduction gear oil is hot. Wait for gear oil to cool
down, then gradually loosen the air release plug to
release pressure.
E215-E235 S2-23

SAFETY PRECAUTIONS

PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body,

serious injury may result.

- Guard against injury from flying pieces of metal or

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

S0046

HANDLE FLUIDS SAFELY - AVOID

FIRES

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

ignites, an explosion and/or a fire may occur, possi-
bly resulting in serious injury or death.

- Do not refuel the machine while smoking or when

near open flame or sparks.
- Always stop the engine before refuelling the ma-
chine.
- Fill the tank outdoors.

S0050

• All fuels, most lubrificants, and some antifreeze

fluids are flammable.

- Store flammable fluids well away from fire haz-

ards.
- Do not burn or puncture pressurized containers.
- Do not store oily rags; they can ignite and burn
spontaneously.

S0051
S2-24 E215-E235

SAFETY PRECAUTIONS

PREVENT FIRES
• Check for Oil Leaks:
- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other,
damage to the oil-cooler, and loose oil-cooler
flange bolts which may cause oil leaks.
- Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil- S0051
cooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.
• Check for Shorts circuits which could cause fires:
- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10) hour
operation for missing or damaged terminal caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc.
• Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
• Check Key-start Switch:
- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF position to
confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.
• Check Heat Shields:
- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the machine.
E215-E235 S2-25

SAFETY PRECAUTIONS

EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the

following way:

- Stop the engine by turning the key-start switch to

the OFF position if there is time.

- Use a fire extinguisher if there is time.

- Exit the machine.

S0060

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.

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

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

S0061

USE APPROPRIATE TOOLS

• Use tools appropriate for the job to be performed.

- Inappropriate tools, parts and procedures might

generate dangerous conditions.

- Use tools of correct size to tighten or loosening

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

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

on metric fasteners and vice versa.

• Use only FIAT KOBELCO genuine spare parts

(please refer to the PARTS CATALOG). S0120
S2-26 E215-E235

SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

Flammable spray can be generated by heating near

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

Pressurized lines can be accidentally cut when heat

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

AVOID APPLYING HEAT TO LINES

S0062
CONTAINING FLAMMABLE FLUIDS

- Do not weld or flame cut pipes or tubes that contain

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

REMOVE PAINT BEFORE WELDING

OR HEATING

• Hazardous fumes can be generated when paints is

heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
- Avoid breathing potentially toxic fumes and dust.
- Do all such work outside or in a well-ventilated
area.
- Dispose of paint and solvents properly.
- Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the
dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove S0063
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
E215-E235 S3-1

SAFETY PLATES

Triple articulation version

Triple articulation version

R0697

1 - Attachment operating range safety plate

2 - Track adjuster plate
S3-2 E215-E235

SAFETY PLATES

10
4 5 6

13

11
8
12

R0698

3 - Counterweight operating range safety plate 8 - Engine hood warning plate

4 - Read-your-manual plate
5 - Boom and arm movement warning plate
(Triple articulation version)
6 - Open windscreen warning plate (inside the cab)
7 - Tag indicating maintenance in progress
9 - Controls lock/unlock plate (safety lever)
10 - Biodegradable hydraulic oil level check plate (opt.)
11 - Burns warning plate
12 - Safety distance plate
13 - No-stepping warning plate
E215-E235 S3-3

SAFETY PLATES

1 - Attachment operating range safety plate

Ensure that any person near the working site is

outside the machine operating range before
starting the machine or operating the attachments.
Sound the horn.
Yellow background
Black border and icons

S0074

2 - Track adjuster plate

It shows that obligation is made to consult the

Operation and Maintenance Instruction Manual
prior to acting on the track adjust valve.
Danger of severe injuries.
Yellow background
Black border and icons

S0076

3 - Counterweight operating range safety plate

Ensure that any person near the working site is

outside the machine operating range before
starting the machine or operating the attachments.
Sound the horn.
Yellow background
Black border and icons

S0075
S3-4 E215-E235

SAFETY PLATES

4 - Read-your-manual plate

It is positioned in the cab to recommend to care-

fully read the Operation and Maintenance Instruc-
tion Manual prior to starting, operating, servicing,
refuelling or carrying out any other work on the
machine.
Yellow background
Black border and icons

S0077

5 - Boom and arm movement warning plate

(triple articulation version)

It shows the danger represented by the bucket

hitting the cab.
Pay special attention as no stops are provided to
prevent this problem.
Yellow background
Black border and icons

S0139

6 - Open windscreen warning plate

(inside the cab)

It indicates the risk of injuries deriving from the

windscreen not being locked or being improperly
locked in the open position.
Yellow background
Black border and icons

S0079
E215-E235 S3-5

SAFETY PLATES

7 - Tag indicating maintenance in progress

Maintenance staff is obliged to apply the tag that

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

S0080

8 - Engine hood warning plate

It highlights the obligation to stop the engine be-

fore opening engine hood.
Danger of severe injuries following the presence
of rotating parts such as fan, pulleys, and belts.
Yellow background
Black border and icons

S0081

9 - Controls lock/unlock plate (safety lever)

It shows the position that the safety lever can

assume when the engine is running.
When the operator is about to leave the cab with
the engine running, even if for a short time, he
must move the safety lever to the LOCK posi-
LOCK
tion. Controls are disabled and therefore no acci-
dental machine or attachment movement is pos-
sible. S0083
White background
Black border and icons
S3-6 E215-E235

SAFETY PLATES

10 - Biodegradable hydraulic oil level check plate

(optional)

It shows that the machine is filled with

biodegradable hydraulic oil and that it is
necessary to consult this manual for correct
practices (oil level check, sampling, and change).
Yellow background
Black border and icons

S0088

11 - Burns danger plate

It indicates that a burns danger exists, since the

zone is characterised by high temperature.
Background: yellow
Lettering and edges: black

S0095

12 - Safety distance plate

It instructs to keep at a safe distance from a zone

dangerous for personal safety.
Background: yellow
Lettering and edges: black

S0096

13 - No-stepping warning plate

It instructs not to step on the zone where this decal

is attached.
Background: yellow
Cross: red
Lettering and edges: black

S0097
OPERATIONAL PRINCIPLE

R0077
OPERATIONAL PRINCIPLE E215-E235

SECTION AND GROUP CONTENTS

Section 1 GENERAL
Group 1 Specifications
Group 2 Component Layout

Section 2 SYSTEM
Group 1 Mechatro Control System
Group 2 Mechatro Controller
Group 3 Hydraulic System
Group 4 Electrical System

Section 3 COMPONENT OPERATION

Group 1 Hydraulic Pump Assy
Group 2 Pilot Valve
Group 3 Control Valve
Group 4 Swing Device
Group 5 Travel Device
Group 6 Swing Joint
Group 7 Cylinders
Group 8 Air Conditioner
SECTION 1 E215-E235

GENERAL

CONTENTS

Group 1 - Specifications Group 2 - Component Layout

Excavator Dimensions Main Components ................................... T1-2-1

(E215 Monobloc Version) ........................ T1-1-1
Digging Performances
(E215 Monobloc Version) ........................ T1-1-2
Excavator Dimensions
(E215 Triple Articulation Version) ............. T1-1-3
Digging Performances
(E215 Triple Articulation Version) ............. T1-1-4
Excavator Dimensions
(E235 Monobloc Version) ........................ T1-1-5
Digging Performances
(E235 Monobloc Version) ........................ T1-1-6
Excavator Dimensions
(E235 Triple Articulation Version) ............. T1-1-7
Digging Performances
(E235 Triple Articulation Version) ............. T1-1-8
Excavator Performance ........................... T1-1-9
Engine Data ............................................ T1-1-9
Hydraulic Components .......................... T1-1-10
Electrical System
(Overall System) ..................................... T1-2-2
Electrical System (Control Cab,
Instrument and Switches) ....................... T1-2-3
Electrical System
(Cluster Gauge and Indicator Lights) ....... T1-2-4
Electrical System (Fuse Box,
Mechatro Controller and Relays) ............. T1-2-5
Electrical System
(Fuse Box) .............................................. T1-2-6
Electrical System
(Batteries, Fuse Link, Relays) ................. T1-2-7
Electrical System
(Engine Electrical Components) .............. T1-2-8
Electrical System (Hydraulic
System Electrical Components) .............. T1-2-9
Electrical System
(Lights, Horn) ........................................ T1-2-10
E215 T1-1-1

SPECIFICATIONS

EXCAVATOR DIMENSIONS (E215 Monobloc version)

M0154

VERSIONS A B C D E F G H I L
(1) 9 550 (1) 3 010
(2) 9 490 (2) 2 970
E215 3 373 4 197 1 062 2 750 2 490 2 970 952 468
(3) 9 430 (3) 2 820
(4) 9 900 (4) 3 010
(1) 9 550 (1) 3 020
(2) 9 490 (2) 2 980
E215E 3 373 4 197 1 076 2 750 2 490 2 984 952 482
(3) 9 430 (3) 2 820
(4) 9 490 (4) 3 010
(1) 9 550 (1) 3 010
(2) 9 490 (2) 2 970
E215LC 3 656 4 480 1 067 2 750 2 490 2 975 952 473
(3) 9 430 (3) 2 820
(4) 9 490 (4) 3 010

Arm: (Dimensions in mm)

(1) 2 080 mm
(2) 2 400 mm
(3) 2 940 mm
(4) 3 500 mm

E215 E215E E215LC

M-Track shoe width 600 700 800 900 500 600 700 600 700 800 900

N-Maximum width 2 800 2 900 3 000 3 100 2 490 2 590 2 690 2 990 3 090 3 190 3 290

Working weight (kg) 21 500 21 750 22 000 22 250 20 800 21 050 21 300 21 950 22 220 22 490 22 760
Specific ground
0.54 0.47 0.42 0.37 0.63 0.53 0.46 0.51 0.44 0.39 0.35
pressure (bar)

(Dimensions in mm)
T1-1-2 E215

SPECIFICATIONS

DIGGING PERFORMANCES (E215 Monobloc version)

M0123

(Dimensions in mm)

Arm 2 080 2 400 2 940 3 500

A 9 133 9 445 9 926 10 320
A’ 8 952 9 270 9 765 10 165
B 5 821 6 141 6 681 7 241
B’ 5 592 5 938 6 505 7 062
C 9 235 9 450 9 670 9 579
D 6 488 6 661 6 908 6 935
E 3 630 3 555 3 625 3 553
F 4 117 3 830 3 432 2 857
G 5 074 5 283 5 812 6 608
E215 T1-1-3

SPECIFICATIONS

EXCAVATOR DIMENSIONS (E215 Triple articulation version)

M0155

VERSIONS A B C D E F G H I L
(1) 9 580 (1) 3 100
(2) 9 520 (2) 3 100
E215 3 373 4 197 1 062 2 750 2 490 2 970 952 468
(3) 9 500 (3) 3 040
(4) 9 480 (4) 3 270
(1) 9 580 (1) 3 100
(2) 9 520 (2) 3 100
E215E 3 373 4 197 1 076 2 720 2 490 2 984 952 482
(3) 9 500 (3) 3 030
(4) 9 490 (4) 3 270
(1) 9 580 (1) 3 100
(2) 9 520 (2) 3 100
E215LC 3 656 4 480 1 067 2 750 2 490 2 975 952 473
(3) 9 500 (3) 3 040
(4) 9 480 (4) 3 270

Arm: (Dimensions in mm)

(1) 2 080 mm
(2) 2 400 mm
(3) 2 940 mm
(4) 3 500 mm

E215 E215E E215LC

M-Track shoe width 600 700 800 900 500 600 700 600 700 800 900

N-Maximum width 2 800 2 900 3 000 3 100 2 490 2 590 2 690 2 990 3 090 3 190 3 290

Working weight (kg) 22 100 22 350 22 600 22 850 21 750 22 000 22 250 22 500 22 770 23 040 23 310
Specific ground
0.56 0.48 0.43 0.38 0.66 0.55 0.48 0.52 0.45 0.40 0.36
pressure (bar)

(Dimensions in mm)
T1-1-4 E215

SPECIFICATIONS

DIGGING PERFORMANCES (E215 Triple articulation version)

M0124

(Dimensions in mm)

Arm 2 080 2 400 2 940 3 500

A 9 210 9 530 10 030 10 444
A’ 9 033 9 357 9 866 10 291
B 5 454 5 777 6 304 6 801
B’ 5 335 5 664 6 199 6 703
C 10 539 10 821 11 235 11 455
D 7 612 7 902 8 311 8 529
E 2 649 2 566 2 361 2 552
F 4 854 4 479 3 903 3 370
G 2 219 2 315 2 701 3 489
E235 T1-1-5

SPECIFICATIONS

EXCAVATOR DIMENSIONS (E235 Monobloc version)

M0154

VERSIONS A B C D E F G H I L
(1) 9 550 (1) 3 060
(2) 9 490 (2) 3 010
E235 3 420 4 281 1 168 2 750 2 490 3 076 1 154 507
(3) 9 400 (3) 2 840
(4) 9 480 (4) 3 120

Arm: (Dimensions in mm)

(1) 2 080 mm
(2) 2 400 mm
(3) 2 940 mm
(4) 3 500 mm

E235
M-Track shoe width 550 (*) 700 800 (*)
N-Maximum width 2 500 2 700 2 700
Working weight (kg) 23 100 23 620 24 140
Specific ground
0.63 0.50 0.45
pressure (bar)

(*) Asymmetric type shoes

T1-1-6 E235

SPECIFICATIONS

DIGGING PERFORMANCES (E235 Monobloc version)

M0123

(Dimensions in mm)

Arm 2 080 2 400 2 940 3 500

A 9 133 9 445 9 926 10 320
A’ 8 952 9 270 9 765 10 165
B 5 715 6 035 6 575 7 135
B’ 5 486 5 832 6 399 6 956
C 9 341 9 556 9 776 9 685
D 6 594 6 767 7 014 7 041
E 3 630 3 555 3 625 3 553
F 4 223 3 936 3 538 2 963
G 5 074 5 283 5 812 6 608
E235 T1-1-7

SPECIFICATIONS

EXCAVATOR DIMENSIONS (E235 Triple articulation version)

M0155

VERSIONS A B C D E F G H I L
(1) 9 580 (1) 3 150
(2) 9 520 (2) 3 140
E235 3 420 4 281 1 168 2 750 2 490 3 076 1 154 507
(3) 9 490 (3) 3 060
(4) 9 510 (4) 3 290

Arm: (Dimensions in mm)

(1) 2 080 mm
(2) 2 400 mm
(3) 2 940 mm
(4) 3 500 mm

E235
M-Track shoe width 550 (*) 700 800 (*)
N-Maximum width 2 500 2 700 2 700
Working weight (kg) 23 650 24 170 24 420
Specific ground
pressure (bar) 0.64 0.51 0.46

(*) Asymmetric type shoes

T1-1-8 E235

SPECIFICATIONS

DIGGING PERFORMANCES (E235 Triple articulation version)

M0124

(Dimensions in mm)

Arm 2 080 2 400 2 940 3 500

A 9 210 9 530 10 030 10 444
A’ 9 033 9 357 9 866 10 291
B 5 348 5 671 6 198 6 695
B’ 5 229 5 558 6 093 6 597
C 10 645 10 927 11 341 11 561
D 7 718 8 008 8 417 8 635
E 2 649 2 566 2 361 2 552
F 4 960 4 585 4 009 3 476
G 2 219 2 315 2 701 3 489
E215-E235 T1-1-9

SPECIFICATIONS

EXCAVATOR PERFORMANCE

GRADEABILITY ......................................................................................................................................... 70%

TRAVEL SPEED

Excavator
E215 E235
Speed
First speed 3.5 km/h 3.1 km/h
Second speed 6.0 km/h 5.0 km/h

ENGINE DATA

MAIN SPECIFICATIONS
- Manufacturer ....................................................................................................................................... IVECO
- Model ................................................................................................................................ F4BE0684B*D402
- Type ....................................................................................... Diesel, 4 stroke, direct injection, turbocharged
- Number of cylinder ............................................................................................................................. 6 in-line
- Bore ................................................................................................................................................... 102 mm
- Stroke ................................................................................................................................................ 120 mm
- Total displacement ..........................................................................................................................5 883 cm3
- Compression ratio ................................................................................................................................... 17:1
- Net power at flywheel (at 2150 rpm) ................................................................................................... 112 kW
- Torque (at 1400 rpm) .......................................................................................................................... 660 Nm
- Engine idle at no-load ....................................................................................................................... 700 min-1

INJECTION PUMP
- Type ................................................................................................................................................... PES 6A
- Injection order ............................................................................................................................... 1-5-3-6-2-4
- Injection pressure ............................................................................................................................ 24.5 MPa

BATTERY
- Voltage - Capacity ............................................................................................................... 2 x 12 V - 100 Ah

STARTER MOTOR
- Manufacturer ...................................................................................................................................... BOSCH
- Voltage - Output ............................................................................................................................ 24V - 4 kW

ALTERNATOR
- Manufacturer ...................................................................................................................................... BOSCH
- Type .................................................................................................................................. NCB1 28V 35-70A
- Voltage - Output ..............................................................................................................................28V - 70A
T1-1-10 E215-E235

SPECIFICATIONS

HYDRAULIC COMPONENTS

HYDRAULIC PUMP

Item Main pump Gear pump for pilot

Pump model K3V112DTP1TLR-9TFL ZX10LPRZ7-07D

Variable displacement
Fixed displacement
Type plunger pump: regulator
type gear pump
attached type

Max. displacement capacity cm3 97.7 × 2 10

Rated min-1 2150 ←

Revolution (Clockwise seen
Hi idle from shaft end) 2400 or less ←
Rated 34.3
Pressure MPa 4.9
ATT boost 37.8
Max. flow L/min 210 × 2, at 7.8 MPa 21.5

Max. input Horse Power kW 110 3.4

Max. input torque N·m 488 14.7

Model KR3G-9TFL

Control function Electric flow control, positive flow control, total

power control at back-up and power shift control
Regulator
at back-up.

Others With solenoid proportional reducing valve

(KDRDE5K-31/30C50-102)

Weight kg 131

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

SWING DEVICE
Item STD VALVE
Model KMX15YC / B33041
Max. flow L/min 210x2
Main relief valve set pressure MPa 34.3 at 160 L/min
When power boost pressure 37.8 at 140 L/min
Over load relief valve set pressure MPa
Boom H, Bucket H, Arm R 39.7 at 30 L/min
Boom R, Bucket R, Arm H 37.8 at 30 L/min
OPT2 H&R 37.8 at 30 L/min
E215-E235 T1-1-11

SPECIFICATIONS

PILOT VALVE
TOOL TRAVEL

Model PV48K1126A 07291-00000

Primary pressure 5.0 MPa 4.9 MPa

Secondary pressure 0.6 ~ 3.2 MPa 0.54 ~ 2.35 MPa

Rated flow 20 L/min 10 L/min

Weight Approx. 2 kg Approx. 11 kg

SWING MOTOR

Model M5X130CHB–10A–17B/285–122

Type Swash-plate type, fixed-displacement plunger motor

Displacement cm3 121.6

Hydraulic motor

Working pressure MPa 34.3

Max. flow L/min 179

Braking torque Nm 818

Release pressure MPa 2.3~5.0

Relief set pressure MPa 28

Weight kg 49

Anti- Type 2KAR6P72/240-712

reaction
valve block Weight kg 2.5

Hydraulic motor assy weight kg 51.5

Model M2X120B

Speed reduction type Planetary 2-stage

Reduction ratio 15.38

Reduction unit

Lubicate oil Gear oil SAE90 (API class GL–4 grade)

Lubicate oil volume L 7.5

Grease Extreme pressure multipurpose grease

Grease volume A small amount

Weight kg 158.5

Total weight kg 210

T1-1-12 E215-E235

SPECIFICATIONS

TRAVEL DEVICE

Item E215 E235

Reduction gear unit Epicycloidal, three-stage planetary type

Model 710 C3 K

Gearbox ratio 1 : 49,5

Travel motor Two speed, axial piston swash plate type

Model MAG 170 VP 2 MAG 170 VP 3

high speed 86.5 cm3/rev 97.1 cm3/rev

Displacement
low speed 129.3 cm3/rev 147.8 cm3/rev

Max. flow 210 L/min 241.5 L/min

Max. output torque (theoretical) 705.8 Nm at 343 bar 807.1 Nm at 343 bar

low speed 34 930 Nm 39 941 Nm

Max. gearbox output torque
high speed 23 369 Nm 26 233 Nm

static 470 Nm
Parking brake torque
dynamic 370 Nm

Min. pressure parking brake release 14 bar

cracking 310 bar at 1.2 L/min

Relief valve set pressure
total flow 353 bar at 40 L/min

CYLINDERS

Center distance
Cylinder bore / of pins
Use Stroke Cushion Dry weight
Rod Dia. Full extend B /
Full retract A
mm mm mm kg

With cushion
Boom Ø 125 / Ø 85 1 240 3 000 / 1 760 177
on rod side

With cushion
Arm Ø 135 / Ø 95 1 490 3 520 / 2 030 251
on both sides

With cushion
Bucket Ø 120 / Ø 80 1 080 2 684 / 1 604 149
on rod side

Positioning Ø 150 / Ø 100 1 090 2 760 / 1 670 – 251

E215-E235 T1-2-1

COMPONENT LAYOUT

MAIN COMPONENTS

5
6

10
11

3
12

2 13
8
14
9
15

1
16

29

28
17
27

26
18
25
19
24

23
22 20

21
R0696

1 - Bucket 11 - Swing motor 21 - Track link

2 - Bucket link 12 - Fuel tank 22 - Batteries
3 - Idler link 13 - Hydraulic oil tank 23 - Upper roller
4 - Bucket cylinder 14 - Control valve 24 - Track guide
5 - Arm 15 - Engine muffler 25 - Lower roller
6 - Arm cylinder 16 - Hydraulic pump 26 - Air cleaner
7 - Boom 17 - Engine 27 - Crawler adjuster
8 - Boom cylinder 18 - Counterweight 28 - Front idler
9 - Cab 19 - Engine radiator 29 - Shoe plate
10 - Swivel joint 20 - Travel motor
T1-2-2 E215-E235

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Overall system)

.75-

D R0443

A - Control cab D - Engine electrical components

B - Fuse Box, Mechatro controller and relays E - Hydraulic system electrical components
C - Batteries, Battery relay, Fuse link and solenoid valve
assembly
E215-E235 T1-2-3

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Control cab, Instrument and switches)

12
1

14 3
4
11 15
5
6
7
8
13 9

10

R0444

1 - Cluster gauge (C-2) 9 - Tuner (E-7)

2 - Power boost pushbutton 10 - Socket 12 V D.C. (E-23)
3 - Hand control accelerator (SE-16) 11 - Air conditioning switch (SW-13)
4 - Working light switch (SW-20) 12 - Swing parking release switch (SW-4)
5 - Cab working light switch (SW-26) 13 - Hydraulic Pressure remove switch (SW-50)
6 - Load alarm select switch (SW-12) 14 - Key switch (SW-1)
7 - Quick coupler operation switch (SW-40) 15 - Cigarette lighter (E-14)
8 - Heavy lift switch (SW-35)
T1-2-4 E215-E235

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Cluster gauge and indicator lights)

1
3

13
5
12
6
11

10 9 8 7
R0445

1 - Engine coolant temperature indicator 8 - Conflux select switch

2 - Working Mode Indicators 9 - Buzzer stop switch
3 - Fuel meter 10 - Auto Idle switch
4 - Display 11 - Travel speed select
5 - Washer switch 12 - Led
6 - Wiper switch 13 - Display select switch
7 - MODE switch
E215-E235 T1-2-5

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Fuse box, Mechatro controller and relays)

6
1

7 8 9 10 11 12

2
5 4 3
R0446

1 - Mechatro controller (C-1) 7 - Safety relay (R-4)

2 - Fuse box (E-4) 8 - Horn relay (R-5)
3 - "MODE CANCEL" switch (SW-2) 9 - Engine stop relay (R-28)
4 - Swing parking release switch (SW-4) 10 - Preheating control relay (R-29)
5 - Wiper relay assy (R-7) 11 - Rotary Bucket (Extra) Left relay (R-27)
6 - Socket 12 V D.C.(E-23) 12 - Rotary Bucket (Extra) Right relay (R-26)
T1-2-6 E215-E235

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Fuse Box)

FUSES IN THE BOX

PROTECTED Value
Fuse Label
CIRCUIT (A)

MECHATRO Mechatro
1 20
CONTROLLER controller

2 RELAY Relay 10

3 LIGHTER Lighter 10

Converter
4 CONVERTER 10
(Tuner-Soket 12 V)

5 HORN Horn 10

FUEL SUPPLY Fuel Supply

6 20
PUMP Pump

CONTROLLER Mechatro
7 10
BACK UP Controller Back up

8 / / /

9 ROOM LIGHT Room Light 10

10 KEY SWITCH Key Switch 20

11 AUTO GREASE Auto Grease 10

12 HEATING SEAT Heating Seat 20

CLUSTER Cluster Gauge

13 10
GAUGE

WIPER
14 Wiper Washer 20
WASHER

15 SOLENOID Solenoid Valve 10

WORKING
16 Working Light 20
LIGHT

OPTIONAL
Optional Working
17 WORKING 20
Light Room
LIGHT

AIR
Air Conditioner
18 CONDITIONER 20
Heater
HEATER

AIR
19 Air Conditioner 10
CONDITIONER

20 RESERVE X 20
R0447
E215-E235 T1-2-7

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Batteries, Fuse link, Relays)

5 1
60 A

4 3 2 R0448

Fuses in the Air filter/Batteries compartment

Label Fuse No. Protected circuit Value (A)

FUSE 1 Alternator 80
Box A
FUSE 2 Fuel Heater 40
FUSE 3 Fuses (11-20) power 60
FUSE 4 Starter relay 40
Box B
FUSE 5 Engine stop solenoid 40
FUSE 6 Mechatro Controller 30
FUSE 7 Fuses (6, 7, 9,10) power 60

1 - Battery relay (R-1) 5 - Starter relay (R-2)

2 - Fuse link 7 60 A (E-27) 6 - Fuel filter Heater (R-23)
3 - Box B Fuse Link 3, 4, 5 and 6 (E-25) 7 - Batteries (E-1)
4 - Box A Fuse Link 1 and 2
T1-2-8 E215-E235

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Engine electrical components)

15
3

14

16
13

5
12

11 10 9 8

7 6

R0449

1 - Air filter restriction switch (SW-8) 10 - Engine oil pressure switch (SW-7)
2 - Engine coolant level switch (SW-24) 11 - Air compressor clutch (E-11)
3 - Stepping Motor (M-2) 12 - Glow Plug (E-12)
4 - Starter motor assy (M-1) 13 - Fuel filter heater (E-20)
5 - Thermo-switch for heater (SW-57) 14 - Engine stop solenoid (SV-13)
6 - Coolant thermo sensor (SE-14) 15 - Fuel sensor (SE-15)
7 - Engine coolant temperature switch (SW-6) 16 - Engine oil level switch (SW-23)
8 - Alternator assembly (E-2)
9 - Engine revolution sensor (SE-13)
E215-E235 T1-2-9

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Hydraulic System electrical components)

27
26 2

28

25
24
23
A
22
21
3
20

19

18
17

16

15 14
4

12 11 10 9 8 7 6 5

13
Vistafrom
View da AA

R0450

1 - Travel un-load proportional solenoid valve (PSV-F) 15 - Rotary Bucket (Extra) solenoid valve (B) (SV-15) (opt)
2 - Pomp P2 proportional solenoid valve (PSV-P2) 16 - P1 Opt. sensor valve (SE-20)
3 - Pump P1 proportional solenoid valve (PSV-P1) 17 - Travel right sensor (SE-9)
4 - Swing sensor (SE-5) 18 - Travel left sensor (SE-10)
5 - Operating lever lock solenoid valve (SV-4) 19 - P2 Opt. sensor valve (SE-11)
6 - Power boost solenoid valve (SV-2) 20 - Bucket digging sensor (SE-1)
7 - P2 By-pass cut proportional solenoid valve (PSV-B) 21 - Bucket dump sensor (SE-2)
8 - Travel priority proportional solenoid valve (PSV-C) 22 - Boom raising sensor (SE-3)
9 - P1 By-pass cut proportional solenoid valve (PSV-D) 23 - Boom lowering sensor (SE-4)
10 - Arm variable re-circulation proportional solenoid valve 24 - Arm in sensor (SE-7)
(PSV-A) 25 - Arm out sensor (SE-8)
11 - Two speed select solenoid valve (SV-3) 26 - Pump P1 sensor (SE-22)
12 - Swing parking brake solenoid valve (SV-1) 27 - Pump P2 sensor (SE-23)
13 - Hydraulic level switch (SW-25) 28 - Attachment un-load proportional solenoid valve (PSV-E)
14 - Rotary Bucket (Extra) solenoid valve (A) (SV-16) (opt)
T1-2-10 E215-E235

COMPONENT LAYOUT

ELECTRICAL SYSTEM (Lights, Horn)

3 R0451

1 - Frame Working light (L-2) 3 - Engine room light (L-12)

2 - Boom Working lght (L-1) 4 - Horn
SECTION 2 E215-E235

SYSTEM

CONTENTS

Group 1 - Mechatro Control System Group 3 - Hydraulic Circuit

Outline .................................................. T2-1-1 Summary .............................................. T2-3-1

Boom up Conflux .................................. T2-1-4 Neutral Circuit ....................................... T2-3-3
Arm in Recirculation & Sequence Travel Circuit ......................................... T2-3-6
Conflux ................................................. T2-1-6 Bucket Circuit ....................................... T2-3-8
Arm in Anti-cavitation Control ............... T2-1-8 Boom Circuit ......................................... T2-3-10
Arm out Conflux .................................... T2-1-9 Swing Circuit ........................................ T2-3-14
Travel Straight ....................................... T2-1-10 Arm Circuit ........................................... T2-3-16
Swing Priority Control ........................... T2-1-12 Combined Operation ............................ T2-3-22
Pressure Draining (releasing) Pressure Drain (release) Circuit ........... T2-3-26
Control .................................................. T2-1-14
Crusher & Breaker Circuit ..................... T2-3-28
Pump Control (Positive Control
Foreword .............................................. T2-3-29
& P-Q Control) ...................................... T2-1-16
Hydraulic Diagram for Crusher
Standby Flow Constant Control ............ T2-1-18
& Breaker ............................................. T2-3-30
Positioning Circuit ................................. T2-3-34

Group 2 - Mechatro Controller Group 4 - Electrical System

Summary of Mechatro Controller .......... T2-2-1 Outline .................................................. T2-4-1
Self Diagnosis Display Function ........... T2-2-6 Electric Power Circuit
Service Diagnosis ................................. T2-2-7 (Key switch in OFF position) ................. T2-4-2
Trouble History Diagnosis ..................... T2-2-9 Accessory Circuit
(Key switch in ACC position) ................. T2-4-4
How to Correct the Cumulative Time .... T2-2-11
Electric Power Circuit
Contrast of Display Adjusting
(Key switch in ON position) ................... T2-4-6
Procedure ............................................. T2-2-12
Starting Circuit
Mechatro Control Equipment ................ T2-2-13
(Key switch in START position) ............. T2-4-8
Charging Circuit
(Key switch in ON position) ................... T2-4-10
Preheating Circuit ................................. T2-4-12
Engine Stop Circuit ............................... T2-4-14
Emergency Operating Circuit ................ T2-4-16
E215-E235 T2-1-1

MECHATRO CONTROL SYSTEM

OUTLINE

System summary Features Purposes

P1, P2 pump is control- P1 pump is controlled by proportional A) The power curve shall be an ideal
led by proportional 1 valve (PSV-P1). curve.
valve.
P2 pump is controlled by proportional B) Supply an optimum flow for each
2 valve (PSV-P2). operation.
The travel straight valve is controlled • Make the changeover soft.
3 by proportional valve (PSV-C).
The bypass cut valve P1 and P2 are • Make the changeover soft.
4 controlled by proportional valve
Part of the (PSV-D) and (PSV-B) respectively.
control valve
is controlled by the The arm variable recirculation valve • Control the arm speed as you de-
proportional valve. 5 is controlled by proportional valve sire.
(PSV-A).
ATT boost is controlled by solenoid
The main spool 6
valve (SV-2).
is controlled
hydraulically. The open and close actions of the
7 swing P/B are controlled by solenoid
valve (SV-1).
Unlead valve is controlled by propor- A) Travel speed keeping at travel
8 tional valves (PSV-E) and (PSV-F). straight.
B) Pressure releasing of main circuit.
T2-1-2 E215-E235

MECHATRO CONTROL SYSTEM

Line coding for control system circuit (see page T2-1-3).

ELECTRIC: CONTROLLER
INPUT SIGNAL

678
HYDRAULIC: PILOT SECONDARY
PRESSURE

SOLENOID PROPORTIONAL
VALVE SECONDARY PRESSURE

PILOT PRIMARY PRESSURE

MAIN CIRCUIT

: GOVERNOR MOTOR
: ENGINE SPEED SENSOR
: HIGH PRESSURE SENSOR (P1, P2: 2 pcs)
: LOW PRESSURE SENSOR (ATT: 7 pcs,
: Travel: 2 pcs)
: ACCEL DIAL POTENTIOMETER
 BOOM CYLINDER
BOOM UP CONFLUX

PL 1
BOOM DOWN
REVERSE

Pis
PB 1
5

PCb
7 REVERSE 2 3
E215-E235

ARM CYLINDER
ARM OUT CONFLUX
LH RH LH RH ARM IN CONFLUX

VALVE
CONFLUX
BOOM
CUT VALVE
P1 BYPASS

VALVE
RECIRCULATION
ARM VARIABLE
PILOT VALVE PLOT

ARM
BUCKET
BOOM
FOR ATT

SWING
VALVE FOR

OPT. VALVE
BUCKET CYLINDER

VALVE
TRAVEL STRAIGHT

TRAVEL LEFT
TRAVEL

TRAVEL RIGHT
VALVE
CONFLUX
ARM

CUT VALVE
P2 BYPASS
P1
P2
SE - 9

8 6 FOR- FOR- 1 4
SE - 10

PTb

PCa
WARD WARD

PA 1
GAUGE
CLUSTER LOW PRESSURE SENSOR
DISPLAY SE - 4 4
A / W / HM
SELECT
SE - 3 SWING MOTOR PARKING BRAKE RELEASE
LOWER SW. 3

SE - 2
2
UNLOAD
SENSOR SE - 1 VALVE TRAVEL MOTOR 1,2-SPEED SELECT
BLOCK 1

SE - 8
8

SE - 7 PSV-E PSV-F
7
ATT. TRAVEL.
UNLOAD UNLOAD
PROPORTIONAL
6 UNLOAD
VALVE BLOCK
ACCEL DIAL

OUTPUT VOLTAGE
SE - 5
SE - 16 5

SERIAL COMMUNICATION
HIGH PRESSURE SENSOR
SE - 22
A3
MECHATRO CONTROL SYSTEM

C-1 SE - 23

SERIAL COMMUNICATION
MECHATRO CONTROLLER A1 A2
ENGINE

PROPORTIONAL
VOLTAGE
GOVERNOR SPEED
MOTOR SENSOR
M-2 SE - 13

PROPORTIONAL VALVE/
SOLENOID VALVE BLOCK

PSV - P1
P1 PUMP
PROPORTIONAL VALVE
ATT BOOST

PSV - P2
P1 BYPASS CUT
P2 BYPASS CUT

TRAVEL STRAIGHT

P2 PUMP
TRAVEL 1,2 SPEED
SAFETY LOCK LEVER

PROPORTIONAL VALVE
SWING PARKING BRAKE
ARM VARIABLE RECIRCULATION

SV-1 SV-3 PSV-A PSV-D PSV-C PSV-B SV-2 SV-4

LEVER LOCK
SW-11
VOLTAGE 24V

R0370
T2-1-3

PROPORTIONAL COMMAND CURRENT

T2-1-4 E215-E235

MECHATRO CONTROL SYSTEM

BOOM UP CONFLUX

PILOT VALVE

RECIRCULATION
ARM VARIABLE

P1 BYPASS
CUT VALVE
VALVE

TRAVEL RIGHT
TRAVEL LEFT

TRAVEL STRAIGHT

BUCKET
SWING

BOOM
ARM

VALVE
P2 BYPASS
CUT VALVE

CONFLUX
CONFLUX

VALVE
VALVE
BOOM

ARM
P2 P1

PB1

LOW PRESSURE SENSOR

SE - 3

A2 A1

Pi
P2 BYPASS CUT
PILOT SIGNAL PROCESS PROPORTIONAL Pi
VALVE
PSV - B

BOOM UP SECONDARY PRESSURE

BOOM UP

Pi
P2 PUMP
PILOT SIGNAL PROCESS PROPORTIONAL Pi
VALVE
PSV - P2

BOOM UP SECONDARY PRESSURE

Pi
P1 PUMP
PILOT SIGNAL PROCESS PROPORTIONAL Pi
VALVE
PSV - P1

BOOM UP SECONDARY PRESSURE

MECHATRO CONTROLLER

Pi ; PROPORTIONAL VALVE
SECONDARY PRESSURE R0371
E215-E235 T2-1-5

MECHATRO CONTROL SYSTEM

BOOM UP CONFLUX

1. Start boom up operation, and the boom up opera-

tion pilot pressure switches boom spool and boom
conflux spool, and inputs into low pressure sensor.

2. The voltage output by low pressure sensor is input

into mechatro controller, and the controller proc-
esses the pilot signal and outputs the command
corresponding to input voltage to P1, P2 pump and
P2 bypass cut valve.

3. Each proportional valve puts out the secondary

pressure for the pilot proportional valve according
to command values from the mechatro controller,
changes the delivery rates of the P1, P2 pump and
switches the P2 bypass cut valve.

4. A pure hydraulic command switches the boom

main spool and the boom conflux valve. A
mechatro command switches the P1, P2 pumps
and the P2 bypass cut valve. This causes the oil
delivered by the P1 pump to combine with that by
the P2 pump at boom up operation.
T2-1-6 E215-E235

MECHATRO CONTROL SYSTEM

ARM IN RECIRCULATION & SEQUENCE CONFLUX

PILOT
VALVE

RECIRCULATION
ARM VARIABLE

P1 BYPASS
CUT VALVE
VALVE

TRAVEL RIGHT
TRAVEL LEFT

TRAVEL STRAIGHT

BUCKET
SWING

BOOM
ARM

VALVE
P2 BYPASS
CUT VALVE

CONFLUX
CONFLUX

VALVE
ARM
VALVE
BOOM
P2 P1

LOW PRESSURE SENSOR SE - 23

SE - 2
SE - 7 HIGH PRESSURE SENSOR
A2 A1

MECHATRO CONTROLLER

Pi
PILOT SIGNAL PROCESS
P1 BYPASS CUT Pi
PROPORTIONAL
VALVE
PSV - D

P2 PUMP PRESSURE

Pi
200K
PILOT SIGNAL PROCESS ARM VARIABLE Pi
PROPORTIONAL
VALVE
PSV - A

P2 PUMP PRESSURE

Pi 220K

PILOT SIGNAL PROCESS TRAVEL STRAIGHT Pi

PROPORTIONAL
VALVE
PSV - C

P2 PUMP PRESSURE

Pi

PILOT SIGNAL PROCESS P1 PUMP Pi

PROPORTIONAL
VALVE
PSV - P1

ARM IN PILOT SECONDARY PRESSURE

Pi
P2 PUMP
PILOT SIGNAL PROCESS PROPORTIONAL Pi
VALVE
PSV - P2

ARM IN PILOT SECONDARY PRESSURE

Pi; PROPORTIONAL VALVE

SECONDARY PRESSURE R0372
E215-E235
MECHATRO CONTROL SYSTEM
ARM IN RECIRCULATION & SEQUENCE
CONFLUX
Recirculation cut control
1. If load increases and the load pressure of the pump
rises above set pressure during arm in operation,
the output voltage of the high pressure sensor
(SE-23) is put into the mechatro controller.
The mechatro controller processes pilot signals
and puts out a command current that cuts off the
variable recirculation, to the variable recirculation
proportional valve.
2. The variable recirculation proportional valve puts
out secondary pilot pressure according to a com-
mand current of the mechatro controller, brings
back the variable recirculation valve to the
recirculation cut position and blocks the
recirculation passage.
Sequence conflux control
1. If load increases and the load pressure rises above
set pressure during arm in operation, the mechatro
controller processes a pilot signal and puts out a
command current to the travel straight proportional
valve and the P1 bypass cut proportional valve
according to the secondary operating pilot pres-
sure.
2. The travel straight proportional valve and the P1
bypass cut proportional valve put out the sec-
ondary pilot pressure according to a command
current of the mechatro controller and switches
the travel straight valve and the P1 bypass cut
valve.
T2-1-7
3. When the travel straight valve is changed over, the
parallel passage on the P1 side connects with the
parallel passage on the P2 side.
When the P1 bypass cut valve is changed over, the
oil delivered by the P1 pump is combined with that
by the P2 pump by arm operation.
Recirculation control
1. Start arm in operation, and arm operation pilot
secondary pressure switches arm spool, and is
input into low pressure sensor.
2. The output voltage of the low pressure sensor is put
into the mechatro controller. The mechatro control-
ler processes the pilot signal and puts out a com-
mand current according to the input voltage to the
P2 pump proportional valve, and the variable
recirculation proportional valve.
3. Each proportional valve puts out secondary pilot
pressure according to a command current from the
mechatro controller and switches the delivery rate
of the P2 pump. At the same time it switches the
variable recirculation valve of the control valve.
4. The pure hydraulic command switches the arm
main spool. Then a command from the mechatro
controller switches the P2 pump, and the variable
recirculation valve. This causes the returned oil of
the arm cylinder rod side to be recirculated to the oil
delivered by the P2 pump.
T2-1-8 E215-E235

MECHATRO CONTROL SYSTEM

ARM IN ANTI-CAVITATION CONTROL

PILOT

RECIRCULATION
VALVE
ARM VARIABLE

P1 BYPASS
CUT VALVE
VALVE

TRAVEL RIGHT
TRAVEL LEFT

TRAVEL STRAIGHT

BUCKET
SWING

BOOM
ARM

VALVE
P2 BYPASS
CUT VALVE

CONFLUX
CONFLUX

VALVE
VALVE
BOOM

ARM
P2 P1

LOW PRESSURE SENSOR

SE - 7
A2 A1
ACCEL POTENTIO

Pi

PILOT SIGNAL PROCESS

ARM IN PILOT PRESSURE

Pi
VARIABLE ARM VARIABLE
PILOT RECIRCULATION Pi
RECIRCULATION
SIGNAL PROCESS VALVE COMMAND VALVE
PSV - A

ENGINE SPEED (COMMAND VALUE)

Pi
P2 PUMP Pi
PILOT SIGNAL PROCESS PROPORTIONAL
VALVE
PSV - P2

ARM IN PILOT PRESSURE

MECHATRO CONTROLLER

Pi; PROPORTIONAL VALVE

SECONDARY PRESSURE R0373

1. If the arm in is performed, the secondary pilot
pressure for arm operation switches the arm spool
and is put into the low pressure sensor.
2. An engine speed command put out from the accel-
eration potentiometer is put into the mechatro
controller.
3. The output voltage from the low pressure sensor is
put into the mechatro controller, and processes the
pilot signal and puts out a command current ac-
cording to the input voltage to the P2 pump propor-
tional valve.
4. Also, the mechatro controller puts out a command
current to the variable recirculation proportional
valve according to the input voltage from the accel
potentiometer.
5. Each proportional valve puts out a secondary pilot
pressure according to a command current from the
mechatro controller. This controls the variable
recirculation valve to provide a spool stroke ac-
cording to the engine speed and changes the
recirculation ratio. This holds down cavitation when
the engine speed is low and the delivery rate of the
pumps is low.
E215-E235 T2-1-9

MECHATRO CONTROL SYSTEM

ARM OUT CONFLUX

PILOT VALVE

RECIRCULATION
ARM VARIABLE

P1 BYPASS
CUT VALVE
VALVE

TRAVEL RIGHT
TRAVEL LEFT

TRAVEL STRAIGHT

BUCKET
SWING

BOOM
ARM

VALVE
P2 BYPASS
CUT VALVE

CONFLUX
CONFLUX

VALVE
VALVE

ARM
BOOM
P2 P1

LOW PRESSURE SENSOR

SE - 8

A2 A1

MECHATRO CONTROLLER

Pi
P1 BYPASS CUT Pi
PILOT SIGNAL PROCESS PROPORTIONAL
VALVE PSV - D

ARM OUT PILOT SECONDARY PRESSURE

Pi
P2 PUMP Pi
PILOT SIGNAL PROCESS PROPORTIONAL
VALVE
PSV - P2

ARM OUT PILOT SECONDARY PRESSURE

Pi
PILOT SIGNAL PROCESS
P1 PUMP Pi
PROPORTIONAL
VALVE PSV - P1

ARM OUT PILOT SECONDARY PRESSURE

Pi; PROPORTIONAL VALVE

SECONDARY PRESSURE R0374

1. Start arm out operation, and arm operation pilot mechatro controller, changes the delivery rate of
pressure switches arm spool, arm conflux spool the P1 and P2 pumps and switches the P1 bypass
and is input into low pressure sensor. cut valve of the control valve.

2. The output voltage of the low pressure sensor is put 4. A pure hydraulic command switches the arm main
into the mechatro controller. The mechatro control- spool and arm conflux spool. A mechatro com-
ler processes pilot signals and puts out command mand switches the P1, P2 pumps and the P1
current according to the input voltage to the P1, P2 bypass cut valve. This causes the oil delivered by
pump proportional valves and the P1 cut propor- the P1 pump to combine with the oil delivered by
tional valve. the P2 pump during arm out operation.

3. Each proportional valve puts out a secondary pilot

pressure according to a command current from the
T2-1-10 E215-E235

MECHATRO CONTROL SYSTEM

TRAVEL STRAIGHT

PILOT VALVE

RECIRCULATION
ARM VARIABLE
(LEFT)

P1 BYPASS
(RIGHT)

CUT VALVE
VALVE

TRAVEL RIGHT
PILOT VALVE

TRAVEL LEFT

TRAVEL STRAIGHT
FOR TRAVEL

BUCKET

BOOM
SWING
ARM

VALVE
P2 BYPASS
CUT VALVE

CONFLUX
CONFLUX

VALVE
VALVE
BOOM

ARM
P2 P1
SE - 10

SE - 9

LOW PRESSURE SENSOR

(SE - 1 - SE - 8)
UNLOAD VALVE

A2 A1

TRAVEL STRAIGHT
SIGNAL
MECHATRO CONTROLLER

Pi

PILOT SIGNAL PROCESS TRAVEL STRAIGHT Pi

PROPORTIONAL
VALVE
PSV - C

PILOT SECONDARY PRESSURE

P2 BYPASS CUT P2 BYPASS CUT Pi

PROPORTIONAL PROPORTIONAL
Pi VALVE COMMAND VALVE
PSV - B
PILOT SIGNAL
PROCESS

P1 BYPASS CUT P1 BYPASS CUT Pi

PROPORTIONAL PROPORTIONAL
PILOT SECONDARY PRESSURE VALVE COMMAND VALVE
PSV - D

Pi

PILOT SIGNAL PROCESS P2 PUMP Pi

PROPORTIONAL
VALVE
PSV - P2

BOOM UP PILOT SECONDARY PRESSURE

Pi

PILOT SIGNAL PROCESS P1 PUMP Pi

PROPORTIONAL
VALVE
PSV - P1

BOOM UP PILOT SECONDARY PRESSURE

Pi

PILOT SIGNAL PROCESS ATT UNLOAD Pi

PROPORTIONAL
VALVE PSV - E

BOOM UP PILOT SECONDARY PRESSURE

Pi

TRAVEL UNLOAD Pi
PILOT SIGNAL PROCESS PROPORTIONAL
VALVE
PSV - F

TRAVEL PILOT SECONDARY PRESSURE

Pi; PROPORTIONAL VALVE

SECONDARY PRESSURE R0375
E215-E235
MECHATRO CONTROL SYSTEM
TRAVEL STRAIGHT
1. Start ATTs work operations (boom, arm, bucket,
swing) in travel operation (right and left), and the
pilot pressure switches respective spools, and is
input into respective low pressure sensors.
NOTE - Boom up operation is explained here.
2. If mechatro controller receives the input satisfying
the following combination shown in Table, the
controller determines it as travel straight, and the
travel straight signal turns on.
3. After the travel straight signal has turned on, the
signal is input to respective proportional valve
corresponding to the following commands.
Travel straight proportional valve command
Outputs switching command corresponding to boom
up pilot pressure
(Selection of the higher ATT pilot pressure in opera-
tion)
Operating condition where travel straight signal turns on
ATT operation
Boom
In travel right operation (P1) { {
In travel left operation (P2) – –
T2-1-11
P1 bypass cut valve command
The P1 bypass cut valve does not operate if the boom
up operation is performed. During the arm and swing
operation, the higher of the remote control pressures
is selected to put out a select pressure.
P2 bypass cut valve command
Outputs switching command corresponding to boom
up pilot pressure (Selection of the higher ATT pilot
pressures from Control Value on P1 side during
operation) and the pressure selected by travel right
pilot pressure as high priority.
ATT unload proportional valve command
Outputs switching command corresponding to pres-
sure that is processed by boom up pilot pressure
(Selection of the higher ATT pilot pressure on P1 side
in operation) and right travel pilot pressure.
Travel unload proportional valve command
Outputs switching command corresponding to pres-
sure that is processed by right and left travel pilot
pressure.
Bucket Arm Swing
– –
{ {
T2-1-12 E215-E235

MECHATRO CONTROL SYSTEM

SWING PRIORITY CONTROL

PILOT
RECIRCULATION
VALVE
ARM VARIABLE

P1 BYPASS
CUT VALVE
VALVE

TRAVEL RIGHT
TRAVEL LEFT

TRAVEL STRAIGHT

BUCKET
SWING

BOOM
ARM

VALVE
P2 BYPASS
CUT VALVE

CONFLUX

CONFLUX
VALVE
BOOM

VALVE
P1

ARM
P2

SE - 7 SE - 5
A2 A1
LOW
PRESSURE SENSOR

MECHATRO CONTROLLER

Pi
PILOT SIGNAL PROCESS

ARM VARIABLE ARM VARIABLE Pi

RECIRCULATION RECIRCULATION
VALVE COMMAND VALVE
PSV - A
ARM IN OPERATING PILOT PRESSURE

Pi

PILOT SIGNAL PROCESS

SWING OPERATING PILOT PRESSURE

PILOT SIGNAL PROCESS P2 PUMP Pi

Pi PROPORTIONAL
VALVE
PSV - P2

ARM IN, SWING OPERATING PILOT PRESSURE

PILOT SIGNAL PROCESS

P1 PUMP Pi
Pi PROPORTIONAL
VALVE
PSV - P1

ARM IN, SWING OPERATING PILOT PRESSURE

PILOT SIGNAL PROCESS TRAVEL STRAIGHT Pi

Pi PROPORTIONAL
VALVE
PSV - C

ARM IN, SWING OPERATING PILOT PRESSURE

P1 BYPASS CUT P1
PILOT SIGNAL PROCESS PROPORTIONAL
Pi
VALVE
PSV - D

ARM IN, SWING OPERATING PILOT PRESSURE

Pi; PROPORTIONAL VALVE

SECONDARY PRESSURE R0376
E215-E235 T2-1-13

MECHATRO CONTROL SYSTEM

SWING PRIORITY CONTROL AT ARM IN

(THE FORCED RECIRCULATION POSITION)

1. If swing operation is performed during arm in (or
arm in is performed during swing), the secondary
pilot pressure for arm operation switches arm spool
and swing spool. Respective pressure is simulta-
neously put into each low-pressure sensor (SE-7,
SE-5).
2. The output voltage of the low pressure sensor is put
into the mechatro controller.
The mechatro controller processes pilot signals.
The command currents according to the input
voltage are put out to the P1 pump proportional
valve(PSV-P1), P2 pump proportional valve (PSV-
P2), travel straight proportional valve (PSV-C), P1
bypass cut proportional valve (PSV-D) and the arm
variable recirculation valve (PSV-A).
3. Each proportional valve puts out a secondary pilot
pressure according to a command current from the
mechatro controller and switches the delivery rate of
the P1&P2 pumps. At the same time, the pressure
moves the P1 bypass cut spool to full stroke posi-
tion, and switches the arm variable recirculation
valve to the forced recirculation position.
5. Delivery oil of P2 pump flows into swing and arm
sections of P2 side, but it flows preferentially into
swing side because the operation pressure of arm
cylinder is higher than swing side pressure.
6. On the other hand, as travel straight spool is shifted
to travel straight position and P1 bypass cut spool
is switched, delivery oil of P1 pump flows into
parallel circuit of P2 side and confluxes with swing
circuit, and swing priority is accelerated.
7. By this operation, delivery oil of P2 pump preferen-
tially flows into swing side which pressure is lower
than arm.
Therefore arm working speed keeps required
speed because recirculation oil is used to arm
cylinder, and as P1 pump delivery oil confluxes with
swing circuit, swing priority control is more avail-
able.
8. If arm in or swing operation are performed, ener-
gized signal from mechatro controller to swing
parking brake solenoid valve (SV-1) is cut, and
swing parking brake is released.

4. If arm in and swing operations are performed

simultaneously, the secondary pilot pressure
moves sub-spool of arm spool and consequently
passage in arm cylinder head is restricted. The
return oil from rod side is recirculated while
restricton, and flows into head side because of the
arm variable recirculation spool is shifted to forced
recirculation position. Consequently the operation
pressure of arm cylinder is risen.
T2-1-14 E215-E235

MECHATRO CONTROL SYSTEM

PRESSURE DRAINING (RELEASING) CONTROL

PILOT
VALVE

RECIRCULATION
ARM VARIABLE

P1 BYPASS
CUT VALVE
VALVE

TRAVEL RIGHT
TRAVEL LEFT

TRAVEL STRAIGHT

BUCKET

BOOM
SWING
ARM
(LEFT) (RIGHT)

VALVE

CONFLUX
P2 BYPASS
CUT VALVE

CONFLUX

VALVE
ARM
VALVE
BOOM
P1
P2

UNLOAD VALVE

SE - 23 SE - 22
HYDRAULIC
PRESSURE A2 A1
ENGINE
RELEASE
SWITCH
M-2
GOVERNOR MOTOR

PRESSURE
RELEASING
CONTROL

Pi

ENGINE SPEED CONTROL

Pi

PILOT SIGNAL PROCESS P2 PUMP Pi

PROPORTIONAL
VALVE
PVS - P2

Pi

PILOT SIGNAL PROCESS P1 PUMP Pi

PROPORTIONAL
VALVE
PVS - P1

Pi

PILOT SIGNAL PROCESS P1 BYPASS CUT Pi

PROPORTIONAL
VALVE
PVS - D

Pi

PILOT SIGNAL PROCESS P2 BYPASS CUT Pi

PROPORTIONAL
VALVE
PVS - B

Pi

PILOT SIGNAL PROCESS ATT UNLOAD Pi

PROPORTIONAL
VALVE
PVS - E

Pi

PILOT SIGNAL PROCESS TRAVEL UNLOAD Pi

PROPORTIONAL
VALVE
PVS - F

MECHATRO CONTROLLER

Pi; PROPORTIONAL VALVE

SECONDARY PRESSURE R0377
E215-E235 T2-1-15

MECHATRO CONTROL SYSTEM

PRESSURE DRAINING (RELEASING) CONTROL

1. When the hydraulic pressure release switch is
switched, the mechatro controller judges it as Pres-
sure Releasing Control.
2. If the mechatro controller judges it pressure releas-
ing control, the mechatro controller performs the
following regardless of input signals (From opera-
tion pilot valve, accel potentiometer, etc.):
a. Puts out a minimum tilting angle command to the
P1 and P2 pump proportional valve (PSV-P1)
and (PSV-P2).
4. The mechatro controller senses the output voltage
of the high pressure sensor of the main pump,
judges it as pump pressure and displays "DRAIN-
ING HYD. PRESS" or "FAIL DRAIN HYD. PRESS"
on the gauge cluster.
5. Since the unload valve is in the pressure releasing
position, the oil delivered by each pump is un-
loaded to the tank passage.
If the operating levers are operated and the spools
switched, the pressure remaining in the actuators
may be discharged.

b. Puts out a command current for pressure releas-

ing control revolution to the governor motor.
c. Puts out a command current for the pressure
position switch to the attachment and travel
unload proportional valve (PSV-E) and (PSV-F).
d. Puts out a standby command current to the P1
bypass cut valve and the P2 bypass cut propor-
tional valve (PSV-D) and (PSV-B).

3. A command current from the mechatro controller

causes the following to occur:
a. The pump proportional valve puts out a second-
ary pilot pressure to the pump to minimize the
tilting angle of the pump.
b. The governor motor controls the engine revolu-
tion to a pressure releasing control revolution.
c. The attachment and travel unload proportional
valve puts out a secondary pilot pressure to
switch the unload valve to the pressure releas-
ing position.
d. The P1 bypass cut valve and the P2 bypass cut
proportional valve put out a secondary pilot
pressure to hold the P1 bypass cut valve and the
P2 bypass cut valve in their standby position.
T2-1-16 E215-E235

MECHATRO CONTROL SYSTEM

PUMP CONTROL (POSITIVE CONTROL & P-Q CONTROL)

PILOT VALVE

RECIRCULATION
ARM VARIABLE

P1 BYPASS
CUT VALVE
(LEFT) (RIGHT)

VALVE

TRAVEL RIGHT
PILOT VALVE

TRAVEL LEFT

TRAVEL STRAIGHT
FOR TRAVEL

BUCKET
SWING

BOOM
ARM

VALVE
P2 BYPASS
CUT VALVE

CONFLUX
CONFLUX

VALVE
VALVE
BOOM

ARM
SE - 1 ~ SE - 8
SE - 10

SE - 9

HIGH PRESSURE SENSOR SE - 22

LOW SE - 23 A2 A1
PRESSURE
SENSOR

Pi Pi
PILOT SIGNAL
PROCESS
P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE
PSV - P2

Pi PILOT SIGNAL
PROCESS

PILOT SIGNAL
PROCESS

Pi
PILOT SIGNAL P1 PUMP P1 PUMP Pi
PROCESS PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE
PSV - P1

MECHATRO CONTROLLER R0378

Pi; PROPORTIONAL VALVE

SECONDARY PRESSURE
E215-E235
MECHATRO CONTROL SYSTEM
Positive control
1. If any operation performed, the secondary pilot
pressure switches the spools and is put into the low
pressure sensors.
2. The output voltage of the low pressure sensor is put
into the mechatro controller which processes pilot
signals and puts out command current to the pro-
portional valve of each pump according to the input
voltage.
3. The proportional valve of each pump puts out a
secondary pilot pressure according to a command
current from the mechatro controller, switches the
tilting angle of the pump and controls the delivery
rate of the pump.
4. This causes the delivery rate according to a lever
stroke to be supplied to the actuator, thus an
operating speed according to a lever stroke is
achieved.
POSITIVE CONTROL
PILOT SIGNAL PROCESS
SECONDARY PRESSURE
PUMP PROPORTIONAL
Pi
PILOT PRESSURE
R0379
T2-1-17
P-Q control
1. The output voltage of the high pressure sensor
attached to each pump piping is put into the
mechatro controller, which processes pilot signals
and computes command current according to input
voltage (load pressure).
2. The lower of the command current computed by
positive control and the command value (1) com-
puted by P-Q control is selected and put out to the
proportional valve of each pump as a command
current.
3. The proportional valve of each pump puts out a
secondary pilot pressure according to a command
current of the mechatro controller, switches the
tilting angle of the pump and controls the delivery
rate of the hydraulic pressure.
4. This increases the load of the actuator, enabling
the engine to keep running even if the pump is
highly loaded.
P - Q CONTROL
PILOT SIGNAL PROCESS
SECONDARY PRESSURE
PUMP PROPORTIONAL
Pi
PUMP DELIVERY PRESSURE
R0380
T2-1-18 E215-E235

MECHATRO CONTROL SYSTEM

STANDBY FLOW CONSTANT CONTROL

RECIRCULATION
ARM VARIABLE

P1 BYPASS
CUT VALVE
VALVE

TRAVEL RIGHT
TRAVEL LEFT

TRAVEL STRAIGHT

BUCKET
SWING

BOOM
ARM

VALVE
P2 BYPASS
CUT VALVE

CONFLUX
CONFLUX

VALVE
VALVE
BOOM

ARM
P2 P1

ACCEL POTENTIOMETER
SE - 16

A2 A1

Pi
Pi
P2 PUMP
PILOT SIGNAL PROCESS PROPORTIONAL
VALVE
PSV - P2

ENGINE SPEED

Pi
P1 PUMP Pi
PILOT SIGNAL PROCESS PROPORTIONAL
VALVE
PSV - P1

ENGINE SPEED
MECHATRO CONTROLLER
Pi; PROPORTIONAL VALVE
SECONDARY PRESSURE R0381
E215-E235
MECHATRO CONTROL SYSTEM
Standby flow constant control
1. An engine rotation command put out of the accel
potentiometer is put into the mechatro controller.
2. The mechatro controller processes pilot signals
and puts out a command current to the proportional
valve of each pump so as to make the delivery rate
of the pump constant when the engine speed is
below an intermediate rpm.
3. The proportional valve of each pump puts out a
secondary pilot pressure according to a command
current of the mechatro controller, changes the
tilting angle of the pump till the engine speed
arrives at an intermediate rpm.
PILOT SIGNAL PROCESS
SECONDARY PRESSURE
PUMP PROPORTIONAL
Pi
E/G SPEED
R0382
T2-1-19
4. If the engine speed increases an intermediate rpm,
command current from the mechatro controller
become constant, with the result that the delivery
rate of each pump rises linearly as the engine
speed increases.
5. The result is that the motion of the lever at the start
of each operation becomes the same as that when
a standby flow is available. Also, if the engine
revolution is increased, the operating feeling ac-
cording to each revolution is available.
PILOT SIGNAL PROCESS
PUMP DELIVERY RATE
Q
E/G SPEED
R0383
T2-1-20 E215-E235

MECHATRO CONTROL SYSTEM

NOTE:
E215-E235 T2-2-1

MECHATRO CONTROLLER

SUMMARY OF MECHATRO CONTROLLER

Electro-hydraulic conversion information is displayed cation time may be changed over if the screen change
on the multi display of the gauge cluster. However, the switch is pressed.
mechatro display and the cumulative engine oil lubri-

6 5
R0384

1 - Safety lock lever 5 - Swing parking brake release switch

2 - Starter switch 6 - Mode cancel switch
3 - Gauge cluster 7 - Pressure release switch
4 - Accel dial 8 - Power Boost button
T2-2-2 E215-E235

MECHATRO CONTROLLER

WORK MODE DISPLAY

The work mode selector switch contains the fol-

lowing functions

1. The work mode indicator lamp is switched W → HM

→ A... in order every time when the work mode
switch is pressed.
2. Scrolling up of indicating items in trouble history
display and canceling trouble history.
3. Scrolling up of time when changing E/G oil supply
total hours.
4. At A (Attachment) mode, flow rate is increased.
5. Time displays are roll upped when correcting fuel
6 LOW E/G
filter, hydraulic oil filter and hydraulic oil replace
OIL PRESS interval.
6. Time displays is roll upped when adjusting clock,
indicating time is increased.

The buzzer stop switch contains the following

functions

R0385 1. Stops the warning sounding.

2. Display item rollbacked in service diagnosis opera-
Screen change switch tion.
3. Display item rollbacked in trouble history opera-
1. Indicated items are scrolled up, when service
tion.
diagnosis is displayed.
4. Time display rollbacked when correcting E/G oil
2. In A (Attachment) mode, adjusting mode is taken.
supply cumulative time.
5. At A (Attachment) mode, flow rate is decreased.
6. Time display are rollbacked when correcting fuel
filter, hydraulic oil filter and hydraulic oil replace
interval.
7. Time display is rollbacked when adjusting clock,
indicating time is decreased.
E215-E235 T2-2-3

MECHATRO CONTROLLER

1. Display on LCD by the work mode switch

Work mode Pattern System summary

HM (Heavy and Mechatro) mode
Display 1. Digging The mode is suited for heavy load
lamp Ditch digging work in which operating lever actions
HM ON Trench box are recognized sensitively and the
digging machine is operated at high speed
with its priority laid on the rate of
2. Leveling operation.
Slope finishing The system recognizes the operator's
action, automatically adjusts the ma-
chine into four patterns shown on the
3. Spreading left and causes the mode to flash.
The below controls are performed as
the result of judgment.
• Engine revolution control
4. Tamping • Pump control
• Arm variable recirculation control
• Boom conflux control

5. Others • In all modes(standby and travel)

10 : 05

W (Working) mode Display The most suitable mode for keeping

lamp balance between fuel consumption
W ON and work efficiency.

A (Attachment) mode Display Where the breaker and other require

lamp a limit to the max. flow rate
A ON • Operation in flow adjust mode
1. After the engine stops, turn the
starter switch to (ON) and the
mode switch to "A" and turn the
screen change switch to (ON) for
3 to 10 sec. Then the adjust mode
is available.
2. When the engine starts, 210 L/min
is indicated in the primary stage.
After that, the previous value is
indicated. The value increases by
10 L/min each time the mode
switch is pushed one time and
decreases by 10 L/min each time
the buzzer stop switch is pressed.
3. To release the adjust mode, turn
the screen change switch to (ON)
again.
T2-2-4 E215-E235

MECHATRO CONTROLLER

2. Display on LCD by the screen change switch

The engine revolution and the cumulative hours from the engine oil change are indicated.

LCD display Operating procedure Buzzer sound

10 : 05

(After the key switch is in ON (After 5 seconds,

position, "FK" mark is displayed "Clock is displayed")
on the multidisplay)

256Hr AFT
1515 RPM
E/G OIL CH

256Hr AFT
FUEL FIL CH
Normal
None
display

256Hr AFT
HYD FIL CH

256Hr AFT
HYD OIL CH

Note:
If the screen change switch is pressed, the above six screen may be
changed over.
E215-E235
MECHATRO CONTROLLER
The functions displayed on the multidisplay are
classified roughly into the following 8 types.
1. Clock display
After the engine starts, "FK" mark is displayed
on the multidisplay and 5 seconds later it
changes to clock (In normal condition).
•
• •
• 2. CPU error display
Display the error of the mechatro controller, etc.
•
• •
• 3. Self-diagnosis display
Displays the failure of the I/O (Input/Output)
system of the mechatro controller such as the
low pressure sensor, governor motor, propor-
tional valve, solenoid valve, etc.
4. Service diagnosis display
Displays the information output by the mechatro
controller such as the pressure sensor detec-
tion, proportional valve, solenoid valve, etc.
Warning displays item
1 11
CPU
2 12
4 13
5 14
6 15
7 19
9 20
10 29
! later automatically.
T2-2-5
5. Trouble history display
Stores and displays the contents of the troubles
detected through the mechatro self diagnosis.
6. Mechatro A adjustment display
Displays it by procedure during the mechatro A
adjustment.
7. Oil/filter supply cumulative time
Displays the oil/filter supply cumulative time:
1. E/G oil 2. Fuel fiter 3. Hyd. oil filter 4. Hyd. oil.
8. Warning displays
•
In case the self diagnosis ( ) is normal but the
• •
•
machine is faulty, or if the machine condition must
be notified to the operator, the below warning items
are indicated each time it is necessary.
32
PR
37
38
!
NOTE - The buzzer sounds on display # 2, # 5 and
# 6.
In the case of # 5 and # 6, the buzzer is not stopped
even if the buzzer stop switch is pushed.
In the case of # 2, the buzzer stops five seconds
T2-2-6 E215-E235

MECHATRO CONTROLLER

SELF DIAGNOSIS DISPLAY FUNCTION

1. Summary
It performs self diagnosis of control inputs and
outputs of pressure sensors and proportional
valves while the machine is in operation. Errors
coming out of the self diagnosis are displayed on
the multi display of the gauge cluster. Regarding
the connector numbers and the pin numbers, refer
to the C-1 Mechatro Controller which describes
later. Wire numbers and colors may be confirmed
on the electric circuit diagram or on the harnesses
diagram.

2. I/O configuration

INPUT
Pressure sensor
Control SERIAL COMMUNICATION
Proportional valve
Gauge cluster
Selector valve (SOL)
(Buzzer alarm)
Governor motor
Battery relay

3. Self diagnosis display item

No. Contents Display of monitor No. Contents Display of monitor

1 Mechatro controller fail 1. MECHATRO 18 P2 bypass cut D-2 P2 BYPASS
CPU CONT. FAIL propo-valve fail PSV PROPO-VALVE
2 Gauge cluster → Mechatro con- I-1 RECEIVE 19 Travel priority D-3 TRAVEL
troller communication failure ERROR propo-valve fail PSV PROPO-VALVE
3 Battery relay fail I-2 BAT. 20 Arm variable recirculation D-6 RECIRCULAT
RELAY propo-valve fail PSV PROPO-VALVE
4 ROM data A-1 ROM DATA 21 Travel unload D-17 TRAVEL
CPU FAILURE propo-valve fail PSV UNLOAD PSV
5 Mechatro set error A-2 MECHATRO 22 Attachment unload D-18 ATT
CPU SET ERROR propo-valve fail PSV UNLOAD PSV
6 Boom raising pressue B-1 BOOM RAISE 23 P1 pump propo-valve E-1 PUMP P1
sensor fail
SE SENSOR fail PSV PROPO-VALVE
7 Boom lowering pressue B-2 BOOM LOWER 24 P2 pump propo-valve E-2 PUMP P2
sensor fail
SE SENSOR fail PSV PROPO-VALVE
8 Arm in pressure B-4 ARM IN 25 Power up solenoid F-1 POWER BOOST
sensor fail
SE SENSOR valve fail SV SOLENOID
9 Arm out pressure B-3 ARM OUT 26 Travel 2-speed solenoid F-3 TWO-SPEED
sensor fail
SE SENSOR valve fail SV SOLENOID
10 Bucket digging pressure B-5 BUCKET DIG 27 Swing parking solenoid F-2 SWING BRAKE
sensor fail
SE SENSOR valve fail SV SOLENOID
11 Bucket dump pressure B-6 BUCKET DUNP 28 Governor motor G-1 STEP MOTOR
sensor fail
SE SENSER current fail M CURRENT-NG
12 Swing pressure sensor B-7 SWING (R) 29 Governor motor starting G-2 STEP MOTOR
fail
SE SENSOR point indexing fail M S/PT. ERROR
13 Travel right pressure B-9 TRAVEL (R) 30 E/G speed sensor fail G-3 E/G REV.
sensor fail SE SENSOR RPM SENSOR
14 Travel left pressure B-10 TRAVEL (L) 31 Accel potentio meter fail H-1 ACCELERATOR
sensor fail
SE SENSOR
POT
POTENTIO
15 P1 pump pressure C-1 PUMP P1 32 Hydraulic pressure 32 DRAINING
sensor fail
SE SENSOR release stand by
PR
HYD. PRESS
16 P2 pump pressure C-2 PUMP P2 33 Hydraulic pressure 33 FAIL DRAIN
sensor fail SE SENSOR release fail
PR
HYD. PRESS
17 P1 bypass cut D-1 P1 BYPASS
propo-valve fail PSV PROPO-VALVE
E215-E235 T2-2-7

MECHATRO CONTROLLER

SERVICE DIAGNOSIS

The present service diagnosis in 25 items is displayed 3. Each time the screen change switch on
on the multidisplay according to the data received the gauge cluster is pressed, the number
from the mechatro controller. runs like No. 2, No. 3 ... in order.
4. Each time the buzzer stop switch on the
How to display switch panel is pressed, the number re-
1. Keep the buzzer stop switch pressing, turn the turns like No. 25, No. 24 ... in order.
starter switch (ON) and starts the engine. 5. The display disappears only when the starter
2. The 1st item Parts No. of Mechatro controller and switch is turned OFF.
the program version are displayed.
(Example)
No. 1
MAIN CONTROLLER P/No.
YN22E00120F1
PROGRAM VERSION
VER 03.12

Service diagnosis indication

No. Display Remarks No. Display Remarks

No. 1 No. 6
MAIN CONT. P/No. SOL. VALVE
YN22E00120F1 P/No. indication F-3 1/2-TRAVEL
1 6
PROGRAM VER Version indication COMP. OFF ON/OFF indication
VER 03.12 MEAS. OFF ON/OFF indication
SWITCH OFF ON/OFF indication

No. 2 No. 7
E/G SET 2150 No load set rpm SOL. VALVE
MEAS 2150 Actual rpm F-1 POWER UP
2 E/G PRS. LIVE LIVE/DEAD indication 7 COMP. OFF ON/OFF indication
KPSS SW W W / H / A indication MEAS. OFF ON/OFF indication
(C indication SWITCH OFF ON/OFF indication
at mode cancel)

No. 3 No. 8
H-1 RELAY
ACCEL VOLT. 4.9V Potentio voltage I-2 BAT. RELAY Sensor voltage /
3 8
POS. 100% Voltage position COMP. ON Pressure converted value
MOTOR STEP 420 No of motor steps MEAS. ON Sensor voltage /
POS. 100% Step position KEY SWITCH ON Pressure converted value

No. 4 No. 9
GOVERNOR MOTOR PRESS. SENSOR
G-1 COIL A 1.0A A phase current B-1 BOOM RAISE Sensor voltage /
4 9
G-1 COIL B 1.0A B phase current 4.5V 3.0M Pressure converted value
G-2 LIMIT OFF ON/OFF indication B-2 BOOM LOWER Sensor voltage /
4.5V 3.0M Pressure converted value

No. 5 No. 10
SOL. VALVE PRESS. SENSOR Sensor voltage /
F-2 SWING-BRAKE B-3 ARM OUT Pressure converted value
5 10
COMP. ON ON/OFF indication 4.5V 3.0M Sensor voltage /
MEAS. ON ON/OFF indication B-4 ARM IN Pressure converted value
RELEASE SW OFF ON/OFF indication 4.5V 3.0M
T2-2-8 E215-E235

MECHATRO CONTROLLER

No. Display Remarks No. Display Remarks

No. 11 No. 23
PRESS. SENSOR PROPO-VALVE
B-5 BUCKET DIG Sensor voltage / D-6 A-RECIRCULAT Command current /
11 4.5V 3.0M Pressure converted value 21 COMP. 538mA 1.8M Pressure converted value
B-6 BUCKET DUNP Sensor voltage / MEAS. 533mA 1.8M Feedback current /
4.5V 3.0M Pressure converted value Pressure converted value
(Arm in at no load)

No. 12 No. 24
PRESS. SENSOR PROPO-VALVE
B-7 SWING (R) Sensor voltage / E-1 P1 PUMP Command current /
12 22
4.5V 3.0M Pressure converted value COMP. 750mA 2.9M Pressure converted value
B-8 SWING (L) Sensor voltage / MEAS. 745mA 2.9M Feedback current /
0V 3.0M Pressure converted value POWER SHIFT 0mA Pressure converted value

No. 13 No. 25
PRESS. SENSOR PROPO-VALVE
B-9 TRAVEL (R) Sensor voltage / E-2 P2 PUMP Command current /
13 23
4.5V 3.0M Pressure converted value COMP. 750mA 2.9M Pressure converted value
B-10 TRAVEL (L) Sensor voltage / MEAS. 745mA 2.9M Feedback current /
4.5V 3.0M Pressure converted value POWER SHIFT 0mA Pressure converted value

No. 14 No. 39
PRESS. SENSOR MECHATRO ADJT.
C-1 PUMP P1 Sensor voltage / CONT. SW TEST RUN/TEST indication
14 24
3.3V 3.5M Pressure converted value CONT. VOL 50% 50% fixed indication
C-2 PUMP P2 Sensor voltage / PROG. SW OFF ON/OFF indication
3.3V 3.5M Pressure converted value

No. 15 No. 40
PRESS. SENSOR RELEASE SW
B-16 P1 OPT. Sensor voltage / KPSS OFF OFF fixed indication
15 25
4.5V 3.0M Pressure converted value SWING BRAKE OFF ON/OFF indication
B-17 P2 OPT. Sensor voltage /
4.5V 3.0M Pressure converted value

No. 20 No. 47
PROPO-VALVE PROPO-VALVE
D-1 P1 CUT Command current / D-17 TRVL UNLOAD Command current /
18 COMP. 706mA 2.7M Pressure converted value 26 COMP. 665 mA 2.6M Pressure converted value
MEAS. 701mA 2.7M Feedback current / MEAS. 665 mA 2.6M Feedback current /
Pressure converted value Pressure converted value
(Arm out relief)

No. 21 No. 48
PROPO-VALVE PROPO-VALVE
D-2 P2 CUT Command current / D-18 ATT UNLOAD Command current /
19 COMP. 706mA 2.7M Pressure converted value 27 COMP. 665 mA 2.6M Pressure converted value
MEAS. 701mA 2.7M Feedback current / MEAS. 665 mA 2.6M Feedback current /
Pressure converted value Pressure converted value
(Boom up relief)

No. 22
PROPO-VALVE
D-3 S-TRAVEL Command current /
20 COMP. 513mA 1.6M Pressure converted value
MEAS. 508mA 1.6M Feedback current /
Pressure converted value
(Arm in relief)

NOTE - The examples of displays are in the W mode with the engine at Hi and with the operating lever to full stroke.
E215-E235 T2-2-9

MECHATRO CONTROLLER

TROUBLE HISTORY DIAGNOSIS

The error item detected by the self-diagnosis is stored 5. To erase the display, turn the starter switch to
in the mechatro controller as a history and is displayed (OFF).
on the multidisplay.

How to cancel the contents of the trouble history

How to display
1. Display the trouble history mode.
1. Turn the starter switch (ON).
2. Press the work mode select switch and the buzzer
2. Press the buzzer stop switch 5 times in sequence stop switch for 10 seconds or more concurrently.
for 10 seconds.
3. When the erasing is completed, the "NO ERROR"
(Example) is displayed.
Contents Display 4. Turn the starter switch (OFF).
No errors NO ERROR
NOTE - All the stored items are erased.
00025H It is impossible to erase data partially.
Error detected B-10 TRAVEL LEFT
in the past D-2 P2 BYPASS CUT
F-3 TRAVEL 1.2-SPEED

3. Transmits the error data (one or many) and hour

meter to the gauge cluster.

• Hour meter and 3 error data are displayed on the

screen.

• If three error data or more exist, display the data

three by three in order for every 5 seconds.

4. Scrolling pages (Item number)

• The item number increases each time the work

mode select switch is pushed.

• The item number decreases each time the

buzzer stop switch is pushed.

NOTE - The system stores all error items at each hour

meter reading. To check error items at different hour
meter readings, push the work mode select switch or
the buzzer stop switch.
T2-2-10 E215-E235

MECHATRO CONTROLLER

Contents of the trouble history

Symbol Display

A-1 ROM DATA FAILURE

A Controller relation
A-2 MECHATRO SET ERROR

B-1 BOOM RAISE SENSOR

B-2 BOOM LOWER SENSOR
B-3 ARM OUT SENSOR
B-4 ARM IN SENSOR
B Low pressure sensor B-5 BUCKET DIG SENSOR
B-6 BUCKET DUMP SENSOR
B-7 SWING (R) SENSOR
B-9 TRAVEL (R) SENSOR
B-10 TRAVEL (L) SENSOR

High pressure sensor C-1 PUMP P1 SENSOR

C
(Hydraulic pump) C-2 PUMP P2 SENSOR

D-1 P1 BYPASS PROPO-VALVE

D-2 P2 BYPASS PROPO-VALVE
Proportional valve D-3 TRAVEL PROPO-VALVE
D
(Control valve) D-6 RECIRCULAT PROPO-VALVE
D-17 TRAVEL UNLOAD
D-18 ATT UNLOAD

Portional valve E-1 PUMP P1 PORPO-VALVE

E
(Hydraulic pump) E-2 PUMP P2 PORPO-VALVE

F-1 POWER BOOST SOLENOID

F Solenoid valve F-2 SWING BRAKE SOLENOID
F-3 TWO-SPEED SOLENOID

G-1 STEP MOTOR CURRENT-NG

G-2 STEP MOTOR S/PT. ERROR
G E/G Accessory G-3 E/G REV. SENSOR
G-4 E/G COOL.
G-5 E/G OIL PRS

H Potentio relation H-1 ACCELERATOR POTENTIOMETER

I-1 RECEIVE ERROR

I
I-2 BAT. RELAY

MONITOR SYSTEM OK
E215-E235 T2-2-11

MECHATRO CONTROLLER

HOW TO CORRECT THE CUMULATIVE TIME

1. The method of cumulative time indication change 2. Corrective action

is described on page T2-2-4. For example, correction method of engine oil sup-
ply cumulative time is described in following.

Procedure Operating procedure Display on multidisplay

(Normal)
A Turn the starter switch on. is displayed, and after 5 seconds
display changes to clock.

Press the gauge cluster screen change

Press once
B switch once, and the E/G speed (rpm) is 10 : 05 2150 RPM
displayed.

E/G speed is displayed

Press once more, and the engine oil sup-
C Press once 100 Hr AFT
ply cumulative time screen is displayed. 2150
10 :RPM
05 10 : 05
E/G OIL CH

Press the screen change switch and re-

100 Hr AFT 100 Hr AFT 100 Hr AFT
D lease in the range of 3 to 10 seconds, it
E/G OIL CH FUEL FIL CH E/G OIL CH
returns to the correction mode.

Press the work mode selector switch and 100 Hr AFT Cumulative time 101 Hr AFT
E
the cumulative time increases. (once 1 Hr) E/G OIL CH increases E/G OIL CH

Press the Buzzer stop switch, the cumula- 100 Hr AFT Cumulative time 99 Hr AFT
F
tive time decreases. (once 1 Hr) E/G OIL CH decreases E/G OIL CH

Press the gauge cluster screen change

switch once, the correcting time is stored, Complete the
99 Hr AFT 100 Hr AFT
G and exits from the correction mode and
E/G OIL CH correction FUEL FIL CH
"Fuel filter supply cumulative time" is dis-
played to complete the correction.

NOTES
1. Press screen change switch on the procedure D or later once, and the status is stored and the correction is
finished.
2. When altering the accumulated elapsed time of fuel filter, hydraulic oil filter and hydraulic oil respectively, press
the screen change switch and display the accumulated time screen corresponding to items required to be
altered, then repeat the procedures D to G.
3. The engine oil change time is displayed by 500 hours for warning on the display, but no buzzer sounds.
4. For fuel filter, hydraulic oil filter and hydraulic oil, press the screen change switch, and the "Hours elapsed after
change" is displayed on the display, but no warning displays and no buzzer sounds.
5. The display time is 4 digits for hydraulic oil, and 3 digits for others.
•
• •
• The display time can be returned to zero by simultaneously pressing " " selector switch and " " buz-
zer stop switch.
T2-2-12 E215-E235

MECHATRO CONTROLLER

CONTRAST OF DISPLAY ADJUSTING

PROCEDURE

If buzzer stop switch and mode switch are pressed at

the same time for 5 to 10 seconds, the contrast
adjusting mode is appeared and the contrast of dis-
play becomes adjustable, but except the following
conditions.
Under (Adjustment) and (Service diagnosis)

1. Contrast enhancement
Press the mode switch:
LCD indication is enhanced.
Press the buzzer stop switch:
LCD indication becomes dim.

2. Contrast complete

Press the screen change switch, consequently the

mode is set for required contrast level.

22 : 00
CONTRAST 50
E215-E235 T2-2-13

MECHATRO CONTROLLER

MECHATRO CONTROL EQUIPMENT

C-1 Mechatro controller

1. Outside view

2 1 6 21 4 2 18 2 1
10
16
26
34
27 22 18 16 12 28 22
CN35F CN36F CN37F CN38F
13 2 18 2 1 11 2 1

CN35F CN36F CN37F CN38F

CN39F CN40F CN41 F

26 14 16 9 22 12
CN39F CN40F CN41F
R0386

2. List of connectors

Connector Pin Port Specification IN/OUT Signal level

No. No. name PUT
1 0VA IN Ground 0V
2 A1 Boom up pressure sensor IN 0.5~4.5V
3 5VA IN Power source 5V
4 5VA IN Power source 5V
5 A2 Boom down pressure sensor IN 0.5~4.5V
6 0VA IN Ground 0V
7 0VA IN Ground 0V
8 A3 Arm in pressure sensor IN 0.5~4.5V
9 5VA IN Power source 5V
10 5VA IN Power source 5V
11 A4 Arm out pressure sensor IN 0.5~4.5V
12 0VA IN Ground 0V
13 0VA IN Ground 0V
14 A5 Bucket digging pressure sensor IN 0.5~4.5V
15 5VA IN Power source 5V
16 5VA IN Power source 5V
17 A6 Bucket dump pressure sensor IN 0.5~4.5V
CN35F
18 0VA IN Ground 0V
19 0VA IN Ground 0V
20 A7 Swing pressure sensor IN 0.5~4.5V
21 5VA IN Power source 5V
22 E2 IN Constant current circuit
23 A8 IN 0~32V
24 B37 IN +24V/OPEN
25 0VA IN Ground 0V
26 A9 Travel right pressure sensor IN 0.5~4.5V
27 5VA IN Power source 5V
28 5VA IN Power source 5V
29 A10 Travel left pressure sensor IN 0.5~4.5V
30 0VA IN Ground 0V
31 0VA IN Ground 0V
32 A18 IN 0.5~4.5V
33 A19 IN 0.5~4.5V
34 5VA IN Power source 5V
T2-2-14 E215-E235

MECHATRO CONTROLLER

Connector Pin Port Specification IN/OUT Signal level

No. No. name PUT
1 0VA IN Ground 0V
2 A11 Accel potentiometer IN 0.5~4.5V
3 5VA IN Power source 5V
4 5VA IN Power source 5V
5 A12 P1 pump pressure sensor IN 0.5~4.5V
6 0VA IN Ground 0V
7 0VA IN Ground 0V
8 A13 P2 pump pressure sensor IN 0.5~4.5V
9 5VA IN Power source 5V
10 5VA IN Power source 5V
11 A14 (P1 OPT. pressure sensor) IN 0.5~4.5V
CN36F
12 0VA IN Ground 0V
13 0VA IN Ground 0V
14 A15 (P2 OPT. pressure sensor) IN 0.5~4.5V
15 5VA IN Power source 5V
16 5VA IN Power source 5V
17 A21 IN 0.5~4.5V
18 A22 IN 0.5~4.5V
19 0VA IN Ground 0V
20 E1 IN
21 0VD Engine revolution sensor OUT GND
22 SHG Shield
1 B1 IN GND / OPEN
2 B2 Key SW. (ON) IN +24V / OPEN
3 B3 Key SW. (GLOW) IN +24V / OPEN
4 B4 Travel 1,2 speed IN GND / OPEN
5 B5 Swing P/B release IN GND / OPEN
6 B6 Alternator IN ~12V/12V~
7 B7 Over load IN GND / OPEN
8 B8 E/G coolant limit SW. IN GND / OPEN
CN37F
9 B9 E/G oil limit SW. IN GND / OPEN
10 B10 Air filter limit SW. IN GND / OPEN
11 B11 OPT. press. sensor IN GND / OPEN
12 B12 E/G oil level IN GND / OPEN
13 B13 E/G coolant level IN GND / OPEN
14 B14 Hyd. oil level IN GND / OPEN
15 B15 Fuel level IN 670/1140(Ω)
16 B16 Wiper rise-up lmit IN GND / OPEN
1 B17 Wiper reverse limit IN GND / OPEN
2 B18 ATT boost IN GND / OPEN
3 B20 IN GND / OPEN
4 B21 IN GND / OPEN
5 B22 IN GND / OPEN
6 B23 Lever lock SW. IN +24V / OPEN
7 B24 Extra switch IN GND / OPEN
8 B25 Wiper inter-lock IN 670Ω / 1140Ω
9 B26 IN GND / OPEN
10 B27 IN GND / OPEN
11 B28 IN GND / OPEN
12 B29 IN +24V / OPEN
13 B33 Water separator restriction switch IN +24V / OPEN
14 B34 IN GND / OPEN
CN38F
15 B35 Pressure drain IN GND / OPEN
16 C1 Wiper spark relay OUT GND / OPEN
17 C2 Wiper forward relay OUT GND / OPEN
18 C3 Wiper reverse relay OUT GND / OPEN
19 C4 Washer motor relay OUT GND / OPEN
20 C5 OUT GND / OPEN
21 C6 OUT GND / OPEN
22 C11 OUT GND / OPEN
23 C13 OUT GND / OPEN
24 C14 OUT GND / OPEN
25 C15 OUT GND / OPEN
26 C16 OUT GND / OPEN
27 H1 OUT 0~4.5V
28 0VA Accel 1 IN Signal GND
E215-E235 T2-2-15

MECHATRO CONTROLLER

Connector Pin Port Specification IN/OUT Signal level

No. No. name PUT
1 F1 OUT
Governor motor A phase
2 F1X OUT
3 SHG Shield ground Shield
4 D1 OUT
5 D1X P1 bypass cut proportional valve D OUT
6 D2 OUT
7 D2X P2 bypass cut proportional valve B OUT
8 D3 OUT
9 D3X Travel straight proportional valve C OUT
10 D4 Arm variable recirculation proportional OUT
11 D4X valve A OUT
12 24VP IN 20~32V
13 24VP Power supply + 24V IN 20~32V
CN39F
14 VBATT Battery back up IN 20~32V
15 F2 OUT 24V 1.5A
16 F2X Governor motor B phase OUT 24V 1.5A
17 D5 OUT
18 D5X P1 pump proportional valve (P1) OUT
19 D6 OUT
20 D6X P2 pump proportional valve (P2) OUT
21 C7 Travel 1,2-speed selector valve 2 speed/ OUT +24V / OPEN
1 speed
22 C8 Swing parking selector valve P /Release OUT +24V / OPEN
23 C9 ATT boost pressure solenoid valve OUT +24V / OPEN
24 C10 Battery relay Operation/Stop OUT +24V / OPEN
25 0VP Power input 0V
26 0VP Power supply (GND) Power input 0V
1 TXD1 Cluster TXD OUT TTL level communication
2 RXD1 Cluster RXD IN TTL level communication
3 0VD GND
4 SHG Cluster Shield
5
6 0VD Oil level sensor GN0 0(V) Oil level sensor GND
7 TXD2 RS-232C communication
8 RXD2 PHS RS-232C communication
9 0VD GND
CN40F 10 PHS PHS control 1(CI) IN RS-232C communication (Calling detect)
11 PHS PHS control 2(CS) IN RS-232C communication (Transmitable)
12 PHS PHS control 3(RS) OUT RS-232C communication
(Transmit required)
13 PHS PHS control 4(ER) OUT RS-232C communication
(Data terminal ready)
14 SHG Shield
15 H2 Accel 2 OUT 0~4.5V
16 0VA IN Signal GND
1 0VA OUT Ground 0V
2 A16 IN 0.5~4.5V
3 5VA OUT Power source 5V
4 5VA OUT Power source 5V
5 A17 IN 0.5~4.5V
6 A20 IN 0.5~4.5V
7 A23 IN 0.5~4.5V
8 0VA OUT Ground 0V
9 B19 Mode cancel SW. IN GND / OPEN
10 B30 IN GND / OPEN
11 B31 IN GND / OPEN
CN41F
12 B32 P2 CPT. press. SW. IN GND / OPEN
13 B36 IN GND / OPEN
14 C12 (Orbcomm power) OUT GND / OPEN
15 D7 ATT unload OUT
16 D7X OUT
17 D8 Travel unload OUT
18 D8X OUT
19 DL Down load change SW. OUT GND / OPEN
20 TXD4 RS-232C communication
21 RXD4 Down load/Orbcomm RS-232C communication
22 0VD OUT GND
T2-2-16 E215-E235

MECHATRO CONTROLLER

NOTE:
E215-E235
HYDRAULIC CIRCUIT
SUMMARY
The hydraulic circuits are built up with the following
functions and features in order to achieve easy oper-
Perfor-
mance Device Function
• Travel straight
• Travel 2-speed change & Auto
1st (low) speed return
Travel
• Auto parking brake
• Motor overrun protection
• Travel pilot operation
• Reverse rotation protective function
Easy operability and safety
Swing
• Swing priority circuit
(simultaneous operation of arm in
and swing motions)
• Automatic swing parking brake
• Hydraulic pilot control system
Attachment
• Timer-operated pilot safety lock type
• Lock valve (boom/arm)
• Pressurized hydraulic oil tank
• Suction strainer
• Line filter; pilot circuit
Others
• Return circuit
• Cooling hydraulic oil by oil cooler
• Pressure draining circuit
T2-3-1
ability, safety, mass volume handling and low fuel
consumption.
Features
• Travel straight at combined operation
• 1-2 travel speed change and low speed / high
torque at heavy duty
• Automatic braking when parking
• Prevents overrunning of travel motor on the
down hill slope
• Prevents hunting by the built in travel shockless
mechanism
• Easy positioning to protect it from swinging back
when stops swinging
• Easy operation of stable swing speed,
arm slanted leveling, swing press digging
• Swing parking when operating at on a slope
• Light action with operating lever
• Shut-off of pilot circuit one second after the
safety lock lever is operated
• Protect boom and arm from unexpected drop
(Natural fall)
• To prevent hydraulic oil from entering dust and
to promote self suction ability of pump
• Remove dust on suction side
• To prevent pilot operating circuit from malfunc-
tioning
• To prevent hydraulic oil from contamination
• To prevent hydraulic oil from being deteriorated
• To release the main circuit pressure for piping
repair work
T2-3-2 E215-E235

HYDRAULIC CIRCUIT

Perfor-
mance Device Function Features

• Electric flow controlled variable • Pump delivery rate control by a current com-
Mass handling capability

displacement pump mand to the solenoid proportional valve of the

variable displacement pump
Pump

• Positive flow rate control • Flow control by positive pilot control pressure
• Hydraulics back up control • Backup control by hydraulic when the electric
flow controlled variable displacement pump fails
Attachment

• Boom up conflux circuit • Speed up of boom raise operation

• Arm conflux circuit • Speed up of arm operation
• Optimum operation by work mode • Efficient operation in all work modes
select (A,M,HM)
consumption

• Auto accel • Reduce fuel consumption

computer
Micro

and noise by lowering engine speed

Low
fuel

when control lever is

in neutral position

Line Coding for Hydraulic Circuits

( ) Feed, drain, tank circuit: oil pressure less than 245 kPa

( ) Return, make up circuit: oil pressure 245 kPa to 490 kPa

( ) Secondary pilot pressure: oil pressure 0.59 MPa to 5 MPa

( ) Primary pilot pressure: oil pressure 0.34 MPa to 5 MPa

( ) Main pump drive pressure: oil pressure 5 MPa to 34.3 MPa

With power boost operating: oil pressure 37.7 MPa

NOTE - Regarding the electrical symbols in this manual, refer to the electric circuit diagram.
E215-E235 T2-3-3

HYDRAULIC CIRCUIT

NEUTRAL CIRCUIT: Positive control system with safety lever turned forward (unlock position)

14
SV-4

R0286
T2-3-4 E215-E235

HYDRAULIC CIRCUIT

NEUTRAL CIRCUIT

This section describes the following:
1. Safety lock lever and pilot circuit.
2. Pump positive flow control.
3. Pump P-Q (Pressure-Quantity) curve control.
1. SAFETY LOCK LEVER AND PILOT CIRCUIT
Purpose:
To protect attachment from unexpected motion for
safety.
Principle:
Cut pressure source of pilot valve for operation.
Operation:
If the safety lock lever is turned forward after the
engine starts, the limit switch (SW-11) is turned on.
The timer relay is actuated one second later which
causes the solenoid (SV-4) of the solenoid valve
block (14) to be energized and makes the pilot
operating circuit to stand by.
On the regulator attached on the pump, the spool
(652) through piston (643) is pushed leftward, and
stops at the position where being in proportion to the
force of pilot spring (646).
The tank port connected to the large diameter of servo
piston (532) opens, and the piston moves leftward by
delivery pressure P1 of the small bore resulting in the
increase of tilt angle (αα).
The servo piston (532) and the sleeve of the spool
(652) are connected to feedback lever (611), and
servo piston moves to leftward according to the spool
(652) moves to rightward by motion of the feed back
lever. By this movement of the spool, opening of spool
and sleeve begin to close gradually and servo piston
stands still at full closed position.
<Flow rate reduction operation
(Eg. P1 pump)>
As the current value I of mechatro controller reduces,
the secondary pressure of solenoid proportional val-
ve reduces, and spool (652) is moved rightward by the
force of pilot spring (646). With the movement of
spool, the delivery pressure P1 usually flows into the
large diameter of servo piston (532) through the spool
(652).

2. PUMP POSITIVE FLOW CONTROL

Type:
Electric flow controlled variable displacement
pump.

Principle:
The current command I to the pump's solenoid
proportional valve controls the delivery rate of the
pump.
PSV-P1 PSV-P2
Operation:
<Flow rate rise operation
(Eg. P1 pump)>
654
By operating any of control levers, the operating
secondary pressure of pilot valve rises, and the
rising pressure is transformed to the rise of 611
output voltage corresponding to the pressure
input by the low pressure sensor. Mechatro con-
643
troller signal-processes this change of voltage,
resulting in rise of command current value I to 646
the pump proportional solenoid valve and conse- 652
quently the pump flow rate rises. This is called
Positive Control System . 532
As the pump command current value I rises, the
secondary pressure of proportional solenoid valve
also rises. R0298
E215-E235 T2-3-5

HYDRAULIC CIRCUIT

The delivery pressure flows in the small diameter of

servo piston, but the servo piston moves rightward
due to the difference of area, resulting in the reduction
α). Similarly, when the servo piston (532)
of tilt angle(α
moves rightward, the spool (652) is moved leftward by
the feedback lever (611).
The operation is maintained until the opening of spool
and sleeve are closed.

3. PUMP P-Q CURVE CONTROL OPERATION

Type:
Electrical flow control type variable pump.

Principle:
Perform an operation of the value from pump high
pressure sensor to P-Q curve control value, and
send a command to the pump solenoid propor-
tional valve.

Operation:
The pump high pressure sensor converts the pres-
sure to the output voltage corresponding to the
pump delivery pressure.
The mechatro controller converts the voltage out-
put by the high pressure sensor to the P-Q curve
control value. On the other hand, select the pump
positive control command current value from the
low pressure sensor in lower order, and the values
are output to respective pump proportional valve
as a command current.
With this operation, the pump power is controlled
so as not to be exceed the engine power, therefore
engine dose not stall.
T2-3-6 E215-E235

HYDRAULIC CIRCUIT

TRAVEL CIRCUIT: 2nd speed travel, simultaneous operations

SE-10
SE-9
11
9
4

24
2
23

PSV-F
PSV-E
PSV-P2
22

14

PSV-C
SV-4

SV-3
1

PSV-P1

R0287
E215-E235
HYDRAULIC CIRCUIT
TRAVEL CIRCUIT
This section describes the following:
1. Travel forward pilot simultaneous operation circuit.
2. 2nd speed travel solenoid command circuit and auto
1st speed return function.
3. Travel main circuit.
4. Travel motor function.
1. TRAVEL FORWARD PILOT SIMULTANEOUS
OPERATION CIRCUIT
Purpose:
Light operating force and shockless operation.
Mechatronics
1. If the travel lever with damping mechanism is
operated for travel right, left and forward motions,
the secondary pilot proportional pressure comes
out of the 2 and 4 ports of pilot valve (11). The
higher of the pressures is selected, comes out of
the 5 and 6 ports and acts upon the low pressure
sensors (SE-9) and (SE-10).
2. The pilot secondary pressure flows to PAr and PAL
ports of the control valve (2), moves the travel
spool, and switches the main circuit.
The other hand, travel straight valve (24) is
switched simultaneously to full stroke position at
one stroke.
3. The voltage output by low pressure sensors (SE-9,
SE-10) is input to the mechatro controller and
signal-processed, and the mechatro controller out-
puts the increased flow rate current to P1 pump
proportional valve (PSV-P1) and P2 pump propor-
tional valve (PSV-P2).
4. P1 and P2 pump proportional valves increase the
flow rate by the pump positive control operation.
(Refer to paragraph "Pump Positive Flow Con-
trol".)
5. If sensors sense the operation of travel, mechatro
controller processes the signal according to output
voltage of low pressure sensors, and the signal
current are imputed from controller to ATT and
Travel unload valve (PSV-E, PSV-F) (23), conse-
quently unload valve (22) is switched to unload
position.
Then travel lever is operated, the unload valve (22)
is switched from unload position to full stroke
position in proportion to the movement of travel
lever. In this time, travel straight valve (PSV-C)
returns to neutral position in inversely proportion to
the movement of travel lever.
T2-3-7
2. 2nd SPEED TRAVEL SOLENOID COMMAND
CIRCUIT AND AUTO 1 st SPEED RETURN
FUNCTION
Purpose:
Change travel motor speed with switch.
Principle:
If the switch is turned, an electric signal is issued.
It excites the travel 1-2 speed changeover solenoid
(SV-3) which in turn converts the primary pilot
pressure and the self pressure to a tilting angle of
the variable displacement motor.
Operation:
If the rabbit marked switch on the gauge cluster is
pressed, the solenoid (SV-3) of the proportional
valve block (14) is excited and changes the propor-
tional valve. Then the solenoid command pressure
is issued from A7 port, enters the P port of the travel
motor (4), opens the oil passage to the 2nd speed
select piston, and causes the motor to run in the 2nd
speed tilting mode by its self pressure. However,
when the main circuit pressure rises above
27.4 MPa, the motor's self pressure pushes the 2nd
speed select piston back to the 1st speed.
3. TRAVEL MAIN CIRCUIT
Operation:
The delivery oil from Pump A1 and A2 ports by
changing the travel spool with the operation of
travel pilot flows in each VB port on the right and left
sides of travel motor (4) through C, D ports of swivel
joint (9) from AL, Ar ports of control valve (2), and
rotates the travel motor.
4. TRAVEL MOTOR FUNCTION
Function:
1. Prevents the motor from over running on a slope.
2. Check valve that prevents cavitation of the hydrau-
lic motor.
3. Shockless relief valve and anti cavitation valve
when inertia force stops.
4. High/Low 2 step speed change mechanism and
auto 1st speed return at high load.
5. Travel parking brake.
T2-3-8 E215-E235

HYDRAULIC CIRCUIT

BUCKET CIRCUIT

10

8
R
H
2

SV-4
PSV-P1
1

R0288
E215-E235 T2-3-9

HYDRAULIC CIRCUIT

BUCKET CIRCUIT

This section describes the following: 3. CONSTANT CONTROL OF STANDBY FLOW

RATE
1. Bucket digging pilot circuit.
2. Auto accel operation. Principle:
3. Constant control of standby flow rate. Outputs the current which maintains the pump
4. Bucket digging main circuit. delivery rate constant when operating in decel
condition or the engine speed is intermediate or
less.

1. BUCKET DIGGING PILOT CIRCUIT Operation:

Mechatronics:
1. When the operation for bucket digging is performed,
the pilot proportional secondary pressure is deliv-
ered through port 1 of the right pilot valve (10), flows
to PBc port of the control valve (2), and acts on the
low pressure sensor (SE-1), and at the same time
the bucket spool is switched.
2. The voltage output by the low pressure sensor (SE-
1) sent to the mechatro controller and is signal-
processed, and then the mechatro controller out-
puts the command current to increase the pump
flow rate to solenoid proportional valve (PSV-P1)
on the P1 pump side. P1 pump proportional valve
increases the flow rate by the pump positive control
operation. (Refer to paragraph "Pump Positive
Flow Control".)
Even when the engine speed of accel
potentiometer is in low speed, the flow rate equiva-
lent to the above decel speed and intermediate
speed is delivered. With this function, the actuator
actuates before the control lever is moved and
reached to the required angle.
4. MAIN CIRCUIT FOR BUCKET DIGGING
Operation:
With the pilot operation, the bucket spool is
switched, the pressure oil is supplied to (H) side of
bucket cylinder (8) through Bc port of control valve
(2). On the other hand, the return oil from (R) side
of bucket cylinder (8) is restricted by bucket spool
and returns to the tank circuit thorough Ac port of
control valve (2).

2. AUTO ACCEL OPERATION

Principle:
Start operating with signal output by low pressure
sensor.

Operation:
<Lever in neutral position>
If no signal is sent out to the low pressure sensor for
more than 4 seconds even if the accel dial is turned
to MAX, the engine revolution is set to 1050 rpm.
<Lever in operation position>
If a pressure signal of 0.56 MPa or over enters the
low pressure sensor of the machine with standard
specifications (travel, bucket, boom, swing and
arm), a proportional voltage signal from the low
pressure sensor enters the mechatro controller
and brings the engine revolution back to the accel
dial setting according to the lever strokes.
T2-3-10 E215-E235

HYDRAULIC CIRCUIT

BOOM CIRCUIT: boom up operation, confluence function

20
10

5
R

R
H

H
25

29
2

14

PSV-B
SV-4
1

R0289
E215-E235
HYDRAULIC CIRCUIT
BOOM CIRCUIT
This section describes the boom raise conflux opera-
tion:
1. Boom up pilot circuit.
2. Boom up 2 pumps conflux main circuit in control
valve.
1. BOOM UP PILOT CIRCUIT
Mechatronics:
1. If boom up operation is performed, the secondary
pilot proportional pressure from the right pilot valve
(10) gets out of port 4 and acts upon the low
pressure sensor (SE-3). At the same time, the
pressure acts upon the PAb and PB1 ports of
control valve (2).
2. The voltage output of the low pressure sensor
(SE-3) is put into the mechatro controller and
processed. The controller then puts out a current
command to the P2 bypass cut solenoid propor-
tional valve (PSV-B). The valve puts out a second-
ary proportional pressure that acts upon the PCa
port of the control valve (2).
3. Next, the secondary pressure which enters the
PAb port of the control valve (2) shifts the boom
spool. The secondary pressure which enters the
PB1 port shifts the boom conflux valve (25).
Meanwhile, the secondary solenoid proportional
pressure which enters the PCa port changes over
the P2 bypass cut valve (29).
T2-3-11
2. BOOM UP 2 PUMPS CONFLUX MAIN CIRCUIT
IN CONTROL VALVE
Purpose:
Boom up speed up.
Principle:
Confluxing oil from 2 pumps.
Operation:
1. The oil delivered through A1 port of P1 pump flows
into control valve (2) P1 port, and branches into
bypass circuit and parallel circuit. However since
the boom spool is moved and bypass circuit is
closed, the oil opens load check valve LCb through
parallel circuit and flows into boom spool.
2. Then the oil passes through boom spool, opens
lock valve of boom lock valve CRb, and is led into
(H) side of boom cylinders through control valve (2)
Ab port.
3. Meanwhile, the oil delivered from the A2 port of the
P2 pump enters the P2 port of control valve (2) and
is branched to the bypass circuit and the parallel
circuit. If the P2 bypass cut valve (29) is changed
over, the center bypass circuit is closed. The oil
then passes through the parallel circuit and via the
restrictor on the circumference of the boom conflux
spool (25), pushes the load check valve CCb open
from the boom conflux circuit, and combines the oil
delivered by the P1 pump internally.
4. The return oil from boom cylinder (R) side flows into
tank circuit through boom spool from control valve
(2) Bb port.
T2-3-12 E215-E235

HYDRAULIC CIRCUIT

BOOM CIRCUIT: boom down operation & prevention of natural boom falling

10

5
R

R
H

H
2

14
SV-4
1

R0290
E215-E235
HYDRAULIC CIRCUIT
This section describes boom lower operation:
3. Boom down pilot circuit.
4. Prevention of natural fall by lock valve.
5. Constant recirculation function of boom down main
circuit.
3. BOOM DOWN PILOT CIRCUIT
Mechatronics:
1. If the boom down operation is performed, the
secondary pilot proportional pressure comes out of
port 2 of the right pilot valve (10) and acts upon the
low pressure sensor (SE-4).
At the same time, the pressure is branched off into
two lines and acts upon the PBb port and the PLc1
port of control valve (2).
2. The voltage output of the low pressure sensor
(SE-4) enters the mechatro controller and proc-
essed in it.
3. Then, the proportionl secondary pressure fed into
control valve (2) PBb port switches boom spool.
And the proportional secondary pressure flown
into control valve (2) PLc1 port switches boom lock
valve selector and release closed poppet CRb.
4. PREVENTION OF NATURAL FALL BY LOCK
VALVE
Purpose:
Prevention of natural fall when the lever is neutral.
Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
Operation:
In the boom down action, the selector valve is
changed over by the boom down pilot pressure.
Then the poppet spring chamber of the lock valve
gets through the drain line (Drc) and makes the lock
valve poppet open.
T2-3-13
When the boom spool is at neutral, the drain line on
the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leakage from the boom spool zero.
Thus the boom cylinder is prevented from making
a natural fall.
5. CONSTANT RECIRCULATION FUNCTION OF
BOOM DOWN MAIN CIRCUIT
Purpose:
Prevention of cavitation during boom
lowering motion.
Principle:
The oil returning from the boom cylinder head (H)
is recirculated to the rod (R).
Operation:
When the oil is supplied to the boom cylinder rod
(R) side during boom down operation, the boom
moves faster than it should do in some cases by the
self weight of the attachment.
On that occasion, the circuit pressure on the rod
(R) side is on the negative side.
The oil supplied to the boom cylinder rod (R) flows
into the A1 port of the P1 pump and the P1 port of
control valve. The oil then passes through the
boom spool and goes out of the Bb port.
On that occasion, the oil returning from the head
(H) goes through the recirculation path in the boom
spool, pushes the check valve C in the spool open,
is recirculated to the Bb port and is supplied to the
rod (R). When the (R) pressure is larger than the
(H) pressure, the check valve C closes. There-
upon, the recirculation is stopped.
T2-3-14 E215-E235

HYDRAULIC CIRCUIT

SWING CIRCUIT: swing operation (LH)

10
3

26
2

14
SV-4

SV-1
1

R0291
E215-E235 T2-3-15

HYDRAULIC CIRCUIT

SWING CIRCUIT

This section describes the following operations: 3. The swing parking solenoid (SV-1) is excited five
seconds after the pressure of the swing low pres-
1. Swing left pilot circuit.
sure sensor (SE-5) is reduced to zero.
2. Swing auto parking brake. In the case of arm in operation, the swing parking
3. Swing main circuit. solenoid (SV-1) is excited the moment the pres-
sure of the arm in low pressure sensor (SE-7) is
4. Swing motor circuit. reduced to zero. This causes the mechanical brake
to operate.

1. SWING LEFT PILOT CIRCUIT

Mechatronics:
1. When the left swing operation is performed, the
pilot proportional secondary pressure is delivered
through port 1 of left pilot valve (10), and the
secondary pressure acts on PBs and PBs2 ports of
control valve (2), and simultaneously flows out
from Pss port of control valve and acts on low
pressure sensor (SE-5).
2. The voltage output by the low pressure sensor
(SE-5) is input in the mechatro controller, and is
signal-processed.
3. SWING MAIN CIRCUIT
Operation:
The oil delivered from the A2 port of the P2 pump
enters the P2 port of control valve (2) and is
branched off into the bypass line and the parallel
circuit. However, since the bypass line is closed as
the swing spool is shifted, the oil pushes the load
check valve LCs open through the parallel circuit,
enters the B port of the swing motor (3) via the Bs
port of control valve (2), and rotates the swing
motor counterclockwise.

3. Then, the secondary pressure led into PBs port of

control valve (2) switches the swing spool.
4. SWING MOTOR CIRCUIT

1. Anti cavitation circuit at swing deceleration.

2. SWING AUTO PARKING BRAKE
2. Shockless relief valve that prevents the swing
Purpose: motor from being reversed.

Swing lock in neutral position and parking.

Principle:
Release mechanical brake only when required to
operate swing and arm in.

Operation:
1. The swing parking system excites the swing park-
ing soleniod (SV-1) usually if the key switch is
turned in ON position and works by the action of the
mechanical brake.
2. The mechanical brake is released if the swing
parking solenoid is de-excited only when the sec-
ondary operating pressure in the swing and arm in
actions acts upon any of the low pressure sensors
(SE-5) or (SE-7).
T2-3-16 E215-E235

HYDRAULIC CIRCUIT

ARM CIRCUIT: Arm in operation (light load)

10
3

7
20

R
H

26
2
PSV-P2

14

PSV-A
SV-4

SV-1
1

R0292
E215-E235 T2-3-17

HYDRAULIC CIRCUIT

ARM CIRCUIT

This section describes the following operations:
1. Arm in, light-load operating pilot circuit.
2. Arm in, light-load variable normal recirculation
main circuit.
1. ARM IN, LIGHT-LOAD OPERATING PILOT
CIRCUIT
Purpose:
Speed-up and Anticavitation when the arm is at
light loaded.
Principle:
The oil returning from the arm cylinder rod (R) is
recirculated variably to the head (H) at inside of
control valve.
Operation:
1. If the arm digging operation is performed, the
secondary pilot proportional pressure gets out of
port 4 of the left pilot valve (10) and acts upon the
low pressure sensor (SE-7).
At the same time, the pressure is branched off to
two flows, acts upon the PAa port and the PLc2
port, changes over the arm spool and the arm lock
valve selector and release closed poppet CRa.
2. The voltage output by the low pressure sensor is
input into mechatro controller, and is pilot signal-
2. ARM IN, LIGHT-LOAD VARIABLE NORMAL
RECIRCULATION MAIN CIRCUIT
Operation:
1. The oil returning from the arm cylinder (R) pushes
the arm lock valve CRa open and enters the arm
variable recirculation spool past the arm spool.
2. Since the passage to the tank is restricted by the
arm variable recirculation spool, the oil returning
from the arm cylinder (R) arrives at the load check
valve CAr.
3. Since the (R) side pressure of the cylinder is higher
than the (H) side pressure of it when working load
is light, the pressure pushes the load check valve
open and is recirculated to the (H) side so as to
speed up the light-load digging operation.
Cavitation prevention control in arm in
operation
If the engine speed and the arm in pilot pressure
are processed in the controller, the controller puts
out a current command to the arm variable solenoid
proportional valve, and brings the arm to its forced
variable recirculation position to prevent cavitation
from occurring.
Arm variable recirculation valve (26)
From arm spool
To tank

processed by the mechatro controller, and is out- From

arm
put to P2 pump proportional valve (PSV-P2) and To
recirculation
tank
arm variable recirculation proportional valve proportional
valve
(PSV-A).
3. The P2 pump proportional valve (PSV-P2) oper-
ates the P2 pump in proportion to the pilot operating To CAr
check
Recirculation
cut
Normal
recirculation
Forced
recirculation
pressure, but in case of the arm variable valve
R0299
recirculation proportional valve, since the second-
ary pressure of solenoid proportional valve is pilot-
signal- processed in the mechatro controller in
inversely proportion to the pilot operating pressure,
the secondary pressure of solenoid proportional
valve with pilot operating pressure for arm light
digging becomes smaller and is switched into the
regular recirculation section.
T2-3-18 E215-E235

HYDRAULIC CIRCUIT

ARM CIRCUIT: Arm in operation (heavy load)

10
3

7
20

R
H

26
24
2

28
14

PSV-C

PSV-D

PSV-A
SV-4

SV-1
1

R0293
E215-E235
HYDRAULIC CIRCUIT
This section describes the following operations:
3. Arm in, heavy load operating pilot circuit
(recirculation cut).
4. Arm in, heavy load operating sequence confluxed
main circuit.
3. ARM IN, HEAVY LOAD OPERATING PILOT
CIRCUIT (RECIRCULATION CUT)
Mechatronics:
1. In the arm digging operation, if the heavy load is
applied to the arm, the current of arm variable
recirculation solenoid proportional valve is mini-
mized and the arm variable recirculation is cut.
2. The travel straight solenoid proportional valve
(PSV-C) and P1 by-pass cut solenoid proportional
valve (PSV-D) are energized at the same time
when the command current of arm variable
recirculation solenoid proportional valve (PSV-A)
is minimized, the secondary pressure of respective
solenoid proportional valve is delivered and the
pressure acts on PTb and PCb ports of control
valve (2), switches the travel straight valve (24) and
P1 by-pass cut valve (28), enabling the circuit for
arm sequence to be confluxed.
3. With the arm digging operation, the function of pilot
valve is the same as that in light loading.
T2-3-19
4. ARM IN, HEAVY LOAD OPERATING
SEQUENCE CONFLUXED MAIN CIRCUIT
Purpose:
Speed up for arm in operation
Principle:
P1 pump flow is confluxed with P2 pump flow in
control valve (2).
Operation:
1. P2 pump delivery oil flows in the travel left section
through P2 port of control valve (2) and separated
into by-pass circuit and parallel circuit. Conse-
quently the arm spool is switched and pushes and
opens load check valve LCa through parallel cir-
cuit, and flows in the arm spool.
2. On the other hand, P1 pump delivery oil flows into
P1 port of control valve (2), and the travel straight
section, and opens load check valve CT2, then the
delivery oil confluxes with the oil delivered from
load check valve CP2 on P2 parallel circuit, and
flows in the arm spool.
3. Next, oil is supplied to the arm cylinder (H) side via
the arm spool and the Aa port of control valve (2).
4. Meantime, the oil returning from the arm cylinder
(R) side enters the Ba port and reaches the arm
lock valve CRa.
If the arm lock selector is shifted, the oil enters the
arm spool as the arm lock valve CRa is open.
5. The oil returning from the arm spool returns to the
tank line without being restricted by the arm vari-
able recirculation valve (26).
T2-3-20 E215-E235

HYDRAULIC CIRCUIT

ARM CIRCUIT: Arm out operation, confluence function

10

7
21

R
H

27
2

28
14

PSV-D
SV-4
1

R0294
E215-E235 T2-3-21

HYDRAULIC CIRCUIT

This section describes the following operations: Operation:

5. Arm out pilot circuit. 1. The delivery oil of P1 pump confluxes with the oil in
the arm cylinder (R) side through the arm conflux
6. Arm out 2 pumps conflux main circuit.
valve (27) and load check valve CCa.
7. Natural fall protection with arm lock valve.
2. Then, the oil passes through arm spool opens arm
lock valve CRa with free flow and flows into arm
cylinder (R) side through control valve (2) Ba port.
5. ARM OUT PILOT CIRCUIT
3. And, the return oil from arm cylinder (H) side flows
into Aa port, passes through arm spool, and returns
Mechatronics:
into tank circuit.
1. If the arm out operation is performed, the second-
ary pilot proportional pressure gets out of port 2 of
the left pilot valve (10), and acts upon the low
7. NATURAL FALL PROTECTION WITH ARM
pressure sensor (SE-8). At the same time, the oil is
LOCK VALVE
branched off into two flows and acts upon the PA1
and PBa ports of control valve (2).
Purpose:
2. The operating proportional secondary pressure
To prevent the arm from falling naturally by the
entered in PBa port of control valve (2) switches the
weight of the arm & bucket.
arm spool.
3. Then, the operating secondary pressure entered in Principle:
PA1 port of control valve (2) switches the arm
Complete seat of the return circuit against the arm
conflux valve (27).
spool of the arm cylinder (R) side circuit.
4. The voltage output by low pressure sensor (SE-8)
is input to the mechatro controller and is processed Operation:
in signal, and the mechatro controller outputs com-
1. If the secondary pressure for arm operation disap-
mand current to by-pass cut solenoid proportional
pears and the arm cylinder stops, the pressure on
valve (PSV-D). This solenoid valve delivers the
the rod (R) side passes through the selector of the
secondary pressure, and the secondary pressure
lock valve from the Ba port of control valve (2), acts
acts on PCb port of control valve (2) and switches
the back pressure on the lock valve CRa and seats
P1 by-pass cut valve (28).
the lock valve.
2. Since the oil flow into the arm spool from the lock
valve is shut off completely, natural fall of the arm
6. ARM OUT 2 PUMPS CONFLUX MAIN CIRCUIT
due to oil leaks through the arm spool is prevented.
Purpose:
Arm out operation speed up.

Principle:
The oil delivered by the P1 pump is confluxed with
that delivered by the P2 pump in control valve (2).
T2-3-22 E215-E235

HYDRAULIC CIRCUIT

COMBINED OPERATION: Boom up/Travel forward 1st speed operation, travel straight function

20
10

11
6

5
R

R
H

H
9

25
4

26
24

29
2
23
22

14

PSV-C
PSV-B
SV-4
1

R0295
E215-E235
HYDRAULIC CIRCUIT
COMBINED OPERATION
This section describes only the difference in com-
bined operation:
1. Boom up/travel, pilot circuit.
2. Boom up/travel, main circuit.
1. BOOM UP/TRAVEL, PILOT CIRCUIT
Mechatronics:
<Pilot circuit other than independent operation>
1. If the mechatro controller processes low pressure
sensors signals, a current command is put out to
two valves; the travel straight solenoid proportional
valve (PSV-C) and the P2 bypass cut solenoid
proportional valve (PSV-B). These valves put out
secondary pressure which acts upon the PTb and
the PCa ports of control valve (2).
2. The pilot pressure of solenoid proportional valve
(PSV-C) enters to the PTb port of control valve (2)
and changes over the travel straight valve (24).
Meanwhile, the solenoid proportional valve (PSV-B)
which enters the PCa port of control valve (2)
changes over the P2 bypass cut valve (29).
T2-3-23
2. BOOM UP/TRAVEL, MAIN CIRCUIT
Purpose:
To insure straight travel movement during travel
operation even if the attachment is operated.
Principle:
The travel action and the attachment action are
actuated by separate pumps.
Operation:
1. The oil delivered by the P1 and P2 pumps runs into
the travel straight section from the P1 and P2 ports
of control valve (2). Since the travel straight spool
is shifted, the oil delivered by the P2 pump is
branched off to the P1 and P2 bypass lines.
In the meantime, the oil delivered by the P1 pump
flows through travel straight valve and flows into
load check valve CT1 and CT2 and flow to the P1
and P2 parallel circuits.
2. Next, since the travel right and left actions are
operated by the P2 pump delivery oil. Meantime,
since the boom spool and other spools operate on
the parallel circuits, the oil delivered by the P1
pump is used.
3. However, a portion of the flow is led to the travel
straight spool notch restriction. The speed of
actuators like boom, travel, etc. is adjusted by the
circuit of restriction.
T2-3-24 E215-E235

HYDRAULIC CIRCUIT

COMBINED OPERATION: Swing/Arm in operation, Swing priority function

10
3

7
20

R
H
SE-5

26
24
2

28
14

PSV-C

PSV-D

PSV-A
SV-4

SV-1
1

R0296
E215-E235 T2-3-25

HYDRAULIC CIRCUIT

This section describes difference in combined opera-

tion:
3. Swing/Arm in, pilot circuit.
4. Swing/Arm in, swing priority main circuit.

3. SWING/ARM IN, PILOT CIRCUIT

Mechatronics:
1. When swing left and arm in operations are concur-
rently carried out, with signal processing of
mechatro controller, the secondary pressure of
solenoid valve is increased in proportion to swing
pilot pressure, and spool position of arm variable
recirculation valve (26).

4. SWING/ARM IN, SWING PRIORITY MAIN

CIRCUIT

Purpose:
Stable swing speed.

Principle:
Control the oil flow rate to arm cylinder, and give a
priority of the delivery of P2 pump to swing opera-
tion.

Operation:
Swing main circuit is actuated by P2 pump flow, but
in P2 pump circuit the oil flows into swing and arm
circuits in the same time because both circuits are
paralleled.
Arm variable recirculation spool shifts to forced
recirculation side according to swing pilot pres-
sure. Return oil from arm cylinder rod (R) side is
restricted in arm variable recirculation valve (26).
And swing pilot pressure is led from "Pisc" port to
sub-spool in arm spool, the pressure of arm cylin-
der head (H) rises higher by restricting opening of
arm spool circuit according to swing pilot pressure,
as a result the oil P2 pump flows preferentially into
swing circuit.
This is so-called Swing Priority Control.
T2-3-26 E215-E235

HYDRAULIC CIRCUIT

PRESSURE DRAIN (RELEASE) CIRCUIT

10

11
23

2
PSV-F
PSV-E
PSV-P2
22

14
SV-4
PSV-P1
1

R0297
E215-E235 T2-3-27

HYDRAULIC CIRCUIT

PRESSURE DRAINING (RELEASING)

CIRCUIT

This section describes the following operations:
1. Pressure drain (releasing) pilot circuit.
2. Pressure drain (releasing) main circuit.
1. PRESSURE RELEASE PILOT CIRCUIT
Purpose:
To release the main circuit pressure for piping
repair work.
Mechatronics:
When the hydraulic pressure release switch is
switched, mechatro controller judges this is pres-
sure release control and out puts the following
command:
1. Puts out the minimum tilting command value to the
pump proportional valves (PSV-P1, PSV-P2).
2. Puts out a pressure release control revolution
command value to the governor motor. (electric
system).
2. PRESSURE RELEASE MAIN CIRCUIT
Operation:
If the operating lever is shifted to neutral during
engine running and the hydraulic pressure release
switch is kept,"FAIL DRAIN HYD. PRESS"or
"DRAINING HYD. PRESS" is displayed on the
gauge cluster. If the operating levers of the right
and left four to five times to their full stroke, pres-
sure may be released. If the pump pressure is
determined to be more than 970 kPa by the output
value of the high pressure sensor (SE-22, SE-23),
in that case repeat the pressure releasing proce-
dure once again.
Operation:
ATT & travel unload valves are switched to the
pressure releasing position, consequently the de-
livery oil unloads to tank passage. If the spools are
switched by pilot operation, the remaining pressure
from the actuators may be relieved to the tank
circuit, i.e. the main circuit pressure may be re-
leased.

3. The controller outputs unload position switching

command to ATT unload valve (PSV-E) and travel
unload valve (PSV-F).
4. Puts out a standby command value to the P1, P2
bypass cut proportional valves. (a command that
does not put out the secondary pressure of the P1,
P2 bypass proportional valves).

Hydraulics:
1. The pump proportional valve minimizes the deliv-
ery rates of the P1, P2 pumps.
2. The unload valves are switched to unload position
because pilot pressures are outputted from ATT
unload valve (PSV-E) and travel unload valve
(PSV-F) to ATT & travel unload valve.
T2-3-28 E215-E235

HYDRAULIC CIRCUIT

CRUSHER & BREAKER CIRCUIT

Outline

2
1 3 4

5
6

8 7

10
11

Replacing the
breaker with the
crusher is possible.

12
15

13

14

R0389

1 - Arm hydraulic piping 9 - Arm

2 - Hydraulic piping for boom 10 - Hydraulic breaker
3 - Upper hydraulic piping return hydraulic piping 11 - Arm top piping
4 - Selector valve 12 - Operating pedal
5 - P2 option valve (add-on control valve) 13 - Single/conflux flow select switch
6 - Main control valve 14 - Remote control piping
7 - Hydraulic tank 15 - Crusher
8 - Stop valve
E215-E235 T2-3-29

HYDRAULIC CIRCUIT

FOREWORD

• When using breaker, set the selector valve (item 2) • When using Crusher, according to specification of
to return to hydraulic tank directly hydraulic oil from Crusher installed, choose conflux or single flow by
breaker. conflux flow changeover switch.

• Adjust overload relief valve of opt. port to custom-

ize specification ordinary set pressure.

To tank To tank

Control Control
valve valve

Breaker R0387
Crusher R0388

Selection condition and proportional valve command when any of Crusher single & conflux flow or breaker is
service.

COMMAND SIGNAL OF SOLENOID

SELECTION PROPORTIONAL VALVE
(W: {, W/{: –)

CONFLUX / SELECTOR
P1 P2 TRAVEL P1 P2
SINGLE SELECT VALVE MODE
SW. (ITEM 2) PUMP PUMP STRAIGHT CUT CUT

CRUSHER { { { { { A
CONFLUX ON
CONFLUX

CRUSHER – { – – { A
CONFLUX OFF
SINGLE

BREAKER CONFLUX OFF – { – – { A

T2-3-30 E215-E235

HYDRAULIC CIRCUIT

HYDRAULIC DIAGRAM FOR CRUSHER & BREAKER: at crusher single flow operating

NOTE - This hydraulic circuit is used by adding to

the STD circuit diagram.

4
6

R
H
3

10
11

13
CP2

14
CT2

CT1

1
15

9
12
8

P2 NEUTRAL CUT
5

A1

A3
PSV-B
SV-4

R0300

1 - P2 opt. Control valve 9 - P1 bypass cut valve

2 - Selector valve 10 - P2 bypass cut valve
3 - Stop valve 11 - P2 main circuit
4 - Pilot valve 12 - P1 bypass circuit
5 - Return filter 13 - P2 bypass circuit
6 - Crusher cylinder 14 - P2 parallel circuit
8 - Travel straight valve 15 - P1 parallel circuit
E215-E235 T2-3-31

HYDRAULIC CIRCUIT

CRUSHER & BREAKER CIRCUIT

Set the single/conflux flow select switch, according to

the specifications of the Crusher to be used.

1. SINGLE FLOW FOR CRUSHER

1) Pilot circuit
• Change the single/conflux flow select switch to
single.
• Depress the pilot valve (4) for the Crusher &
Breaker on your tiptoe. Then the secondary pilot
pressure enters the PAo2 port of the control
valve from the B port and changes over the spool
of the P2 opt. valve (1).
• Concurrently, the secondary pilot pressure en-
ters the low-pressure sensor (SE-11) from the
C2 port. The voltage output of the pressure
sensor enters the mechatro controller where
pilot signal processing takes place. The
mechatro controller then puts out current com-
mands, according to the voltage inputs, to the P2
pump proportional valve and the P2 bypass cut
proportional valve (PSV-B).
• The P2 pump proportional valve puts out sec-
ondary pressure to the pump regulator to
change the delivery rate of the P2 pump.
• The P2 bypass cut proportional valve (PSV-B)
puts out secondary pressure to the PCa port of
the control valve and changes over the spool of
the P2 bypass cut valve (10).
2) Main circuit
• The oil delivered by the P2 pump runs into the
bypass circuit (13) on the P2 side from the main
circuit (11) on the P2 side. However, since the
spool of the P2 bypass cut valve (10) has been
changed over, the oil pushes open the load
check valve CP2 and runs into the parallel circuit
(14) on the P2 side.
• The oil pushes open the load check valve of the
P2 opt. control valve (1), passes through the
spool, is supplied to the head (H) of the crusher
cylinder (6) by way of the Ao2 port.
• The oil that comes back from the rod (R) of the
crusher cylinder returns to the oil tank by way of
the Bo2 port of the P2 opt. control valve (1), the
spool and the oil cooler.
2. CONFLUX CIRCUIT FOR CRUSHER
1) Pilot circuit
• Change the single/conflux flow select switch to
conflux.
• Depress the pilot valve (4) for the Crusher &
Breaker on your tiptoe. The secondary pilot
pressure enters to the PAo2 port of the P2 opt.
control valve (1) from the B port of pilot valve (4)
and changes over the spool of the P2 opt. control
valve .
• Concurrently, the secondary pilot pressure en-
ters the low-pressure sensor (SE-11) from the
C2 port. The voltage output from the low-pres-
sure sensor (SE-11) enters the mechatro con-
troller where pilot signal processing takes place.
The mechatro controller then puts out current
commands according to the voltage inputs, to
the proportional valves for the P1 pump and the
P2 pump, the P1 bypass cut proportional valve,
and the travel straight proportional valve.
• The P1 and P2 pump proportional valves put out
secondary pressure to the pump regulators to
change delivery rates of the pumps.
• The P1 cut proportional valve puts out second-
ary pressure to the PCb port of the control valve
and changes over the P1 bypass cut spool (9).
• The P2 cut proportional valve puts out second-
ary pressure to the PCa port of the control valve
and changes over the P2 bypass cut spool (10).
• The travel straight proportional valve puts out
secondary pressure to the PTb port of the con-
trol valve and changes over the spool of the
travel straight valve (8).
2) Main circuit
• The oil delivered by the P1 pump enters the
control valve, but since the spool of the travel
straight valve (8) and the P1 bypass cut spool (9)
have been changed over, the oil pushes the load
check valve (CT2) open and runs into the P2
parallel circuit (14).
• The oil delivered by the P2 pump enters the
control valve, but since the spool of the travel
straight valve (8), the P1 and P2 bypass cut
spools have been changed over, the oil pushes
the load check valve (CP2) open, runs into the
P2 parallel circuit (14), and combines with the oil
delivered by the P1 pump.
• The oil pushes open the load check valve in the
P2 opt. control valve (1), is fed to the head (H) of
the crusher cylinder (6) via the spool and the Ao2
port, and causes the crusher to take close ac-
tion.
• The oil that comes back from the rod (R) of the
crusher cylinder returns to the hydraulic tank, by
way of the Bo2 port of the P2 opt. control valve
(1), the spool and the oil cooler.
T2-3-32 E215-E235

HYDRAULIC CIRCUIT

HYDRAULIC DIAGRAM FOR CRUSHER & BREAKER: at breaker operating

NOTE - This hydraulic circuit is used by adding to

the STD circuit diagram.

4
7
3

10
11

13
CP2

14
CT2

CT1

1
15

9
12
8

P2 NEUTRAL CUT
5

A1

A3
PSV-B
SV-4

R0390

1- P2 opt. Control valve 9 - P1 bypass cut valve

2- Selector valve 10 - P2 bypass cut valve
3- Stop valve 11 - P2 main circuit
4- Pilot valve 12 - P1 bypass circuit
5- Return filter 13 - P2 bypass circuit
7- Breaker 14 - P2 parallel circuit
8- Travel straight valve 15 - P1 parallel circuit
E215-E235 T2-3-33

HYDRAULIC CIRCUIT

3. BREAKER
• Bring the selector valve (2) to the position so as
to return the oil from the breaker directly to the oil
tank.
• Adjust the pressure of the port relief valve in the
option valve, according to the specifications of
the breaker to be mounted to the machine.
1. Pilot circuit
• If the operating pedal (4) for the Crusher &
Breaker is depressed on your heel, secondary
pilot pressure enters the PBo2 port of the control
valve from the A port and changes over the spool
of the option valve.
• Concurrently, the secondary pilot pressure en-
ters the low-pressure sensor (SE-11) from the
C2 port. The voltage output from the pressure
sensor enters the mechatro controller where
pilot signal processing takes place. The
mechatro controller then puts out current com-
mands according to the voltage inputs, to the P2
pump and P2 bypass cut proportional valves
(PSV-B).
• The proportional valve for the P2 pump puts out
secondary pressure to the pump regulator to
change the delivery rate of it.
Procedure of setting the maximum flow:
1. Turn ON the starter switch (without starting the
engine) and bring the machine to the breaker A
mode. If the screen change switch on the gauge
cluster is pressed between 3 seconds and 10
seconds, the machine is brought to the adjust
mode.
NOTE - The adjust mode is not available if the above
step is taken after the engine has been started up.
2. A previously stored flow rate is displayed on the
multi display.
3. The flow increases as the operation mode select
switch is pressed, while it decreases as the buzzer
stop switch is pressed.
4. The flow changes two seconds after either switch
is kept pressed. It changes by the 10 L min-1
(20 L min-1 with conflux selected); let the switch go
at a desired reading.
5. The flow may be set in the range of the max. to min.
values.

• The P2 bypass cut proportional valve (PSV-B) 6. If the screen change switch is turned ON again, the
puts out secondary pressure to the PCa port of adjusted max. flow is stored, and the machine is
the control valve and changes over the spool of released from the adjust mode.
the P2 bypass cut valve (10).

2. Main circuit
• The oil delivered by the P2 pump runs into the
main circuit on the P2 side (11), but since the P2
bypass cut spool (10) has been changed over,
the oil pushes the load check valve CP2 open
and runs into the parallel circuit on the P2 side
(14).
• The oil pushes open the load check valve in the
option valve (1), is fed to the breaker by way of
the spool and the Bo2 port, and causes the
breaker to make blow action.
• The oil that comes back from the breaker returns
directly to the oil tank via the selector valve (2).
T2-3-34 E215-E235

HYDRAULIC CIRCUIT

POSITIONING CIRCUIT: positioning out operation

NOTE - This hydraulic circuit is used by adding to

the STD circuit diagram.

2
R

H
7

6
CP2
CT2

CT1

CP1

37,7 MPa
10

39,7 MPa
5
8

1
3

A5
SV-4

PSV-D

R0464

1 - P1 opt. Control valve 6 - P2 bypass cut valve

2 - Pilot valve 7 - P2 main circuit
3 - Return filter 8 - P1 bypass circuit
4 - Positioner cylinder 9 - P2 bypass circuit
5 - P1 bypass cut valve 10 - P1 parallel circuit
E215-E235 T2-3-35

HYDRAULIC CIRCUIT

POSITIONING CIRCUIT

This section describes the following:

1. Positioning pilot circuit.
2. Positioning main circuit.

1. POSITIONING PILOT CIRCUIT

1) When the operation for positioning is performed,
the pilot proportional secondary pressure is de-
livered through port A of the positioning pilot
valve (2), flows to PAo1 port of the P1 opt. valve
(1), and acts on the low pressure sensor (SE-20),
and at the same time the positioning spool of P1
opt. valve (1) is switched.
2) The voltage output by the low pressure sensor
(SE-20) is sent to the mechatro controller and is
signal-processed. Then the mechatro controller
outputs the command current to solenoid pro-
portional valve (PSV-P1) to increase the P1
pump flow rate, and to by-pass cut solenoid
proportional valve (PSV-D). The solenoid pro-
portional valve (PSV-D) delivers the propor-
tional secondary pressure which acts on PCb
port of control valve and switches P1 by-pass
cut valve (5).

2. POSITINING MAIN CIRCUIT

Operation:
With the pilot operation, the positioning spool of
P1 opt. valve (1) is switched. The pressure oil by
P1 pump, via the P1 parallel circuit (10), is
supplied to (R) side of positioning cylinder (4)
through Ao1 port of P1 opt. valve (1). On the other
hand, the return oil from (H) side of positioning
cylinder is restricted by positioning spool and
returns to the tank circuit thorough Bo1 port of P1
opt. control valve (1).
T2-3-36 E215-E235

HYDRAULIC CIRCUIT

NOTES:
E215-E235 T2-4-1

ELECTRICAL SYSTEM

OUTLINE

The electrical system is classified into the main circuit,

control circuit, and monitor circuit.
• Main circuit operates the engine and accesso-
ries.
• Control circuit functions to control operations of
the engine, hydraulic pumps, and valves (includ-
ing actuators such as solenoid valves, Mechatro
Controller, switch panel, sensors, and pressure
switches).
• Monitor circuit operates the monitoring devices
consisting in indicators, indicators lights and
switches.

In this group, the functions of the main circuit are

shown:
1. Electric Power Circuit: supplies electric power to
all electric system on the machine. (Key Switch,
Batteries, Fuses, Battery Relay)
2. Accessory Circuit: works with the key switch
placed in the ACC position. (Key Switch, Bat-
tery, Fuses)
3. Starting Circuit: starts the engine.(Key Switch,
Starter Relay, Starter)
4. Charging Circuit: recharges the batteries and
supplies consumption electricity. (Alternator,
Regulator, Batteries)
5. Preheating Circuit: automatically controlled by
the Mechatro controller, helps the start of the
engine in cold weather. (Mechatro controller,
preheat relay, glow plug)
6. Engine Stop Circuit: stops the engine with the
Engine stop solenoid device (Key Switch, En-
gine stop solenoid)
7. Engine Emergency Stop Circuit: In case of oil
pressure drop, or in case of coolant engine
overheating, the buzzer is activated. With oil low
pressure persisting, the engine will be automati-
cally stopped. (Engine oil pressure switch, En-
gine coolant temperature sensor, Engine stop
relay, Mechatro controller, Engine stop sole-
noid).
T2-4-2 E215-E235

ELECTRICAL SYSTEM

ELECTRIC POWER CIRCUIT

(Key switch in OFF position)

The battery negative terminal is grounded to the

vehicle.

Current from the battery positive terminal flows as

follows with the key switch in OFF position:

Battery (7) Fuse link 7 (60 A) (2)

Terminal 6
Mega Fuse
• Fuel supply pump
(150 A) (3)
Terminal 7
• Mechatro controller
Backup

Terminal 9
Preheating Relay (R3) (4) Fuse
box (1) • Room light
• Engine room light

Terminal 10
• Key Switch terminal B
• Carrier data system
(Optional)
• Fleet link (Optional)
E215-E235 T2-4-3

ELECTRICAL SYSTEM

1
2 5

4
3

18

7
10
8

9 R0452

1 - Fuse box (E-4) 7 - Battery (E-1)

2 - Fuse link 7 (60 A) (E-27) 8 - Battery relay (R-1)
3 - Mega fuse box (E-24) 9 - Key switch (SW-1)
4 - Preheating (Grid heater) relay (R-3) 10 - Starter motor assembly (M-1)
5 - Mechatro Controller (C-1) 18 - Glow Plug (E-12)
6 - Preheating control relay (R-29)
T2-4-4 E215-E235

ELECTRICAL SYSTEM

ACCESSORY CIRCUIT
(Key Switch in ACC position)

When the key switch (9) is turned to the ACC position,

the terminal ACC is connected to terminal B inside the
key switch (9).

Therefore, the battery (7) current, already existing on

the terminal B (refer to Electric Power Circuit with Key
switch (9) in OFF position), from terminal ACC can
reach the fuse box (1) and from this, thought the relate
fuses, can supply the following accessory: horn, cigar
lighter, and power converter 24 V/12 V D.C. that in
turn, supplies the radio and 12 V power socket.
E215-E235 T2-4-5

ELECTRICAL SYSTEM

1
2

7
10
8

9 R0453

1 - Fuse box (E-4) 8 - Battery relay (R-1)

2 - Fuse link 7 (60 A) (E-27) 9 - Key switch (SW-1)
7 - Battery (E-1) 10 - Starter motor assembly (M-1)
T2-4-6 E215-E235

ELECTRICAL SYSTEM

ELECTRIC POWER CIRCUIT

(Key switch in ON position)

When the key switch (9) is turned to the ON position,

the terminal B is connected to terminals ACC and M.

The current, beside to supply the accessory circuits

connect to terminal ACC, from terminal M is routed to
the terminal 13-2 of mechatro controller C-1 (5) to
feed the "key on" signal (Key switch (9) in ON posi-
tion).

Further, from the same terminal M, the current

through the Diode 16, supplies the coil (terminal 86)
of the Battery relay R-1 (8).

The Battery relay R-1 (8) therefore is actuated and

connects the current of the batteries (7) to:
• Fuse link 1 and 2
• Fuse link 3, 4 and 5, 6
• Power supply to starter motor (10)

By means of the fuse link 1 the terminal B+ of

alternator (17) is connected to power supply line of the
batteries (7).

By means of the fuse link 2 the fuel filter heater and

water separator heater circuits (14) are supplied.

By means of the fuse link 3 the fuses from 11 to 20 in

the fuse box (1) are powered. From these fuses,
power supply are fed to the control of solenoid valves,
work lights, air condition, heater, wiper and further
optional circuits.

By means of the fuse link 4 the power supply is applied

to the starter relay R-2 (15) in order to set the circuit
for the next starting sequence.

By means of the fuse link 5 the power supply is applied

to "pull" coil of engine stop solenoid (11). The "hold"
coil of engine stop solenoid (11) is powered from the
same terminal M of key switch (9), through the con-
tacts of engine stop relay R-28 (12). With these both
power supplies the engine stop solenoid SV-13 (11)
is armed and opened allowing the fuel to route to the
engine injection pump.

By means of the fuse link 6 the fuses 1 and 2 in the

fuse box (1) are powered. From these fuses the power
supply are routed to the Cluster gauge C-2, to the
Mechatro controller C-1 (5) and to the Fuel heater
relay R-23 (4).
E215-E235 T2-4-7

ELECTRICAL SYSTEM

14
4

7
5
10

15 8

11 17

12 R0454

1 - Fuse box (E-4) 10 - Starter motor assembly (M-1)

2 - Fuse link 7 (60 A) (E-27) 11 - Engine stop solenoid (SV-13)
4 - Preheating relay (R-3) 12 - Engine stop relay (R-28)
5 - Mechatro Controller (C-1) 14 - Water separator heater (E-19)
7 - Battery (E-1) 15 - Starter relay (R-2)
8 - Battery relay (R-1) 17 - Alternator (E-2)
9 - Key switch (SW-1)
T2-4-8 E215-E235

ELECTRICAL SYSTEM

STARTING CIRCUIT
(Key Switch in START position)

When the key switch (9) is turned to the START

position, terminal B on the key switch is connected to
terminals G2, M, and ST in the switch.

In this position, other than to maintain the power

supply on the terminal M (refer to circuit with key
switch in ON position), the power on terminal ST of the
key switch is connected to terminal 3 of the coil of
Starter relay R-2 (15).

The battery (7) current can then flow through the coil
of Starter relay R-2 and through the closed contact of
Safety relay R-4 (16) and actuate the Starter relay R-2
(15).

The closure of the contacts of the starter relay R-2

(15) allows the battery (7) current to flow toward the
terminal of the starter motor (10).

The inner starter relay will close and allow to power

the starter motor (10). Thereby, the starter begins to
rotate.

As soon the starter motor (10) puts in turn the engine,

the mechatro controller (5), by means of its terminal
14-23 and 13-6, actuates the safety relay R-4 (16),
that opening its contact, shut-down the power circuit
of coil of starter relay R-2 (15), therefore, the power
supply of starter motor (10) is cut off, and the starter
disengages from engine flywheel, completing in this
way the starting sequence.

The activation of the safety relay R-4 (16) occurs in

any case, even if the key switch (9) is hold on START
position, avoiding in this way a possible dragging of
starter motor (10) or a further starter coupling with
engine already running.
E215-E235 T2-4-9

ELECTRICAL SYSTEM

1
2

15

7
10
8

9 16

11
5

12 R0455

1 - Fuse box (E-4) 10 - Starter motor assembly (M-1)

2 - Fuse link 7 (60 A) (E-27) 11 - Engine stop solenoid (SV-13)
5 - Mechatro Controller (C-1) 12 - Engine stop relay (R-28)
7 - Battery (E-1) 15 - Starter relay (R-2)
8 - Battery relay (R-1) 16 - Safety relay (R-4)
9 - Key switch (SW-1)
T2-4-10 E215-E235

ELECTRICAL SYSTEM

CHARGING CIRCUIT
(Key Switch in ON position)

After the engine starts and the key switch is released,

the key switch (9) is returned to the ON position.

After the engine starts, the alternator (17) begins to

deliver voltage output.

Current from terminal B + of the alternator (17) flows

to the batteries (7) through the fuse link 1 of 80 A and
through the battery relay R-1 (8) actuated. Therefore,
with engine running, the alternator (17) will power all
utility of the machine and will maintain the batteries (7)
in charge.

In addition, through the terminal L of the alternator

(17), a "charge " signal is supplied to the Mechatro
Controller (5), terminal 13-6.

In case of lack of voltage output from alternator (17)

side, the Mechatro Controller (5) will feed to the
cluster gauge a no charge signal.
E215-E235 T2-4-11

ELECTRICAL SYSTEM

14
19

7
10
8
15

11 17

12 R0456

1 - Fuse box (E-4) 11 - Engine stop solenoid (SV-13)

2 - Fuse link 7 (60 A) (E-27) 12 - Engine stop relay (R-28)
5 - Mechatro Controller (C-1) 14 - Water separator heater (E-19)
7 - Battery (E-1) 15 - Starter relay (R-2)
8 - Battery relay (R-1) 17 - Alternator assembly (E-2)
9 - Key switch (SW-1) 19 - Fuel filter heater relay (R-23)
10 - Starter motor assembly (M-1)
T2-4-12 E215-E235

ELECTRICAL SYSTEM

PREHEATING CIRCUIT

When the key switch (9) is turned to ON position, the

battery relay R-1 (8) is activated and a "key on "signal
is fed to the mechatro controller (5).

Further, the current of the batteries (7), routing

through the 60 A fuse link 7 (2) and fuse box (1),
reaches the terminal B of key switch (9).

In these conditions and with engine coolant tempera-

ture low, automatically the mechatro controller (5)
supplies, through the terminal 14-22, a ground to the
preheating control relay R29 (6). Therefore the
preheating control relay R29 (6) that receives power
supply from fuse box (1), is actuated and, by its
closing contact, allows the activation of preheating
relay R-3 (4).

With the preheating relay R-3 (4) closing, the glow

plugs (18) are powered and remain powered until the
relay R-3 (4) remains actuated.

Further, for the all period the glow plugs are powered,
the mechatro controller (5) sends to the cluster gauge
a signal for the indication to the operator of preheating
time.

After elapsing time, the mechatro controller (5) re-

moves the ground from terminal 14-22, then the
preheating control relay R-29 (6) deactivates and
consequently shut down the power supply to the relay
R-3 (4) and in turn the glow plugs (18) are no more
powered.
E215-E235 T2-4-13

ELECTRICAL SYSTEM

5
1

2
4
3

18

R0457

1 - Fuse box (E-4) 6 - Preheating control relay (R-29)

2 - Fuse link 7 (60 A) (E-27) 7 - Battery (E-1)
3 - Mega fuse box (E-24) 8 - Battery relay (R-1)
4 - Preheating relay (R-3) 9 - Key switch (SW-1)
5 - Mechatro Controller (C-1) 18 - Glow Plug (Grid heater) (E-12)
T2-4-14 E215-E235

ELECTRICAL SYSTEM

ENGINE STOP CIRCUIT

When the key switch (9) is turned from the ON position

to the OFF position, the signal "key on" that is con-
nected from terminal M of the key switchto the
mechatro controller (5), is cut off.

Then, the holding coil of engine stop solenoid (11), no

more powered, releases the solenoid SV-13 (11) to
closing position and shut -off the fuel to the engine,
that stops.
E215-E235 T2-4-15

ELECTRICAL SYSTEM

1
2

7
9 8

11
5

12 R0458

1 - Fuse box (E-4) 8 - Battery relay (R-1)

2 - Fuse link 7 (60 A) (E-27) 9 - Key switch (SW-1)
5 - Mechatro Controller (C-1) 11 - Engine stop solenoid (SV-13)
7 - Battery (E-1) 12 - Engine stop relay (R-28)
T2-4-16 E215-E235

ELECTRICAL SYSTEM

EMERGENCY OPERATING CIRCUIT

With key switch (9) on ON position and with engine

running, if a drop of engine oil pressure occurs
(< 90 kPa) or if the temperature of engine coolant
raises ( > 107 °C), the related sensors send signals to
the mechatro controller (5).

On the cluster gauge will be displayed the indication

of engine oil low pressure or the overheating of engine
coolant, and in the mean time will be activated the
warning buzzer.

Only in case a persisting drop of engine oil is oc-

curred, the mechatro controller (5) controls the activa-
tion of the engine stop relay R-28 (12), that, in turn, de-
energized the engine stop solenoid SV-13 (11) that
releases in the closing position.

Therefore in these conditions, the engine will stop for

lack of fuel supply.
E215-E235 T2-4-17

ELECTRICAL SYSTEM

1
2

11
5

12 R0459

1 - Fuse box (E-4) 8 - Battery relay (R-1)

2 - Fuse link 7 (60 A) (E-27) 9 - Key switch (SW-1)
5 - Mechatro Controller (C-1) 11 - Engine stop solenoid (SV-13)
7 - Battery (E-1) 12 - Engine stop relay (R-28)
T2-4-18 E215-E235

ELECTRICAL SYSTEM

NOTE:
SECTION 3 E215-E235

COMPONENT OPERATION

CONTENTS

Group 1 - Hydraulic Pump Assy Group 5 - Travel Device

Outline ...................................................... T3-1-1 Outline ...................................................... T3-5-1

Hydraulic Pump ........................................ T3-1-4 Construction .............................................. T3-5-4
Regulator ................................................ T3-1-10
Control Curve of Pump ........................... T3-1-19
Unload Valve ........................................... T3-1-20

Group 6 - Swivel Joint

Group 2 - Pilot Valve
Outline ...................................................... T3-6-1
Outline (ATT) ............................................ T3-2-1 Construction ............................................. T3-6-2
Construction, Function and Operation .................................................. T3-6-3
Operation (ATT) ........................................ T3-2-2
Outline (Travel) ......................................... T3-2-7
Construction (Travel) ................................ T3-2-8
Operation (Travel) ..................................... T3-2-9
Group 7 - Cylinders

Group 3 - Control Valve Outline ...................................................... T3-7-1

Construction ............................................. T3-7-2
Outline ...................................................... T3-3-1 Operation .................................................. T3-7-5
Construction ............................................. T3-3-4
Hydraulic Circuit ..................................... T3-3-14
Operation ................................................ T3-3-16

Group 8 - Air Conditioner

Group 4 - Swing Device
Construction and Piping ........................... T3-8-1
Outline ...................................................... T3-4-1 Main Components .................................... T3-8-4
Construction ............................................. T3-4-4 Function ................................................... T3-8-8
Hydraulic Motor ........................................ T3-4-7
Valve Casing Section ................................ T3-4-8
Brake Section ......................................... T3-4-11
Swing Reduction Unit ............................. T3-4-12
E215-E235 T3-1-1

HYDRAULIC PUMP ASSY

OUTLINE

General view and hydraulic ports

5
B3

3
PH1 PH2 a2
A3 a1

Dr Dr3
a4 a3 PSV 2

A2
A1
2x4 - M10 Depth 16

PSV 1 a5 VIEW I
EYE BOLT (M10)
MAX FLOW RATE
PSV1 (PSV2) 4
ADJUSTING SCREW
(PSV1) (PSV2)
a5 2
(a4) MIN FLOW
RATE
ADJUSTING
SCREW
Dr3
B3

a3

a2 1 A3
(Dr) a1 a2 A2
B1 I
R0143

No. Parts Q.ty Code Ports name Size

1 Main pump assy 1 A1,2 Delivery port SAE 6000 psi ¾"
2 Regulator assy 2 B1 Suction port SAE 2500 psi 2 ½"
3 Gear pump assy(for pilot) 1
4 Solenoid proportional reducing valve 2 Dr Drain port PF3/4-20
5 PTO unit 1 PSV1,2 Servo assist port PF1/4-15
PH1,2 Pressure sensor port PF3/8-17
a1,2,4,5 Gauge port PF1/4-15
a3 Gauge port PF1/4-14
A3 Delivery port of gear
pump PF3/8-15
B3 Suction port of gear
pump PF3/4-20.5
Dr3 Drain port of gear
pump PF3/8-15
T3-1-2 E215-E235

HYDRAULIC PUMP ASSY

Hydraulic circuit diagram

Solenoid proportional Solenoid proportional

reducing valve (PSV-1) reducing valve (PSV-2)
PSV1 a1 A1 PH1 PH2 A2 a2 PSV2

a4 Dr Regulator a5

Engine Main pump

B1
Regulator
Gear pump
for pilot

a3

(Dr) B3 D3 A3
R0144
E215-E235 T3-1-3

HYDRAULIC PUMP ASSY

Specifications

Item Main pump Gear pump for pilot

Pump model K3V112DTP1TLR-9TFL ZX10LPRZ7-07D

Variable displacement
Fixed displacement
Type plunger pump: regulator
type gear pump
attached type

Max. displacement capacity cm3 97.7 × 2 10

Rated min-1 2150 ←

Revolution (Clockwise seen
Hi idle from shaft end) 2400 or less ←
Rated 34.3
Pressure MPa 4.9
ATT boost 37.8
Max. flow L/min 210 × 2, at 7.8 MPa 21.5

Max. input Horse Power kW 110 3.4

Max. input torque N·m 488 14.7

Model KR3G-9TFL

Control function Electric flow control, positive flow control, total

power control at back-up and power shift control
Regulator
at back-up.

Others With solenoid proportional reducing valve

(KDRDE5K-31/30C50-102)

Weight kg 131

NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump.
T3-1-4 E215-E235

HYDRAULIC PUMP ASSY

HYDRAULIC PUMP

Construction

MAIN PUMP

Apply adhesive
792
THREE BOND No. 1305N
535 789 732 532 214 548 531 724 702 534 901 808 954 717 151 152 211
806 A
953
886
717
261
406
774*

B B

111
127
824
710
123
710
212 263
153
401 251 490 271 156 157 728 313 124 710 116 312 466 855 314 113 141 271 401
468 725

* Apply Sealub L101 to the oil 05

seal surface circumferential

546
725

724

325

407

VIEW A

SECTION B-B
R0145
E215-E235 T3-1-5

HYDRAULIC PUMP ASSY

111 - Front drive shaft 468 - Vp plug; PF3/4 (Q.ty 2) 170 Nm

113 - Rear drive shaft 490 - Plug; NPTF1/16 (Q.ty 2) 8.8 Nm
116 - 1st gear 531 - Tilting pin; M24×2 (Q.ty 2) 240 Nm
123 - Roller bearing (Q.ty 2) 532 - Servo piston; M24×2 (Q.ty 2) 240 Nm
124 - Needle bearing (Q.ty 2) 534 - Large Stopper (Q.ty 2)
127 - Bearing spacer (Q.ty 4) 535 - Small Stopper (Q.ty 2)
141 - Cylinder block (Q.ty 2) 546 - Spacer (Q.ty 2)
151 - Piston (Q.ty 18) 548 - Feed back pin (Q.ty 2)
152 - Shoe (Q.ty 18) 702 - O-Ring (Q.ty 2)
153 - Retainer plate (Q.ty 2) 710 - O-Ring (Q.ty 3)
156 - Spherical bushing (Q.ty 2) 717 - O-Ring (Q.ty 4)
157 - Cylinder spring (Q.ty 18) 724 - O-Ring (Q.ty 18)
211 - Shoe plate (Q.ty 2) 725 - O-Ring (Q.ty 6)
212 - Swash plate (Q.ty 2) 728 - O-Ring (Q.ty 4)
214 - Tilting bushing (Q.ty 2) 732 - O-Ring (Q.ty 2)
251 - Swash plate support (Q.ty 2) 774 - Oil seal
261 - Front seal cover 789 - Back up ring (Q.ty 2)
263 - Rear seal cover 792 - Back up ring (Q.ty 2)
271 - Pump casing (Q.ty 2) 806 - Nut; M16 (Q.ty 2) 130 Nm
312 - Valve block 808 - Nut; M20 (Q.ty 2) 240 Nm
313 - Front valve plate 824 - Snap ring (Q.ty 2)
314 - Rear valve plate 885 - Valve plate pin (Q.ty 2)
325 - Cover 886 - Spring pin (Q.ty 4)
401 - Socket bolt; M20×210 (Q.ty 8) 430 Nm 901 - Eye bolt; M10 (Q.ty 2)
406 - Socket bolt; M8×20 (Q.ty 8) 29 Nm 953 - Socket screw; M16×30 (Q.ty 2)
407 - Socket bolt; M6×30 (Q.ty 3) 12 Nm 954 - Set screw; M20 (Q.ty 2)
466 - Vp plug; PF1/4 (Q.ty 2) 36 Nm 05 - PTO Unit

The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
T3-1-6 E215-E235

HYDRAULIC PUMP ASSY

GEAR PUMP (FOR PILOT)

700 354 351 433

434

B3

728
435
312
311
A3
732

a3

308 466 467

710 361 353 Dr3 310 307 309 434 355 725 850
R0146

307 - Poppet 435 - Flange socket; M8 (Q.ty 2) 17 Nm

308 - Seat 466 - Vp plug; PF1/4 M8 (Q.ty 2)
309 - Ring 467 - Adapter; PF1/2-PF3/8
310 - Spring 700 - Ring
311 - Adjust screw 710 - O-Ring
312 - Lock nut; M14×1.5 29 Nm 725 - O-Ring
351 - Gear case 728 - O-Ring
353 - Drive gear 732 - O-Ring
354 - Driven gear 850 - Locking ring
355 - Filter a3 - Gauge port; PF1/4 16 Nm
361 - Front case A3 - Delivery port; PF3/8 34 Nm
433 - Flange socket; M8×40 (Q.ty 2) B3 - Suction port; PF3/4 74 Nm
434 - Flange socket; M8×55 (Q.ty 2) Dr3 - Drain port; PF3/8 34 Nm
E215-E235 T3-1-7

HYDRAULIC PUMP ASSY

PTO GEAR CASE

326 825 125 118 728 468

117

126 886 435

128

827

115

826

P1 P2
Pump Pump
side side

R0147

115 - Idle shaft 414 - Socket bolt: M10x20 (Q.ty 2)

117 - 2nd gear 435 - Flange socket: M10×20 (Q.ty 4)
118 - 3rd gear 468 - Vp plug: PF3/4
125 - Ball bearing (Q.ty 2) 728 - O-Ring
126 - Roller bearing 825 - Snap ring
128 - Bearing spacer (Q.ty 2) 826 - Snap ring
262 - Cover 827 - Snap ring
326 - Gear case 886 - Pin (Q.ty 2)
T3-1-8 E215-E235

HYDRAULIC PUMP ASSY

Operation
The pump assy is equipped with two pumps arranged
on the same axis that are connected with gear (116)
and distribute the rotating power to the gear trains on REGULATOR
a different axis. Thus the engine rotation is transmit-
ted to front shaft (111) that drives the two pumps and,
at the same time, drives the pilot gear pump arranged
on another shaft. 116
The pump assy consists largely of:
- the rotary group, the main part of the pump that
111
makes rotary on;
- the swash plate group that changes the delivery rate;
- the valve block group that selects between oil
suction and delivery;
- the PTO group that transmits the drive power to the
gear pump.
PTO
GEAR CASE
ROTARY GROUP GEAR PUMP
(For pilot)
The rotary group consists of shaft (111), cylinder R0148

block (141), piston (151), shoe (152), plate (153),

spherical bushing (156), and cylinder spring (157).
The shaft is supported by bearings (123) and (124) at
its both ends. The shoe, which is caulked to the piston,
forms a spherical joint and relieves it of thrust force
that is generated by load pressure.
Further, the piston is provided with a pocket so it moves
lightly on shoe plate (211), taking hydraulic balance.
The sub group of the piston-shoe is pressed against
the shoe plate by the cylinder spring, via the retainer
plate and the spherical bushing, so that it moves
smoothly over the shoe plate. The cylinder blocks
(141) are also pressed against valve plates (313) or
(314) by the action of cylinder spring (157).

141
313
124

312

111

116
124
314
141
157
156
153
151
152
211

R0149
E215-E235 T3-1-9

HYDRAULIC PUMP ASSY

SWASH PLATE GROUP 532

The swash plate group consists of swash plate (212),
shoe plate (211), swash plate support (251), tilting
bushing (214), tilting pin (531),and servo piston (532). 531 214
211
The swash plate is the cylindrical part that is formed 212
on the opposite side of the shoe sliding surface and is
supported by the swash plate support.
The hydraulic force controlled by the regulator flows
251
into the hydraulic chamber that is provided on both
sides of the servo piston. This moves the servo piston
to the right and left. The result is that the swash plate
swings on the swash plate support via the spherical
α).
part of the tilting pin and changes the tilting angle (α
R0150

VALVE BLOCK GROUP

The valve block group consists of valve block (312),
313
valve plates (313) (314), and valve plate pin (885).
The valve plates having two crescent-shaped ports 312
are installed to valve block (312) to feed oil and
recycle it from cylinder block (141). The oil switched
116
over by the valve plate is connected with the external 111
pipe by way of the valve block. 314
141
885

R0151

PTO GROUP 117

The PTO group is composed of 1st gear (116), 2nd gear
(117) and 3rd gear (118). The 2nd and the 3rd gear are 126
supported by bearings (125) and (126) respectively
and installed to the valve block.
Now, if the shaft is driven by the engine, the cylinder
block rotates together by the spline linkage. If the
swash plate is inclined, the pistons arranged in the
cylinder block make reciprocating motion with respect
to the cylinder while rotating with the cylinder block. If
we keep an eye on a single piston, it makes a motion
118
away from the valve plate (oil suction process) in the
125
first 180° and a motion toward the valve plate (oil
delivery process) in the remaining 180°. If the swash
plate is not inclined (zero tilting angle), the piston does
not stroke i.e. delivers no oil. 125
The shaft rotation is taken up by the 1st gear (116) and R0152
transmitted to the 2nd gear (117) and the 3rd gear (118),
in that order, to drive the gear pump that is linked to the
3rd gear.
T3-1-10 E215-E235

HYDRAULIC PUMP ASSY

REGULATOR
Construction

734 654
897 875 874 755 653
A 655
412 612 858 836 651 652 601 624 629 630
641
615 814 628
801

614 925
C
613

611
A
631 627
732
898 756
632 763
733 887
622 621 625 626
623

SECTION A-A

B 496 418 079

757 413
646 438
439
438

PSV
656
B
D

a3

D
465, 755
542 B
722 924
543 545 725 438
755
724 730 643 708 644 645 728 801

VIEW C SECTION B-B

PSV 543 545 542 755

E

801
E

642 753 467, 727

SECTION D-D SECTION E-E

R0153
E215-E235 T3-1-11

HYDRAULIC PUMP ASSY

412 - Socket bolt; M8×50 (Q.ty 2) 29 Nm 646 - Pilot spring

413 - Socket bolt; M8×70 (Q.ty 2) 29 Nm 651 - Sleeve
418 - Socket bolt; M5×12 (Q.ty 2) 6.9 Nm 652 - Spool
438 - Socket bolt; M6×20 (Q.ty 10) 12 Nm 653 - Spring seat
439 - Socket bolt; M6×35 (Q.ty 3) 12 Nm 654 - Return spring
465 - Vp plug; PF1/4 36 Nm 655 - Set spring
467 - Plug; PF3/8×M8 34 Nm 656 - Block cover
496 - Plug; NPTF1/16 (Q.ty 15) 8.8 Nm 708 - O-Ring
541 - Seat 722 - O-Ring (Q.ty 3)
542 - Seat 724 - O-Ring (Q.ty 8)
543 - Stopper 1 (Q.ty 2) 725 - O-Ring
545 - Ball (Q.ty 2) 727 - O-Ring
601 - Casing 728 - O-Ring
611 - Feed back lever 730 - O-Ring
612 - Lever 1 732 - O-Ring (Q.ty 2)
613 - Lever 2 733 - O-Ring
614 - Fulcrum plug 734 - O-Ring
615 - Adjusting plug 753 - O-Ring
621 - Compensating piston 755 - O-Ring (Q.ty 5)
622 - Piston case 756 - O-Ring
623 - Compensating rod 757 - O-Ring
624 - (C) Spring seat 763 - O-Ring
625 - Outer spring 801 - Nut; M8 (Q.ty 3) 16 Nm
626 - Inner spring 814 - Snap ring
627 - (C) Adjusting stem 836 - Snap ring
628 - (C) Adjusting screw 858 - Snap ring (Q.ty 2)
629 - (C) Cover 874 - Pin; Ø4×11.7L
630 - Lock nut; M30×1.5 160 Nm 875 - Pin; Ø4×8L (Q.ty 4)
631 - Sleeve 887 - Pin
641 - Pilot cover 897 - Pin; Ø4×19L
642 - Rod 898 - Pin; Ø8.5×10L
643 - Pilot piston 924 - Socket screw; M8×20
644 - (Q) Spring seat 925 - (Q) Adjusting screw
645 - (Q) Adjusting stem 079 - Solenoid proportional reducing valve

The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
T3-1-12
HYDRAULIC PUMP ASSY
Operation
CONTROL FUNCTION
Electric flow control.
• Positive flow control.
• Total horsepower control.
Back-up control.
• Hydraulic positive control.
• Hydraulic total horsepower control.
SUMMARY
The regulator KR3G-9T for the in-line type axial piston
pump K3V series is composed of the control mecha-
nism as mentioned below:
Electric flow control and positive flow control
The tilting angle of the pump (delivery rate) is control-
led by controlling the current command value of the
solenoid proportional reducing valve attached to the
regulator. The regulator makes positive flow control
(positive control) that increases the delivery rate as
the secondary pressure of the solenoid proportional
reducing valve rises. Since this function permits the
output power of the pump to be varied, it is possible to
attain optimum power according to the operating
condition. Also, since the pump delivers only the
necessary oil flow, the machine does not consume
excessive power.
E215-E235
Back-up total power control
In case the solenoid proportional reducing valve is
disabled, the electric control may be switched over to
the hydraulic control (Back-up mode) if the back-up
select rods (642) of the front and rear regulators are
loosened completely.
In that case, the tilting angle of the pump (delivery
rate) is reduced automatically as the self pump's
delivery pressure P1 and the companion pump's
delivery pressure P2 rise so as to limit the input torque
below a certain level. (The input power is made
constant when the revolution is constant.)
This is the simultaneous total power control that
operates on the sum of the load pressures of two
pumps of the tandem double pump system. When
power control is underway, the regulator of each
pump is controlled at the same tilting angle (delivery
rate). This system automatically prevents the engine
from being overloaded regardless of the loads acting
on the two pumps.
Back-up power shift control
In the back-up operation, the power shift control
(reduced power) is achieved by the primary pressure
that is supplied from PSV1 and PSV2.
The output power of the pumps is controlled to a
constant level by the pressure supplied by PSV1 and
PSV2.
E215-E235 T3-1-13

HYDRAULIC PUMP ASSY

POSITIVE FLOW CONTROL

As shown beside, the delivery rate Q of the pumps is
controlled by the input current I (pilot pressure Pi).

Delivery flow rete Q

Imput current I (Pilot pressure Pi)
R0154

Flow rate increase

612
As the input current I rises, the secondary pressure of 642
P

PSV - 1
the solenoid proportional reducing valve (079) rises. 079 (KDRDE5K) (a5) (a1) A
PH1 625
If the pilot pressure Pi rises, the pilot piston moves (a8)
P1
626
spool (652) to the right and stops where the force of
651
pilot spring (646) balances with the hydraulic power.
If spool (652) moves to the left via lever 2 (613), Cl
652
port is opened to tank port, consequently the pressure
of large bore portion of servo piston (532) is released 898 (pin)
and delivery pressure P1 of small bore portion moves 654
servo piston (532) to the left and increase tilting angle 621 Cl
(Compensating
α).
(α piston) 611
(a4)
Feedback lever (611) is linked with servo piston and 623
sleeve (651), if servo piston moves to the left, sleeve 643 613 646 532 B1

is shifted also to the left by feed back lever. With the (Pilot piston)
movement, sleeve (651) and spool (652) opening R0155

section are gradually closed, and servo piston (532)

rests at the position where it is completely closed.

654

651 652

Flow rate decrease

If the input command current I decreases, the sec-
ondary pressure of solenoid proportional valve also
decreases, and the spool (652) moves to the left.
With the movement of spool (652), the delivery pres-
sure P1 flows into the servo piston large bore cham-
ber via spool through Cl port.
Delivery pressure P1 is led into also small portion of 898
servo piston, but servo piston is moved to the right due
α)
to the different of area and therefore tilting angle (α
625
is decreased. 621 623 626
With the movement of servo piston to the right, the 611 532
sleeve is moved to the left by feed back lever.
And servo piston rests at the position where the Servo piston
Tilting big Tilting small
opening of spool and sleeve are completely closed. R0156
T3-1-14 E215-E235

HYDRAULIC PUMP ASSY

SIMULTANEOUS TOTAL POWER CONTROL AT

BACK-UP OPERATION
When the load pressure rises, as shown in the figure,
the overload of engine is prevented by reducing the tilt

Delivery flow rete Q

angle of pump.
This regulator is of the simultaneous total horse
power control system, the tilt angles (displacement)
of two pumps are controlled to the same value as
calculated by the following formula.

π+P2×q/2π
Tin = P1×q/2π π=(P1+P2)q/2π
π
Delivery pressure (P1+P2)
(q: Displacement)
R0157
The horse power controlling function is the same as
the flow rate control, and explains below briefly. (For
details of movement of parts, refer to Article "Flow
control".)

Prevention of overload Flow return

When the self pump delivery pressure P1 or opposite
pump delivery pressure P2 is raised, P1 and P2 act on
the step section of compensating piston (621), com-
pensating rod (623) is pushed rightward, and moves
to the position where the spring force of outer spring
(625) and inner spring (626) are balanced with the oil
pressure. The movement of compensating rod is
transmitted to spool (652) through lever 1 (612), and
spool (652) moves to the right.
With the movement of spool, the delivery pressure P1
is led into the servo piston large bore section through
Cl port, servo piston moves rightward, the pump
delivery flow rate is reduced, and consequently the
overload of engine is prevented. The movement of
servo piston is transmitted to feed back lever (611)
through the D section, feed back lever (611) moves
spool leftward. Spool continuously moves until the
opening section to sleeve (651) is closed, and rests at
the position where it is completely closed.
When the self pump delivery pressure P1 or opposite
pump delivery pressure P2 is lowered, compensating
rod (623) is pushed back by the spring force of outer
spring (625) and inner spring (626) and lever 1 moves
spool leftward. Consequently the pressure flows into
the tank port through Cl port, the pressure of the large
bore section of the servo piston is released, servo
piston moves leftward, and the pump delivery flow
rate is raised.
The movement of servo piston is transmitted to spool
with the feed back mechanism, and continues the
action until the openings of spool and sleeve are
closed.
E215-E235 T3-1-15

HYDRAULIC PUMP ASSY

BACK-UP FUNCTION (KDRDE5K)

As shown beside, loosen nut (801) and change the a8

position of rod (642). This causes the electric flow PSV

control to be switched to the hydraulic control.

At electric flow control P2
In the electric flow control, the secondary pressure Pi P1 P1 P2

of the solenoid proportional reducing valve is admit-

ted to the pilot piston to perform flow control of the
pump.
In case the solenoid proportional reducing valve is
disabled, the control mode is switched over to the PSV

hydraulic control if rod (642) is switched over.

The primary pressure PSV of the solenoid propor-
tional reducing valve is admitted to pin (898) and
controlled at a constant power level in a power shifted
801
(reduced power) condition.
(KDRDE5K)

642 a8
PSV

898
P2
P1 P1 P2
NOTE - Do not use the back-up select rod (642) when At back-up control
the front and rear regulators are fully tightened or fully
loosened. The pump can not be controlled if the rod
position of the front regulator differs from that of the
rear regulator. Delivery flow rete Q
R0158

Delivery pressure (P1+P2)

R0159
T3-1-16 E215-E235

HYDRAULIC PUMP ASSY

Adjusting the regulator

The regulator may be adjusted in terms of maximum
flow, minimum flow, horsepower (at back-up control)
control characteristics, flow control characteristics
using the adjust screw.

ADJUSTING THE MAXIMUM FLOW

(See HYDRAULIC PUMP-Construction)
Adjust the maximum flow by loosening nut (808) and
by tightening set screw (954) (or loosening it). Tight-

Delivery flow rete Q

ening set screw (954) decreases the delivery rate, as
indicated.
Only the maximum flow varies, but other control
characteristics remain unchanged.

Adjust screw No. 954

No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change Input current I (Pilot pressure Pi)
R0160
Min. increase in delivery flow
l/min 5.8

ADJUSTING THE MINIMUM FLOW

(See HYDRAULIC PUMP-Construction)
Adjust the minimum flow by loosening nut (806) and
by tightening socket screw (953) (or loosening it).
Delivery flow rete Q

Tightening socket screw increases the delivery rate,

as indicated.
Other control characteristics remain unchanged in
the same way as maximum flow adjustment, care
should be used of the fact that overtightening may
increase a required power at the maximum delivery
pressure (at relieving action).

Input current I (Pilot pressure Pi)

Adjust screw No. 953 R0161

No. of turns for tightening 1/4

Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow
l/min 4.6

ADJUSTING THE INPUT HORSEPOWER

(AT BACK-UP CONTROL)
Since the regulator is of total horsepower control type,
turn the adjust screws of both the front (No. 1) and rear
(No. 2) pumps when changing horsepower set val-
ues. Adjust the horsepower settings of both pumps to
a same level. The pressure change values by adjust-
ment are based on two pumps pressurized at the
same time, and the values will by halved when only
one pump is loaded.
E215-E235 T3-1-17

HYDRAULIC PUMP ASSY

Adjusting the Outer Spring (See REGULATOR-

Construction) (At back-up control)
Adjust it by loosening lock nut (630) and by tightening
adjust screw (628) (or loosening it). Tightening the
adjust screw shifts the control chart to the right and

Delivery flow rete Q

increases the input horsepower, as indicated.
Since turning the adjust screw C by N turns changes
the setting of the inner spring, return the adjust screw
(925) by 2.2 turns at first.

Adjust screw No. 628

No. of turns for tightening 1/4
Delivery pressure (P1+P2)
Increase in delivery pressure MPa 1.74 R0162

Increase in input torque Nm 4.6

Adjusting the Inner Spring (See REGULATOR-

Construction) (At back-up control)
Adjust it by loosening nut (801) and by adjust screw
(925) (or loosening it). Tightening the adjust screw
Delivery flow rete Q

increases the flow and then the input horsepower, as

indicated. And the input torque raises.

Adjust screw No. 925

No. of turns for tightening 1/4
Increase in flow l/min 18.4
Increase in input torque Nm 31
Delivery pressure (P1+P2)
R0163

ADJUSTING THE FLOW CONTROL

CHARACTERISTICS (See REGULATOR-
Construction)
Adjust them by loosening nut (801) and socket bolt
(924) (or loosening it). Socket bolt causes the control
Delivery flow rete Q

chart to move to the right as shown. Socket bolt raises

the flow control start pilot pressure. And the delivery
rate increases.

Adjust screw No. 924

No. of turns for tightening 1/4
Increase Pilot pressure Pi MPa 0.13 Input current I (Pilot pressure Pi)
Increase input current I mA 21 mA R0164

Increase in input torque Nm 31

T3-1-18 E215-E235

HYDRAULIC PUMP ASSY

Causes of fault resulting from regulator

When trouble due to this regulator occurs, disassem-

ble and inspect it referring to "Chapter W2-5".

WHEN THE ENGINE IS OVERLOADED

Load every unit of pump, and check on pumps on the
right and left sides for possible damages. When
pumps on both sides are failed, check on them for the
following failures 1), 2). When pump on the one side
is failed, start checking from para. 3).
1. Check that the power shift command current I is
normal.
2. The power shift pressure is low.
• Check the dither of amp.
• Replace solenoid proportional reducing valve.
3. Stick of compensating piston and compensating
rod.
• Disassemble and clean it.
4. Stick of pin (898).
• Disassemble and clean it.

THE MAX. FLOW RATE IS NOT DELIVERED

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

NOTE - When the damage of part is severe, replace

the part with new one.
E215-E235 T3-1-19

HYDRAULIC PUMP ASSY

CONTROL CURVE OF PUMP

Q
L/min

2150 min-1

200 1950 min-1

H/M

100 W

0 P MPa
10 20 30
R0165
T3-1-20 E215-E235

HYDRAULIC PUMP ASSY

UNLOAD VALVE
General view

A2 A1

Dr T

D T

A2 P1 A1 A
P2

P2 P1
A1

A2
Pi2 Pi1
P2 P1

P2' P1'

T Dr

PF1/2 PF1/4

P1' P2'
A2 P2 Dr T P1
A1

A2 A1

VIEW A P2' Pi2 Pi1 P1'

Pi1 Pi2
Hidraulic circuit
R0248

Specifications

240 L/min × 2 (Main line)

Max. flow
30 L/min × 2 (By-pass line)
Max. pressure 37.8MPa
E215-E235 T3-1-21

HYDRAULIC PUMP ASSY

Construction

B Dr T B 351
331
322
151
321
151
361

101

301

A2 P2 A1
P1

362

352
SECTION A-A
B B SECTION B-B
Pi2 Pi1

P2 P1

A A

P2' P1'
261

R0249

101 - Casing 331 - Stopper (Q.ty 2)

151 - Plug (Q.ty 2) 351 - Plug (Q.ty 2)
261 - O-Ring (Q.ty 2) 352 - Plug (Q.ty 2)
301 - Spool (Q.ty 2) 361 - O-Ring (Q.ty 2)
321 - Spring (Q.ty 2) 362 - O-Ring (Q.ty 2)
322 - Spring (Q.ty 2)
T3-1-22 E215-E235

HYDRAULIC PUMP ASSY

NOTE:
E215-E235 T3-2-1

PILOT VALVE

OUTLINE (ATT) Specifications

General view Model PV48K1126A

Operating torque Refer to the curve below

25° 19°
Max. primary pressure 6.9 MPa
SINGLE SINGLE
OPERATION OPERATION Primary pressure 5.0 MPa
ANGLE ANGLE
(PORT 2.4) (PORT 1.3) Rated flow 20 L/min

Weight Approx. 2 kg

The adjust nut Performance characteristics

(Opposing flats: 22)
Fix adjust nut
when the lever is PORT 1.3
installed by means of 4.0 4.0
spanner or the like.
Then tighten the
3.2

Secondary pressure (MPa)

mating lock nut to 3.0 3.0

Operations torque (Nm)

SINGLE OPERATING
41.2 ± 2.9 Nm TORQUE
2.58
R0167

2.0 2.0
34° 34°
SECONDARY
PRESSURE
1.0 1.0
0.85
0.6 1.15
0.96
0 0
0 1.1 2 4 6 7
PUSH-ROD STROKE mm

0 5 10 15 19
Operating angle (deg.)
R0170

PORT 2.4
4.0 4.0

34° 34° 3.2

Secondary pressure (MPa)

3.0 3.0 Operations torque (Nm)

R0168 SINGLE OPERATING
2.82
TORQUE

2.0 2.0
P T SECONDARY
PRESSURE

1.0 1.0
0.85
0.6
1.15
0.96
0 0
0 1.1 2 4 6 8 9.4
PUSH-ROD STROKE mm
1 3 2 4 0 5 10 15 20 25
Hydraulic symbol Operating angle (deg.)
R0169 R0171

Function
Port Tightening Port
size torque (Nm) name LH Pilot Valve RH Pilot Valve
1 Swing left Bucket digging
2 Arm out Boom down
PF 3/8 49 ± 4.9 3 Swing right Bucket dump
4 Arm in Boom up
T Tank port Tank port
PF 1/4 29.4 ± 2.9 P Pilot primary pressure port Pilot primary pressure port
T3-2-2 E215-E235

PILOT VALVE

CONSTRUCTION, FUNCTION AND OPERATION (ATT)

Cross sectional view

312
501

302
Rotating sliding
part, apply
213 grease.
301 Beware of the
assembly
direction
151 212
Apply grease
•
to top
•
• •
• 246
• •
• 218–2
211

214
•
• •
• 218–1

216–2 216–1

241–1
241–2

201–2 201–1

221

231
217 122
Secondary
pressure 101
adjusting shim Not to
121
Designed value 126 be reused
t = 0.4 mm
q.ty 1 125
111
R0172

Apply Loctite #277 to areas marked ✩.

101 - Casing 216–2 - Spring seat 1 (Q.ty 2)

111 - Port plate 217 - Washer 2 (shim) (Q.ty 4)
•
121 - Seal washer (Q.ty 2) • •
• 218–1 - Spring seat 2 (Q.ty 2)
•
122 - O-Ring • •
• 218–2 - Spring seat 2 (Q.ty 2)
125 - Socket bolt; M8×35 (Q.ty 2) 20.6 ± 1.5 221 - Spring (Q.ty 4)
126 - Spring pin 241–1 - Spring (Q.ty 2)
131 - Bushing 241–2 - Spring (Q.ty 2)
•
151 - Plate • •
• 246 - Spring (Q.ty 4)
201–1 - Spool (Q.ty 2) 301 - Joint; M14 47.1 ± 2.9
201–2 - Spool (Q.ty 2) 302 - Circular plate
211 - Plug (Q.ty 4) 312 - Adjust nut; M14 ✩ 68.6 ± 4.9
212 - Push rod (Q.ty 4) 501 - Boots
213 - Seal (Q.ty 4)
214 - O-Ring (Q.ty 4)
216–1 - Spring seat 1 (Q.ty 2)

Note - The parts marked •

• •
• may not to be equipped depending on valve type.
E215-E235 T3-2-3

PILOT VALVE

Construction MAIN FUNCTIONS

The function of spool (201) is to receive the supply
The pilot valve is constructed as shown in the cross-
pressure of the hydraulic pump by port P and admit
sectional view. The casing has a vertical shaft hole in
the hydraulic pressure at port P to output ports (1, 2,
which a reducing valve is assembled.
3, 4) or admit the hydraulic pressure at the output
The reducing valve consists of spool (201), spring
ports to port T. Spring (241) (for secondary pressure
(241) (for secondary pressure setting), spring (221)
setting) acts upon spool (201) and determines the
(for return), spring seat (216), and washer (217). The
output pressure.
spring (241) (for secondary pressure setting) is so set
Push rod (212) that changes the deflection of spring
as to achieve the secondary pressure conversion
(241) (for secondary pressure setting) is inserted in
0.49 ~ 0.98 MPa (varies with the model.). The spool
plug (211) so as to enable smooth movement.
(201) is pressed against push rod (212) by spring
Spring (221) (for return) acts upon casing (101) and
(221) (for return).
spring seat (216) and brings push rod (212) toward
If push rod (212) is pushed down by tilting the control
zero displacement regardless of output pressure, in
part of the handle, the spring seat (216) falls at the
order to positively bring spool (201) back to neutral.
same time and changes a set pressure of spring (241)
The spring also acts as a reactive force that gives the
(for secondary pressure setting).
operator a proper operating feeling.
The casing (101) and the port plate (111) are
provided with an oil inlet (primary pressure) port P
and an outlet (tank) port T. They are further pro-
vided with ports 1, 2, 3, 4 from which secondary
pressure is discharged.

Function

BASIC FUNCTIONS
The pilot valve controls the stroke and the direction of
the control valve spool. This is achieved by applying
the output pressure of the pilot valve to the end of the
control valve spool.
In order to satisfy the functions, the pilot valve is
constructed with the following elements:
1. Inlet port (P) to which the oil of the hydraulic pump
is supplied.
2. Multiple output ports (1, 2, 3, 4) that exert the supply
pressure from the input port upon the end of the
spool of the control valve.
3. Tank port (T) to control the above mentioned output
pressure.
4. Spool that connects the output port with the inlet
port or the tank port.
5. The mechanical means including springs that act
upon the above-mentioned spool, in order to con-
trol the output pressure.
T3-2-4 E215-E235

PILOT VALVE

Now, let us explain the function of the pilot valve, using

the hydraulic diagram (the figure on the right) and the
functional explanation drawing.

1 3
P T

1 Pilot valve 2 Pilot pump

R0173

LEVER IN NEUTRAL
The action of spring (241) (for secondary pressure
setting) that determines the output pressure of the
pilot valve does not act upon spool (201). Therefore,
spool (201) (for return) is pushed up by spring (221)
[spring seat 1 (216)]. The output ports (2, 4) connect
with the T port. The result is that the output pressure
is equal to the tank pressure.

216

241
T
221

201 P

PORT (2, 4)
R0174
E215-E235 T3-2-5

PILOT VALVE

WHEN THE PILOT LEVER IS TILTED

When the lever is tilted and the push rod (212)
strokes, the spool (201) spring seat (216) moves
downward to make the port P to connect with the port
2, 4, with the result that the oil of the pilot pump flows
to the port 2, 4 to produce a pressure.
212

216

T
201

PORT (2, 4) R0175

LEVER HELD
When the pressure at ports (2, 4) rises to a level
equivalent to the action of spring (241) that is set by
tilting the lever, the hydraulic pressure balances the
spring action. When the pressure of ports (2, 4) rises
above a set value, ports (2, 4) and the P port close
while ports (2, 4) and the T port open. When the
pressure at ports (2, 4) falls below a set value, ports
(2, 4) and the P port open while ports (2, 4) and the T
port close. Thus the secondary pressure is kept
constant.

241
T

T PORT
P
T PORT

PORT (2, 4) R0176

OPERATION IN THE AREA WHERE THE

TILTING ANGLE OF THE HANDLE IS LARGE
(VARIES WITH THE MODEL)
If the handle is inclined beyond a certain angle on
certain models, the top end of the spool contacts the
bottom of the bore of the push rod. This keeps the
output pressure connected with the P port pressure.
Furthermore, on a model in which a spring seat and a
spring are built in the push rod, the bottom of the bore
of the push rod contacts the spring if the handle is
turned beyond a certain angle. This causes the sec-
ondary pressure gradient to change by the spring
action. Thereafter, the bottom of the bore of the push
rod contacts the top end of the spring seat, keeping
the output pressure connected with the P port.
T3-2-6 E215-E235

PILOT VALVE

NOTE:
E215-E235 T3-2-7

PILOT VALVE

OUTLINE (TRAVEL) 12.4° ± 0.5 12.4° ± 0.5

Outside view

VIEW FROM MACHINE FRONT SIDE 5

Tightening
Port torque Port Function 4 3
size name
Nm

1 LH travel forward port

2 LH travel reverse port
PF3/8 73.5 ± 4.9 3 RH travel forward port
4 RH travel reverse port
T Tank port

5 Travel pressure sensor port

PF1/4 36.3 ± 2 6 Travel pressure sensor port 2 1
P Pilot primary pressure port 4-Ø11
Through R0177

Specifications Performance characteristics

Type 07291-00000
Secondary pressure Operating torque
Primary pressure 4.9 MPa
MPa Nm
Secondary pressure 0.54 ~ 2.35 MPa 4.90 19.60

Rated flow 10 L/min 4.41 17.64

Weight Approx. 11 kg 3.92 15.68

3.42 13.72
12.7
2.94 11.76
RIGHT LEFT
2.45 9.8
2.35±0.15
1.96 7.84
7.7
1.47 5.83 6.4

0.98 3.92
0.54±0.1
T 0.49 1.96
P
0 0
0 2 4 6 8 10 12
4 6 3 2 5 1 Operating angle (deg.)

Hydraulic symbol Control diagram

R0178 R0179
T3-2-8 E215-E235

PILOT VALVE

CONSTRUCTION (TRAVEL)
Z

13 12 28
36 14
B 33 2 36 33
19
37 26 42
1, 3 30
20 25

34
15
22
21
20 25
20
39
32 17 42
PORT 6
44, 16 40
6 7
33 36 33
18 8
24
A A 25, 42
41 SECTION AA
27
B
4 10, 11
9 31 5 29

35

4-M10
T = 42.1 ± 3.9 Nm
38

24, 41

VIEW Z SECTION BB
R0180

Apply Loctite #262 to areas marked ✩.

1- Orifice (shim) (Q.ty 4)
2- Seat (Q.ty 2) ✩ 14.7 Nm 24 - Plug: PF1/8 (Q.ty 3) 9.8 Nm
3- Orifice (shim) (Q.ty 4) 25 - Plug: PF1/4 (Q.ty 3) 24.5 Nm
4- Spool (Q.ty 4) 26 - Socket bolt: M10×60 (Q.ty 2) 58.8 Nm
5- Body 27 - Flange bolt (Q.ty 4) 4.9 Nm
6- Stopper (Q.ty 4) 28 - Setscrew: M8 (Q.ty 4) 14.7 Nm
7- Spring (Q.ty 4) 29 - Washer (Q.ty 4)
8- Spring (Q.ty 4) 30 - Washer (Q.ty 2)
9- Name plate 31 - Rivet (Q.ty 2)
10 - Shim t = 0.2 (Q.ty 4) 32 - Pin: Ø5 (Q.ty 4)
11 - Shim t = 0.1 (Q.ty 4) 33 - Ball (Q.ty 6)
12 - Cam (Q.ty 2) 34 - Ball (Q.ty 4)
13 - Boots (Q.ty 2) 35 - Ball (Q.ty 4)
14 - Pin (Q.ty 2) 36 - Ball (Q.ty 6)
15 - Cover (Q.ty 2) 37 - U-packing (Q.ty 4)
16 - Piston (Q.ty 4) 38 - O-Ring (Q.ty 4)
17 - Guide (Q.ty 4) 39 - O-Ring (Q.ty 4)
18 - Sleeve (Q.ty 4) 40 - O-Ring (Q.ty 4)
19 - Holder (Q.ty 4) 41 - O-Ring (Q.ty 3)
20 - Ring (Q.ty 12) 42 - O-Ring (Q.ty 3)
21 - Orifice(shim) (Q.ty 4) 44 - Piston assy (Q.ty 4)
22 - Spring (Q.ty 4)
E215-E235 T3-2-9

PILOT VALVE

OPERATION (TRAVEL) • If the cam operates during travel operation, the oil
in the damper chamber is kept from flowing back by
Construction the check valve. Thus the oil flows to part E only
The valve consists of the following parts in terms of from the orifice. Damper action operates by the
hydraulic function: resistance that is built up as the oil passes through
A: Damper section the orifice.
B: Reducing valve section Let us explain the profile of the piston.
C: Shuttle section The upper part of the piston has a diameter of
12 mm, while the lower part of it has a diameter of
11 mm. This results in an areal difference, with the
Operation result that the piston is constantly subject to a
vertical force.
DAMPER SECTION For this reason, the orifice rises by the pressure
caused by the areal difference between the oper-
• If the primary pressure is supplied by P, it is flowed
ating part of the cam and the piston on the opposite
to the damper chamber by way of circuits D and
E . side i.e. the piston follows the cam.
That is to say, constant damper action operates
The pressure is then filled up in the damper cham-
wherever the cam is located.
ber via the orifice and the check valve.
Since the larger diameter of the piston, the cover,
In that case, the air present in the damper chamber
the 11mm diameter part of the piston and the guide
is pushed out to the T port from circuits F and G ,
are manufactured with minimal clearance, only a
in order to prevent the damper characteristics from
little leakage occurs. Consequently, the damper
fluctuating by air mixture.
performance is not affected at all.

CAM

PISTON G
CHECK
COVER
E VALVE

A. DAMPER SECTION

GUIDE

ORIFICE

SPRING FOR
SECONDARY DAMPER
PRESSURE CHAMBER
T
D
B. REDUCING VALVE SECTION

SPOOL P P

SECONDARY PRESSURE PORT

BODY
R0181
T3-2-10 E215-E235

PILOT VALVE

REDUCING VALVE SECTION

At neutral
The primary pressure supplied by P is shut off by the
seal between the circumference of the spool and the
body hole.
The secondary pressure port is connected with the T
port through the vertical hole H and the horizon-
tal hole I in the center of the spool. This causes the
pressure to be reduced to zero.
At operation
If the cam tilts toward the operating direction, the
piston goes down. The spool sub assy moves down.
If the notch J on the circumference of the spool
connects with the secondary pressure port, the pri-
mary pressure supplied by P enters the secondary
pressure port.
In that case, the horizontal hole I enters the hole
of the body and seals it. As the result, the circuit from
the secondary pressure port to the T port is shut off.
If the pressure at the secondary pressure port rises
above the action of the secondary pressure spring,
the spool is pushed up by the pressure. The result is
that the notch J enters the hole of the body, shuts
off the circuit from the primary pressure port to the
secondary pressure port, and causes the horizontal
hole I to connect with the T port to let the pressure
of the secondary pressure port out to the T port.
If the above-mentioned action is repeated, the pres-
sure at the secondary pressure port becomes a level
that balances the compressive load of the secondary
pressure spring proportional to the cam stroke.
The return spring provides proper reactive force and
positively brings the spool of the reducing valve back
to its neutral position.

12

11
RETURN
SPRING

T
I
T

P J
P
J

H
SECONDARY
PRESSURE PORT

R0182
E215-E235 T3-2-11

PILOT VALVE

SHUTTLE SECTION
If pressure is built up at port 1 or 3, the ball is pressed
against the seat by the pressure. The pressure goes
through from port 1 to port 5 (or from port 3 to port 6).
Only a little leakage occurs from port 2 or 4 as the ball
is metallical sealed by the seat.
If pressure occurs at port 2 or 4, the ball is pressed
against the body by the pressure. The result is that the
pressure connects with port 5 from port 2 (with port 6
from port 4).
Only a little leakage occurs at port 1 or 3 as the ball is
metallical sealed against the body.

PORT 2 PORT 1

SEAT BALL

BODY

PORT 4 PORT 3

PORT 6
R0183
T3-2-12 E215-E235

PILOT VALVE

NOTE:
E215-E235 T3-3-1

CONTROL VALVE

OUTLINE

Specifications

Item STD VALVE

Model KMX15YC / B33041
Max. flow L/min 210x2
Main relief valve set pressure MPa 34.3 at 160 L/min
When power boost pressure 37.8 at 140 L/min
Over load relief valve set pressure MPa
Boom H, Bucket H, Arm R 39.7 at 30 L/min
Boom R, Bucket R, Arm H 37.8 at 30 L/min
OPT2 H&R 37.8 at 30 L/min
T3-3-2 E215-E235

CONTROL VALVE

Outside view and hydraulic ports

CT2
CP2 BL
AL
PAL PBL T
As LCs Bs
PBs1 P2
PBs2 Pss PAs T3
CCb Pisc
P1
PB1
(T2)
Aa LCa CRa PLc2
PAa (PBa)
Drd
Ba
CAr P2
Pis PCa
CUT

PAo2 Ao2 Bo2 PBo2

MAIN RELIEF VALVE P1, P2 T (T2)

CT1
CMR2 CMR1 TRAVEL STRAIGHT
PTb TRAVEL LEFT
PL1
Br CP1 Ar
PBr PAr TRAVEL RIGHT SWING
Dra
Drb Bc LCc Ac
BUCKET BOOM
PBc PAC
CONFLUX
Bb LCb CRb
PLc1 ARM
PBb Pab BOOM
Drc
Ab
CCa ARM
ARM PCb P1 CUT
RECIRCULATION
CONFLUX X1
PA1

TB OPTION 2
TB (P4) (P4)

(P4) TB

PBo
ARM PCa
PA1 P2 CUT
CONFLUX

Drd
BOOM PBb ARM
PBa (P4)
PLc2
BUCKET (T3) (P3)
PBc TB

TRAVEL PBr SWING

PBs1
RIGHT

TRAVEL PTb PBL TRAVEL LEFT

STRAIGHT

View A
R0259
E215-E235 T3-3-3

CONTROL VALVE

Port size Tightening torque N m Port name Description

P1 Pump P1 port
P2 Pump P2 port
Ab Boom up port
Bb Boom down port
Ac Bucket dump port
Bc Bucket digging port
Ar Travel right port (forward)
PF1 200 ~ 250
Br Travel right port (reverse)
AL Travel left port (forward)
BL Travel left port (reverse)
Aa Arm in port
Ba Arm out port
As Swing port (right)
Bs Swing port (left)
T2 Tank port
(T3) Tank port
PF3/4 150 ~ 180
P4 Option port
TB Tank port
PF1/2 98 ~ 120 (P3) Option port
PAa Arm in pilot port
PBa Arm out pilot port
PAb Boom up pilot port
PBb Boom down pilot port
PAc Bucket dump pilot port
PBc Bucket digging pilot port
PAr Travel right pilot port (forward)
PBr Travel right pilot port (reverse)
PAL Travel left pilot port (forward)
PBL Travel left pilot port (reverse)
PF3/8 69 ~ 78 PAs Swing right pilot port
PBs1 Swing (left) pilot port 1
PBs2 Swing (left) pilot port 2
PA1 Arm conflux pilot port
PB1 Boom conflux pilot port
PTb Travel straight pilot port
PCa P2 bypass pilot port
PCb P1 bypass pilot port
Pis Arm recirculation pilot port
(PAo2) Option 2 pilot port (A)
(PBo2) Option 2 pilot port (B)
Pisc Swing priority pilot port
PL1 ATT power boost pressure port
Pss Swing low pressure sensor port
Dra Drain port
PF1/4 34 ~ 39 Drb Drain port
Drc Drain port
Drd Drain port
PLc1 Boom lock valve release pilot port
PLc2 Arm lock valve release pilot port
M10 49 ~ 65 T Tank port (Ø 32)
Ao2 Option 2 pilot port (A)
M12 98 ~ 120 Bo2 Option 2 pilot port (B)
T3-3-4 E215-E235

CONTROL VALVE

CONSTRUCTION
273 273
P1,P2 T2 T

TRAVEL TRAVEL
STRAIGHT LEFT
978

TRAVEL SWING
RIGHT 977

BUCKET BOOM
CONFLUX

BOOM ARM

ARM
P1 CUT RECIRCULATION
(ARM CONFLUX) (P2 CUT)

OPTION 2
(P4) TB

I (P3)
R0184

275 274

P4
P3
213 TB
212

275 274
VIEW I
R0185

102
101
974
162 562
515 T2
552
562 CT1 CT2
522
552 P1
512
522

161 P2

T
974

SECTION H-H R0186

E215-E235 T3-3-5

CONTROL VALVE

154 164 101

T T2

PBL PAL

PAs PBs

PBs

Pss

PB1

PBa PAa

PCa Pis

162 (4pc)

PBo PAo

169 155

SECTION A-A R0187

974 154 164 102 974

P2 P1

PTb

973 973

PBr PAr

PBc PAc

973 973

PBb PAb
973
973

PA1 PCb

162 (4pc)
164 154

SECTION B-B R0188

T3-3-6 E215-E235

CONTROL VALVE

203
334
332 166 156
203
340
334
329
PAL 332
327
332 338
601 328
262 327
332
161 262

PLL
512
AL
522 511
CMR1 521
552 CP2
562 CMR2 551
562
164
552
BL 163
522
306 TRAVEL LEFT SPOOL
512
264
205
161
TRAVEL 307 264
STRAIGHT SPOOL PTb 205 PBL

SECTION C-C R0189

203 PBs2
334
Pss
332 PAr 202
PAs 333
338
331
328 336
327 322
332 321
262 331
261
Dra

Ar As
511 511
521 523
551
LCs
CP1
556
164
164
Br Bs

Drb 303 SWING SPOOL

TRAVEL RIGHT SPOOL 306

264 264
PBr PBs
205 205

SECTION D-D R0190

E215-E235 T3-3-7

CONTROL VALVE

201
333 PB 555
331 166
PAc 201
336
322 333
321 331
339
602 324
331
261 321
331
161
261
161 511
521
Ac CCb 551
511
521 164
551 305 BOOM CONFLUX
SPOOL
LAc 551
164
164
165
Bc 153
312 ROD SPOOL
161 164
154

(T3)
BUCKET SPOOL 304 264
PBc 205
602
166
264 205
156
SECTION E-E
R0191

331 201 333 333 201 331 PLc1 Drc

(PLc2) (Drd)
336
322 PAb PAa
336
321
322
331
321
261
SECTION K-K
602
R0193
211
331
163
261
162 302 ARM
Aa SPOOL
164 CRb 511

556 521

524 551
LCb LCa
514 164
551 514
164 CRa 556
Bb
524
521 Pisc
511 164
BOOM 301
SPOOL PBb PBa

211
602 205 264 163 205 264

SEZIONE F-F R0192

T3-3-8 E215-E235

CONTROL VALVE

Pcb Pis

204 204
334 334
332
332 332
337 337
602 326
326 325
325 332
262 262
311 ARM RECIRC. SPOOL
P1 BYPASS CUT SPOOL 309 CAr
161 Ab 562
552
163
522
162 512
168
158 X1
164
551 Ba
CCa
521 310 P2 BYPASS CUT SPOOL
511
ARM CONFLUX SPOOL 308 602
162 262
262 332
326 332 325
337 326
325 337
332 332
334 334
204 PA1 PCa 204

SECTION G-G
R0194

PAo2

212 214

274
275
Ao2
(P4)

Bo2

275 274

PBo2

SECTION J-J
R0195
E215-E235 T3-3-9

CONTROL VALVE

Apply Loctite #262 to areas marked ✩.

101 - Casing A 311 - Arm recirculation spool

102 - Casing B 312 - Rod spool
153 - Plug; PF1 370~410 Nm 321 - Spring (arm, boom, bucket, swing outer) (Q.ty 4)
154 - Plug; PF3/4 (Q.ty 5) 220~250 Nm 322 - Spring (boom, arm, bucket, swing inner) (Q.ty 4)
155 - Plug; PF1/2 110~130 Nm 323 - Spring (boom conflux outer)
156 - Plug; PF3/8 (Q.ty 2) 69~78 Nm 324 - Spring (boom conflux inner)
158 - Plug; PF1/8 13~17 Nm 325 - Spring (arm conflux, cut, arm recirculation outer)
161 - O-Ring (Q.ty 7) (Q.ty 4)
162 - O-Ring (Q.ty 12) 326 - Spring (cut, arm recirculation, arm conflux inner)
163 - O-Ring (Q.ty 4) (Q.ty 4)
164 - O-Ring (Q.ty 16) 327 - Spring (travel outer, travel straight outer) (Q.ty 3)
165 - O-Ring 328 - Spring (travel inner) (Q.ty 2)
166 - O-Ring (Q.ty 3) 329 - Spring (travel straight inner)
168 - O-Ring 331 - Spring seat (Q.ty 10)
169 - O-Ring 332 - Spring seat (Q.ty 14)
201 - Spring cover (Q.ty 4) 333 - Spacer bolt (arm, boom, bucket, swing, boom conflux)
202 - Spring cover sw. sub (Q.ty 5) ✩ 16~18 Nm
203 - Spring cover (Q.ty 3) 334 - Spacer bolt (travel, arm conflux, cut, arm recirculation,
204 - Spring cover (Q.ty 4) travel straight) (Q.ty 7) ✩ 16~18 Nm
205 - Spool cover (Q.ty 8) 336 - Stopper (arm, boom, bucket, swing) (Q.ty 4)
211 - Lock valve selector sub assy (Q.ty 2) 337 - Stopper (arm conflux, cut, arm recirculation) (Q.ty 4)
212 - Plate 338 - Stopper (travel) (Q.ty 2)
213 - Plate 339 - Stopper (boom conflux)
214 - Control valve for option 2 340 - Stopper (travel straight)
261 - O-Ring (Q.ty 5) 511 - Load check valve (poppet) (D=25) (Q.ty 8)
262 - O-Ring (Q.ty 7) 512 - Load check valve (poppet) (D=20) (Q.ty 5)
264 - O-Ring (Q.ty 8) 514 - Load check valve (poppet) (lock valve) (Q.ty 2)
273 - Socket bolt; M8 × 25 (Q.ty 40) 25~34 Nm 521 - Spring (Q.ty 7)
274 - Socket bolt; M12 × 25 or 120 (Q.ty 4) 98~120 Nm 522 - Spring (Q.ty 5)
275 - Socket bolt; M12 × 35 (Q.ty 4) 98~120 Nm 523 - Spring
301 - Boom spool assy 524 - Spring (Q.ty 2)
302 - Arm spool assy 551 - Romh plug; M27 (Q.ty 8) 230~260 Nm
303 - Swing spool 552 - Romh plug; M22 (Q.ty 5) 130~150 Nm
304 - Bucket spool 555 - Plug 69~78 Nm
305 - Boom conflux spool 556 - Plug (lock valve) (Q.ty 3) 230~260 Nm
306 - Travel spool (Q.ty 2) 562 - O-Ring (Q.ty 5)
307 - Travel straight spool 601 - Relief valve (main) 69~78 Nm
308 - Arm conflux spool 602 - Relief valve (over load) (Q.ty 6) 69~78 Nm
309 - Bypass cut spool (P1) 973 - Socket bolt; M14 × 140 (Q.ty 6) 140~180 Nm
310 - Bypass cut spool (P2) 974 - Socket bolt; M14 × 100 (Q.ty 2) 140~180 Nm
T3-3-10 E215-E235

CONTROL VALVE

Main relief valve (Two step relief) (601)

123 124 125 561 562 611 104 103 614 661 613

512 541 521 121 122 621 663 163 664 673 652 671

R0196

103 - Plug M27 69~78 Nm 562 - Back up ring

104 - Adjust screw 611 - Poppet
121 - C-Ring 613 - Stopper
122 - Spacer 614 - Piston
123 - C-Ring 621 - Spring
124 - Filter stopper 652 - Adjust screw
125 - Filter 661 - O-Ring
163 - O-Ring 663 - O-Ring
512 - Plunger 664 - O-Ring
521 - Spring 671 - Lock nut; M14 27~31 Nm
541 - Seat 673 - Lock nut; M24 46~52 Nm
561 - O-Ring

Arm spool (302)

359 302 R0197

302 - Spool
359 - Plug
E215-E235 T3-3-11

CONTROL VALVE

Over load relief valve (602)

564 563 161 123 124 125 101 162 621 661 612

301 541 511 522 521 561 562 611 102 651 671
R0198

101 - Body; M27 69~78 Nm 541 - Seat

102 - Plug; M27 69~78 Nm 561 - O-Ring
123 - C-Ring 562 - Back up ring
124 - Filter stopper 563 - O-Ring
125 - Filter 564 - Back up ring
161 - O-Ring 611 - Poppet
162 - O-Ring 612 - Spring seat
301 - Piston 621 - Spring
511 - Plunger 651 - Adjust screw
521 - Spring 661 - O-Ring
522 - Spring 671 - Lock nut; M14 27~31 Nm

Boom spool (301)

B352 B340 B317 B301 B316 B330 B315 B320 B353

R0199

B301 - Spool B330 - Spring B2

B315 - Plunger 1 B340 - Spring B3
B316 - Plunger 2 B352 - Plug 1 88~98 Nm
B317 - Plunger 3 B353 - Plug 2 88~98 Nm
B320 - Spring B1
T3-3-12 E215-E235

CONTROL VALVE

Lock valve selector sub assy (211)

L101

L541

L162 PLC1(PLC2)

L163

L171 Drc(Drd)

L511

L512

L161

L201
R0200

L101 - Casing L201 - Plug; M27 68.6~78.4 Nm

L161 - O-Ring L511 - Spool
L162 - O-Ring (Q.ty 3) L512 - Spring
L163 - O-Ring (Q.ty 2) L541 - Bushing
L171 - Socket bolt; M6 × 45 (Q.ty 4) 9.8~13.7 Nm
E215-E235 T3-3-13

CONTROL VALVE

Control valve for option 2 (214)

P202
P334
PA0 PA0
P337

P323
P324
P333
P271
Po'
P337

P261 P603 P161

P101 P512 TA' TA
A0
P301 P522
Po
P561 P161
P551
SECTION B-B
Po' Po

P161
Bo
TB' TB

PA0 P262
PBo P603 PBo

P204 SECTION A-A

R0201

Apply Loctite #262 to areas marked ✩.

P101 - Casing P333 - Stopper

P161 - O-Ring (Q.ty 3) P334 - Spacer bolt ✩ 16~18 Nm
P202 - Spring cover P337 - Spring seat
P204 - Spool cover P512 - Poppet
P261 - O-Ring P522 - Spring
P262 - O-Ring P551 - Romh plug; M30 310~350 Nm
P271 - Socket bolt; M8 × 25 (Q.ty 4) 25~34 Nm P561 - O-Ring
P301 - Spool P603 - Relief valve (over load) (Q.ty 2) 69~78 Nm
P323 - Spring (inner) P991 - Name plate
P324 - Spring (outer) P992 - Rivet (Q.ty 2)
T3-3-14 E215-E235

CONTROL VALVE

HYDRAULIC CIRCUIT

601 512 307 306

303

54

TRAVEL 511 TRAVEL

STRAIGHT LEFT
51

306
56
512
TRAVEL
RIGHT SWING
55

52 305
53
304 511
BOOM
602
511 CONFLUX
BUCKET
(HEAD SIDE) Bc 302
(ROD SIDE) Ac

511
602

BOOM ARM
(ROD SIDE) Bb Aa (HEAD SIDE)

301 602
60
602
602 211
602 512 514
(HEAD SIDE) Ab Ba (ROD SIDE)

CUT 602
(CUT)
(ARM
ARM
CONFLUX)
RECIRC.
310 61 311
211

514 309 308 511 OPTION 2

P603 P301 P603

R0202
E215-E235 T3-3-15

CONTROL VALVE

051 - Main passage (P1 side) 0306 - Travel spool

052 - Bypass circuit (P1 side) 0307 - Travel straight spool
053 - Parallel circuit (P1 side) 0308 - Arm conflux spool
054 - Main passage (P2 side) 0309 - P1 bypass cut spool
055 - Bypass circuit (P2 side) 0310 - P2 bypass cut spool
056 - Parallel circuit (P2 side) 0311 - Arm recirculation spool
060 - Arm recirculation passage 0511 - Poppet (D=25)
061 - Passage 0512 - Poppet (D=20)
211 - Lock valve selector spool 0514 - Lock valve poppet
301 - Boom spool 0601 - Main relief valve
302 - Arm spool 0602 - Port relief valve
303 - Swing spool P301 - Spool for option valve
304 - Bucket spool P603 - Over load relief valve for option valve
305 - Boom conflux spool
T3-3-16 E215-E235

CONTROL VALVE

OPERATION
Control valve in neutral
The oil delivered from the hydraulic pump P1 flows
into P1 port of the control valve, passes through the
travel straight spool (307) and main passage (51), is
led into bypass circuit (52) which passes through the
travel right, bucket and boom control sections and P1
bypass cut spool (309).
And the oil is returned to hydraulic tank from tank
port T.
The oil delivered from the hydraulic pump P2 also
passes through main passage (54) and is led into
bypass circuit (55) which passes through the travel
left swing, boom conflux and arm control sections and
P2 bypass cut spool (310) like the oil delivered from
the hydraulic pump P1. And the oil is returned to
hydraulic tank from tank port T.

307 T 309

T2

P1

P2
T

(51) (52) (54) (55) 310

Oil flow from P1 pump Oil flow from P2 pump

R0203
E215-E235
CONTROL VALVE
Functions for travel action
AT INDEPENDENT TRAVEL
If travel operation (forward) is performed, the second-
ary pilot pressure from ports 2 and 4 of the travel
pilot valve acts upon ports PAr and PAL of the control
valve and moves the right and left travel spools (306).
The pressurized oil delivered by pump P1 flows into
the main passage (51) past the travel straight spool
(307), passes between the outer circumference of the
right travel spool (306) and the casing and is supplied
to the right travel motor B by way of port Ar.
In the meantime, the pressurized oil delivered by
pump P2 passes between the outer circumference of
the left travel straight spool (306) and the casing, runs
RIGHT TRAVEL MOTOR
VA VB
306
Br
PBr
51 52
T3-3-17
to port AL and is supplied to the left travel motor VB
side, the same way as the pressure oil by pump P1.
Meanwhile, the oil which has returned from the right
and left travel VA side passes between the outer
circumference of the right and left travel spool (306)
and the casing and returns to the hydraulic tank via
the tank port T of the low pressure circuit D.
At reverse travel action (when the secondary pilot
pressure acts upon ports PBr and PBL of the control
valve), the pressurized oil works the same way as in
the forward travel action.
Ar
PILOT PORT
PAr
51
R0204
T3-3-18 E215-E235

CONTROL VALVE

TRAVEL STRAIGHT VALVE SWITCHING AT

TRAVEL
When the actuator other than that for travelling and
travelling are simultaneously operated, the pilot sec-
ondary pressure of solenoid proportional valve A4
acts on PTb port of the control valve, moves travel
straight spool (307) rightward to the position (II).
The result is that the pressurized oil delivered by
pump P1 flows from A to B in most amount of oil and
becomes the pressure for the actuators except one
for travel action.
The pressure oil delivered by pump P2 flows, in most
amount of oil, in the C➝D direction and the main
passage (54), becomes the oil pressure for the right
travel and the left travel motions and realizes simulta-
neous operation of the actuator and travel action.
(Travel straight function)
Furthermore, the secondary pressure of solenoid
proportional valve A4 is pressurized and the pressure
moves travel straight spool (307) rightward to the
position (III).
Passages A to D are connected to T port, and the
pressure of all circuits are unloaded. (Unloaded
function)
NOTE - Pressure release operation can be operated
with hidden mode of gauge cluster.

P2 P1
CMR2 CMR1

CA
T

PTb

DB
T
T C D A B Usual Position ( I )

CA
T

DB

Travel straight Position ( II ) At travel straight

CA
T

DB

Pressure release postion ( III ) At unload

R0205
E215-E235 T3-3-19

CONTROL VALVE

Bucket

WHEN THE BUCKET IS DIGGING

When the bucket is digging, secondary pilot pressure
coming from port c of the RH pilot valve enters port
PBc of the control valve and moves the bucket spool
(304) to the left.
The pressure oil delivered by pump P1 flows to the
bypass circuit (52) past the main passage (51), but
since it is blocked by the bucket spool (304) that has
shifted, it pushes the check valve CP1 open, enters
the parallel circuit (53), pushes the load check valve
LCc open, goes between the outer circumference of
the bucket spool (304) and the casing by way of the U-
shaped passage and is supplied to the bucket cylin-
der head (H) via port Bc.
In the meantime, the oil which has returned from the
bucket cylinder rod side goes between the outer
circumference of the bucket spool (304) and the
casing through the port Ac and returns to the hydrau-
lic oil tank by way of the low pressure circuit D and the
tank port T.

D (52) (53) 304

PILOT PORT

PAc PBc

Ac Bc
U-SHAPED PASSAGE

LCc

R H

BUCKET CYLINDER
R0206
T3-3-20 E215-E235

CONTROL VALVE

WHEN THE BUCKET IS DUMPED

When the bucket is dumped, secondary pilot pres-
sure from port e of the RH pilot valve enters port PAc
of the control valve and moves the bucket spool (304)
to the right.
The pressure oil delivered by the pump P1 flows to the
bypass circuit (52) through the main passage (51), but
since it is blocked by the bucket spool (304), it pushes
the check valve CP1 open, enters the parallel circuit
(53) the load check valve LCc open, goes between
the outer circumference of the bucket spool (304) and
the casing via the U-shaped passage and supplied to
the bucket cylinder rod (R) via port Ac.
In the meantime, the oil which has returned from the
bucket cylinder head goes between the outer circum-
ference of the bucket spool (304) and the casing
through the port Bc and is supplied to the hydraulic oil
tank by way of the low pressure circuit D and the tank
port T.

(52) (53) D 304

PBc
PAc

Ac

U-SHAPED PASSAGE
Ac Bc

LCc

R H

BUCKET CYLINDER
R0207
E215-E235 T3-3-21

CONTROL VALVE

Boom

WHEN THE BOOM IS UP

When the boom is up, secondary pilot pressure from
port f of the RH pilot valve enters port PAb of the
control valve and moves the boom spool (301) to the
right. It also acts upon port PB1 (Refer to next page)
and change over the boom conflux spool (305).
And at the same time, the pilot secondary pressure
acts on PCa port of the control valve and switches P2
bypass cut spool (310).
The pressure oil delivered by pump P1 flows into
bypass circuit (52) through main circuit (51), but since
the circuit is cut with boom spool (301), the pressure
oil opens check valve CP1 and enters in parallel
circuit (53), and opens load check valve LCb and
flows in the chamber BH through U-shaped passage
and between the outer surface of boom spool (301)
and the casing, then opens lock valve poppet CRb
(514) and finally is led in the boom cylinder head (H)
side through port Ab. Meanwhile, the oil port Bb which
returns from the boom cylinder rod (R) goes between
the outer circumference of the boom spool (301) and
the casing, flows into the tank port T via the low
pressure circuit D and returns to the hydraulic tank.

INSIDE CONFLUX PASSAGE (53) 301 D

CHAMBER E

PAb PBb

BOOM CYLINDER CHAMBER BH (Ab) Bb

514

R R LCb U-SHAPED PASSAGE

H H

R0208
T3-3-22 E215-E235

CONTROL VALVE

CONFLUX FOR BOOM UP

The oil delivered by the pump P2 flows into the main
passage (54), but since the bypass circuit (55) and the
tank circuit are closed by the P2 bypass cut spool
(310) which has shifted as explained in the previous
page the oil opens check valve CP2 at down stream
of travel spool and enters the parallel circuit (56).
The oil then pushes the load check valve CCb open,
passes between the outer circumference of the boom
conflux spool (305) and the casing, enters port Ab
through the conflux passage in the casing and com-
bines with the pressure on the pump P1 side.

P2 BYPASS CUT SPOOL

(55) 310
TANK PASSAGE
Ba

Pca

CONFLUX CHECK VALVE

CCb (56)

U-SHAPED PASSAGE

PB1

305 To port Ab through the conflux passage in casing

BOOM CONFLUX SPOOL

R0209
E215-E235
CONTROL VALVE
WHEN THE BOOM IS DOWN
If the boom down action is performed, the secondary
pilot pressure from port d of the RH pilot valve acts
upon port PBb of the control valve and lock valve
selector port PLc1 and shifts the boom spool (301) to
the left, it also change over the lock valve.
The pressure oil delivered by the pump P1 flows into
the bypass circuit (52) through the main passage (51),
but since it is blocked by the boom spool (301), it
pushes the check valve CP1 open, enters the parallel
circuit (53), pushes the load check valve LCb open,
enters the U-shaped passage, goes between the
outer circumference of the boom spool (301) and the
casing and is supplied to the boom cylinder rod side
via port Bb.
On the other hand, the return oil from the boom
cylinder (H) side flows in the control valve through port
Ab. The lock valve poppet CRb (514) is located just
before boom spool (301), but since the pilot second-
ary pressure acts on PLc1 port and the lock valve
selector spool is switched and the back pressure of
lock valve poppet CRb (514) is connected to Drc, the
valve opens.
D 301
BOOST CHECK
LOCK VALVE
SELECTOR SPOOL
PLC1
Drc
LOCK VALVE
SELECTOR
CHAMBER
BOOM CYLINDER BH
R R
H H
T3-3-23
And the return oil enters in the chamber BH, and flows
in the chamber E inside of boom spool (301) through
the circular notch of boom spool (301). Since the
returned oil has sufficient pressure by the weight of
the boom, arm, etc., it pushes the poppet on the right
of the illustration through in the spool, passes through
its outer circumference and is supplied to the boom
cylinder (R) side as the hydraulic oil for boom down
motion. (Boom fixed recirculation function).
Some of the return oil from the head end of the boom
cylinders forces open the boost check valve, and
flows through the low pressure circuit D to the tank
port T, and back to the hydraulic oil tank. The purpose
is to allow excess return oil to escape to the tank.
This excess oil is caused by the fact that the area of
the piston at the head end is larger than the area of the
piston at the rod end.
The boost check valve acts on oil flowing to the tank
to secure an adequate amount of recirculating oil.
CHAMBER
E
CONFLUX
PASSAGE
IN CASING (52) (53)
PBb
Bb
(Ab)
514 LCb U-SHAPED PASSAGE
R0210
T3-3-24 E215-E235

CONTROL VALVE

Arm

ARM OUT OPERATION

If arm out operation is performed, the secondary pilot
pressure from port d of the LH pilot valve acts upon
ports PBa and PA1,PCb of the control valve. (refer to
next page)
The pressure oil which enters port PBa shifts the arm
spool (302) leftwards. The pressure oil which enters
port PA1 changes over the arm conflux spool (308).
And, the arm out secondary pressure after high
pressure selection in the proportional valve block acts
on PCb port of the control valve and switches P1
bypass cut spool (309).
The pressure oil delivered by pump P2 flows into the
bypass circuit (55) by way of the main passage (54),
but since it is blocked by the arm spool (302), it pushes
the check valve CP2 open, flows into the parallel
circuit (56), pushes the load check valve LCa open,
goes between the outer circumference of the arm
spool and the casing by way of the U-shaped pas-
sage, runs into chamber AR, pushes the lock valve
poppet CRa (514) open and is supplied to the arm
cylinder R side via port Ba.
In the meantime, the oil which returns from the arm
cylinder (H) side passes between the outer circumfer-
ence of the arm spool (302) and the casing by way of
the port Aa, flows into the tank port T from the low
pressure circuit D and returns to the hydraulic oil tank.

ARM CYLINDER

H R

CHAMBER
302 LCa 514 AR
(Ba)

Aa

PAa
PBa

D U-SHAPED (55) (56)

PASSAGE
INSIDE
CONFLUX PASSAGE
R0211
E215-E235 T3-3-25

CONTROL VALVE

ARM OUT CONFLUX

In arm out operation, the oil delivered by pump P1
flows into the bypass circuit (52) through the main
passage (51), but since the bypass circuit (52) and the
low pressure circuit D are blocked by the bypass cut
spool (309), it does not run into the low pressure
circuit D.
Meanwhile, since the arm conflux spool (308) has
now been changed over, the pressure oil of the
bypass circuit (52) goes between the outer circumfer-
ence of the arm conflux spool (308) and the casing.
Part of the delivered oil passes through the parallel
circuit (53) and the restrictor, combines with the
pressure oil of the bypass circuit (52), pushes the
conflux check poppet CCa open, enters port Ba by
way of the conflux circuit in the casing and finally
combines with the pressure oil on the pump P2 side.

To port Ba through the conflux

P1 CUT passage in the casing
309 (52) 308

PCb
PA1

(53) CCa
R0212
T3-3-26
CONTROL VALVE
WHEN THE ARM IS IN (UNDER LIGHT LOAD)
The return oil from the arm cylinder (R) side is
recirculated into the cylinder (H) side in the control
valve.
If the arm in operation is performed, the secondary
pilot pressure coming out of port f of the LH pilot
valve acts upon the PAa port of the control valve and
the PLc2 port of the lock valve selector. This causes
the arm spool (302) to move to the right and changes
the lock valve selector spool (211).
The pressure oil delivered by the pump P2 flows into
the bypass circuit (55) past the main passage (54),
but since the bypass circuit (55) is blocked by the arm
spool (302), the oil pressure pushes the check valve
CP2 open, flows into the parallel circuit (56), pushes
the load check valve LCa open, goes between the
outer circumference of the arm spool (302) and the
casing through the U-shaped passage and is supplied
to the arm cylinder (H) side via port Aa.
Meanwhile, the oil which has returned from the arm
cylinder (R) side enters the control valve through the
port Ba.
The lock valve poppet CRa (514) is located just before
arm spool (302), but since the pilot secondary pres-
E215-E235
sure acts on PLc2 port and the lock valve selector
spool is switched, lock valve poppet (514) opens and
the pressure is led into chamber AR. In addition, the
return oil has sufficient pressure because of the
weight of the arm, etc., consequently the secondary
pressure is led in the arm spool (302).
Consequently, the return oil from the arm cylinder (R)
side passes through the inside of arm spool and notches
on the arm spool, and flows through recirculation circuit
(60) and led in arm recirculation spool (311).
In that case, the secondary pressure of the solenoid
proportional valve A6 is acting on the Pis port of the
control valve and the arm recirculation spool (311) is
in position (II). (Usual recirculation)
Therefore, the oil pressure enters the passage (61)
through the inside of the arm recirculation spool (311),
pushes open the arm recirculation check valve pop-
pet (512) and is supplied once again to the arm
cylinder (H) as the operating oil for arm digging
operation. (Arm recirculation function)
Part of the hydraulic oil led to arm recirculation spool
(311) flows into tank port T from low pressure circuit
D and returns to the hydraulic oil tank.
E215-E235 T3-3-27

CONTROL VALVE

PLc2
Drd

LOCK VALVE
SELECTOR
ARM CYLINDER

LOCK VALVE
H R CHAMBER SELECTOR
514 AR SPOOL

Aa

PAa

302 (60) (56) (55)

311 CAr (61) Ba

Pis

D
(60)
D

Pis
(61)
CAr

Position ( II )
Usual recirculation
R0213
T3-3-28
CONTROL VALVE
WHEN THE ARM IS IN (UNDER HEAVY LOAD)
The arm oil recirculation function is effective when
operating the arm cylinder speedily under a light load,
but under a heavy load (when heavy duty is required),
this function wastes power.
When the arm is under a heavy load, that is, when no
recirculation occurs, the oil supply passage to the arm
cylinder is the same as during recirculation described
above, but the return oil passage is different.
In a heavy duty condition [The pump pressure=Arm
cylinder (H) pressure is more than 19.6 MPa], the
secondary pressure of the solenoid proportional
valve A6 that acting on the Pis port is reduced and the
arm recirclation spool (311) is switched to position (I).
As the result, the passage (61) connects with the low
pressure circuit D. Then the oil returning from the arm
cylinder (R) runs from the low pressure circuit D to the
E215-E235
tank port T and returns to the hydraulic oil tank. The
result is that no oil is supplied to the arm cylinder (H).
(Recirculation cut)
When the load on the arm cylinder head side (H)
becomes higher, the secondary pressure delivered
by the travel straight proportional valve A4 and P1 by-
pass cut valve D contained in the proportional valve
block, together with the recirculation cut valve above
mentioned acts on PTb and PCb ports on the control
valve, and changes the travel straight spool into the
position (travel straight position) in (II), and finally
changes the P1 by-pass cut spool (309).
Consequently, the pressure oil between pump P1 and
P2 is confluxed in the parallel circuit (56) contained in
the control valve, and supplied into the arm cylinder
head side (H) (Sequence conflux).
E215-E235 T3-3-29

CONTROL VALVE

PLc2

Drd

LOCK VALVE
SELECTOR
ARM CYLINDER

H R CHAMBER LOCK VALVE

514 AR SELECTOR
SPOOL
Aa

PAa

ARM SPOOL 302 (60) (56) (55)

CAr (61) Ba

311

Pis

(60)
D
D

Pis

(61)
CAr
Position (I)
Recirculation cut
R0214
T3-3-30 E215-E235

CONTROL VALVE

SIMULTANEOUS OPERATION OF SWING AND

ARM IN
If the swing and arm in actions are performed at the
same time, the hydraulic oil from pump P2 passes
through the parallel circuit (56) and flows into the
swing motor and the arm cylinder at the same time.
However, since the swing system is more heavily
loaded than the arm system at the start of swing action
and during arm in (at light load), most of the hydraulic
oil flow to the arm cylinder that is lighter loaded.
This causes the simultaneous operation to deterio-
rate.
In order to improve such a condition, the load on the
arm in side is increased intentionally so the simultane-
ous operation of swing and arm in motions is per-
formed easily.

Swing priority
In the above condition, the system detects the pilot
pressure that actuates the swing spool. The second-
ary pressure of the solenoid proportional valve A6
acts upon the Pis port of the control valve and
changes the arm recirculation spool (311) to position
(III) (Forced recirculation).
The result is that the hydraulic oil flowed into arm
recirculation spool (311) is higher on the arm cylinder
(R) because the passage to the arm cylinder (H) and
the passage to the low pressure circuit D are re-
stricted. The result is that the pressure on the arm
cylinder (H) side rises which in turn increases the
operating pressure for the arm in operation.
And the pressure oil more than that swing side flows,
making the swing priority control possible.
And swing pilot pressure is led from "Pisc" port to sub-
spool in arm spool, the pressure of arm cylinder head
(H) rises higher by restricting opening of arm spool
circuit according to swing pilot pressure, as a result
the oil P2 pump flows preferentially into swing circuit.
E215-E235 T3-3-31

CONTROL VALVE

PLc2
Drd

LOCK VALVE
SELECTOR
ARM CYLINDER

H R CHAMBER LOCK VALVE

514 AR SELECTOR
SPOOL
Aa Pisc

PAa

ARM SPOOL 302 (56) (56) (55)

CAr (61)
Ba

(311)

Pis

D
D (60)

Pis

(61)
CAr
Position ( III )
Forced recirculation
R0215
T3-3-32 E215-E235

CONTROL VALVE

Swing action

If swing action is performed, the secondary pilot
pressure from port c or e of the LH pilot valve acts
upon port PAs, PBs1 or PBs2 of the control valve and
shifts the swing spool (303) rightward or leftward.
The oil delivered by pump P2 enters the bypass circuit
(55) past the main passage (54), but since the circuit
is shut off as the swing spool (303) is shifted, the
pressure pushes the check valve CP2 open, enters
the parallel circuit (56) and pushes the swing load
check valve LCs open. The pressure, which enters
the U-shaped passage in the swing spool (303),
passes between the outer surface of the swing spool
(303) and the casing and is supplied to A or B of the
swing motor from the As port or the Bs port.
In the meantime, the oil which has returned from the
B or A side of the swing motor passes between the
outer circumference of the swing spool (303) and the
casing through the port Bs or As, flows from the low
pressure circuit D to the tank port T and returns to the
hydraulic oil tank.

P2 SIDE PARALLEL CIRCUIT

(56)
A B

U-SHAPED PASSAGE SWING MOTOR

FOR SWING MOTION LCs
AS BS

303
PBs2
Pss PAs

PBs1

(55)

R0216
E215-E235
CONTROL VALVE
Functions of lock valve
The lock valve (514) is housed in between the arm
cylinder rod side (R) and the arm spool (302) on the
control valve, and the leak is reduced by the hold
pressure from the cylinder.
Similarly, the lock valve (514) is housed in between
the boom cylinder rod side (H) and the boom spool
(301) on the control valve, and the leak is reduced
caused by the hold pressure from the cylinder.
BOOM CYLINDER CHAMBER
HEAD (H) SIDE RH 514
(301)
T3-3-33
WHEN MAIN SPOOL IS AT NEUTRAL POSITION
The following explains the boom spool (301).
(Same as the arm spool (302) )
When the boom spool (301) is placed on the neutral
position, it is held on the position shown in the Figure
below.
That is, the lock valve sub-spool (L511) is pushed
against the bushing (L541) by the spring (L512).
In this position, the hold pressure from the boom
cylinder head side (H) is led into b through the
passage a of bushing (L541) and around the spool
(L511) from the passage Sa, then the lock valve
poppet (514) is pushed down, resulting in the seat
condition, because the pressure flows through the
passage Sb into chamber RH, consequently the leak
is reduced to the minimum.
PLc1
L511 L512
Drc
Sb
Sa
a b L541
R0217
T3-3-34
CONTROL VALVE
AT BOOM LOWER ACTION
The secondary pilot pressure from port d of the RH
pilot valve acts upon the PBb port of the control valve
and the PLc1 port of the lock valve selector and shifts
the boom spool (301) to the right. At the same time,
the pressure shifts the spool (L511) of the lock valve
selector to the right.
As the spool (L511) is shifted, the orifice a in the
bushing (L541) closes. This shuts off the continuity
from passage Sa to passage Sb in the lock valve
selector (212) and the hold pressure received from
the boom cylinder (H) side stops to act upon the
chamber RH of the lock valve poppet (514).
As the spool (L511) moves, continuity is established
from the orifice b of the bushing (L541) to the drain
port Drc through the inside of the bushing (L541).
BOOM CYLINDER
HEAD (H) SIDE CHAMBER
RH 514
Pressurized
part of poppet
(514)
PBb { PAa
301
E215-E235
This causes the orifice b of the bushing (L541) to
connect with the passage Sb, the spring chamber of
the lock valve poppet (514) and the low pressure
circuit. The lock valve poppet (514) is received by the
ring-shaped pressure bearing area that consists of
the guide diameter and the seat diameter of the lock
valve poppet (514), so that the lock valve poppet is
pushed open upwards to release the lock function.
The operation described above is performed before
the opening (meter out opening) which is used to
return the return oil from the boom cylinder (H) side of
boom spool (301) to the tank while performing the
boom lower operation. Therefore, the action does not
affect the controllability of the boom lower motion.
PLc1 L511 L512
Drc
Sb
Sa
a b L541
R0218
E215-E235 T3-3-35

CONTROL VALVE

Operation of main relief valve B A

The main relief valve is built in casing and operates as R

follows:
P

1. The pressure oil P is filled up in chamber A through

the orifice B of the plunger (512) and seats the
PL
plunger (512) securely against the body (541).
541 512
R0219

2. When the hydraulic pressure of P reaches a set

B D
pressure of the spring (621), it pushes open the
poppet (611) through the orifice B and flows
R
through the hole D to R.
P

PL 621
611
R0220

3. When the poppet (611) opens, the pressure in A

chamber A falls, which causes the plunger (512) to
open and the pressure oil of port P to flow directly R
to R.
P

512 611 PL
R0221

PRESS THE BOOST

Press the boost button, and the pilot pressure enters R
in PL port. The pilot pressure pushes piston (614)
leftward, the spring (621) force is raised, and finally P
the relief pressure is raised.

PL
621 614
R0222
• The numbers of the parts of the main relief valve in
this section correspond to those in Fig. shown in
page T3-3-10.
T3-3-36 E215-E235

CONTROL VALVE

Operation of over load relief valve

The over load relief valve is located between the

cylinder port and the low pressure passage, functions
as both a relief valve and an anti cavitation check
valve, as mentioned below. 301 A B

OPERATION AS A RELIEF VALVE

1. The pressurized oil enters the hole A through the P
clearance between piston (301) and plunger (511)
and fills up chamber B. Thus plunger (511) is
R
seated tightly against seat (541).

511 541
R0223

2. When the hydraulic pressure of the port P reaches C

a set pressure of the spring (621), it pushes the
poppet (611) open, flows on the circumference of
the poppet (611) and passes through the hole C
to R.
P

611 621 R0224

3. When the poppet (611) opens, the hydraulic pres- 511 B

sure in chamber B falls which causes the plunger
(511) to open and allows the hydraulic pressure of
port P to flow directly to R.

611 R0225
OPERATION OF ANTI CAVITATION CHECK
VALVE
The check valve supplies oil from port R when a
negative pressure is built up at port P. When the
pressure at R gets higher than that of port P, the push-
up force of circuit R gets stronger than the pressing
force of chamber B.
This causes seat (541) to move to the right. Then the P
oil passes through the clearance of seat (541) and
enters port P in sufficient quantity to fill up the va-
cancy. R

541
• The numbers of the parts of the over load relief R0226
valve in this section correspond to those in Fig.
shown in page T3-3-11.
E215-E235 T3-4-1

SWING DEVICE

OUTLINE

General view

THREAD FOR EYE

BOLT 2-M12
M L
PB DEPTH 24
RELIEF VALVE
B
(B PORT SIDE)

(SH)

IP
PG

RELIEF VALVE
(A PORT SIDE)
A
DB
PA
R0227

A, B - Main port (PF3/4) 167 Nm PG - Parking brake release port (PF1/4) 36 Nm

DB - Drain port (PF3/8) 74 Nm L - Gear oil level gauge (PT1/2) 65 Nm
M - Make-up port (PF3/4) 167 Nm IP - Gear oil filling port (PT3/4) 98 Nm
PA, PB - Pressure measuring port (PF1/4) 36 Nm
T3-4-2 E215-E235

SWING DEVICE

ANTI-REACTION
PB PA VALVE BLOCK

M DB
A, (B)

PG
IP
FILLING PORT
PT3/4

R0228

PG

DB

PA PB

A B
Hydraulic diagram

R0229
E215-E235 T3-4-3

SWING DEVICE

Specifications

Model M5X130CHB–10A–17B/285–122

Type Swash-plate type, fixed-displacement plunger motor

Displacement cm3 121.6

Hydraulic motor

Working pressure MPa 34.3

Max. flow L/min 179

Braking torque Nm 818

Release pressure MPa 2.3~5.0

Relief set pressure MPa 28

Weight kg 49

Anti- Type 2KAR6P72/240-712

reaction
valve block Weight kg 2.5

Hydraulic motor assy weight kg 51.5

Model M2X120B

Speed reduction type Planetary 2-stage

Reduction ratio 15.38

Reduction unit

Lubicate oil Gear oil SAE90 (API class GL–4 grade)

Lubicate oil volume L 7.5

Grease Extreme pressure multipurpose grease

Grease volume A small amount

Weight kg 158.5

Total weight kg 210

T3-4-4 E215-E235

SWING DEVICE

CONSTRUCTION

Swing motor

993

VALVE CASING
SECTION

702 712

ANTI
CAVITATION
PLUNGER
351 Arrangement of brake spring

355
051 RELIEF VALVE

469
051-1
488 ANTI-REACTION
VALVE BLOCK 401
052 151,
303 162 171 161 163

985
985 444 984 131 451
712
A A

472 390 391

VIEW I
702

707

706
100

980

743

742
400-1
111
400-2 052

121
400

123 994

SECTION A – A
122
114 301
124 443 491 101

R0230
E215-E235 T3-4-5

SWING DEVICE

051 - Relief valve; M33-P1.5 (Q.ty 2) 177 Nm 400 - Anti-reaction valve; M22-P1.5 (Q.ty 2) 69 Nm
051-1 - O-Ring (Q.ty 2) 400-1 - O-Ring (Q.ty 2)
052 - Anti-reaction valve sub 400-2 - Backup Ring (Q.ty 2)
100 - Casing for anti-reaction valve 401 - Socket bolt; M20 × 45 (Q.ty 4) 431 Nm
101 - Drive shaft 443 - Roller bearing
111 - Cylinder 444 - Roller bearing
114 - Spring plate 451 - Pin (Q.ty 2)
121 - Piston (Q.ty 9) 469 - Romh plug; M30-P1.5 (Q.ty 2) 334 Nm
122 - Shoe (Q.ty 9) 472 - O-Ring
123 - Set plate 488 - O-Ring (Q.ty 2)
124 - Shoe plate 491 - Oil seal
131 - Valve plate 702 - Brake spring
151 - Plug; PF1/4 (Q.ty 2) 36 Nm 706 - O-Ring
161 - O-Ring (Q.ty 2) 707 - O-Ring
162 - O-Ring (Q.ty 2) 712 - Brake spring (Q.ty 16)
163 - O-Ring (Q.ty 2) 742 - Friction plate (Q.ty 3)
171 - Socket bolt; M8 × 55 (Q.ty 4) 29 Nm 743 - Separator plate (Q.ty 4)
301 - Casing 980 - Plug; PF1/4 0.9 Nm
303 - Valve casing 984 - Plug; PF3/8 1.7 Nm
351 - Plunger (Q.ty 2) 985 - Plug; PF3/4 (Q.ty 3) 4.4 Nm
355 - Spring (Q.ty 2) 993 - Plug; PT1/2 65 Nm
390 - Name plate 994 - Plug; PT3/4 98 Nm
391 - Rivet (Q.ty 2)
T3-4-6 E215-E235

SWING DEVICE

Swing reduction unit

33 29 28 27 26
19 25
18 22
17 23
16 24
14 22
20

15
21

13 10

12

11
34

31
30

32 9

8
7
5

2 1
R0231

1- Pinion shaft 19 - #.1 Sun gear

2- Sleeve 20 - Spring pin (Q.ty 4)
4- Plug 21 - Shaft (Q.ty 4)
5- O-Ring 22 - Thrust washer (Q.ty 8)
6- Oil seal 23 - #.2 Pinion (Q.ty 4)
7- Retainer 24 - Needle bearing (Q.ty 4)
8- Socket bolt; M8 × 25 (Q.ty 12) 33 Nm 25 - Thrust washer (Q.ty 3)
9- Bearing 26 - #.1 Pinion (Q.ty 3)
10 - Housing 27 - Roller (Q.ty 102)
11 - Spacer 28 - Thrust washer (Q.ty 3)
12 - Bearing 29 - Snap ring (Q.ty 3)
13 - Snap ring 30 - Pipe; L=180
14 - #.2 Spider 31 - Elbow
15 - #.2 Sun gear 32 - Plug; PT3/4 (Q.ty 2)
16 - Ring gear 33 - Snap ring
17 - #.1 Spider assy 34 - Set screw; M20 × 20 (Q.ty 2)
•
18 - Socket bolt; M14 × 130 (Q.ty 10) • • • 181 Nm

•
• •
• Apply Three-Bond #1360K
E215-E235 T3-4-7

SWING DEVICE

HYDRAULIC MOTOR

Operation
CILINDER BLOCK (111)
If the high pressure oil flows into the cilynder through
the inlet port (a) of valve plate (131), as shown on the
figure on the right, the hydraulic pressure acts upon F2
piston (121) and creates force F in the axial direction. F1
The force F may be divided into force F1 vertical to
shoe plate (124) via shoe (122) and force F2 at right F
angles with the shaft.
The force F2 is transmitted to cylinder block (111) via
pistons (121) and causes drive shaft to turn so as to DRIVE SHAFT (101)
produce a rotating moment.
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to drive shaft
by turns by pistons connected to inlet port of high
pressure oil. VALVE
If the oil supply and discharge directions are reversed, PLATE
the drive shaft rotates in the opposite direction. SHOE SHOE PISTON
(131)
PLATE (122) (121)
(124)
R0232
Theoretical output torque T can be given by the
following equation.
(LOW PRESSURE OIL) (HIGH PRESSURE OIL)
p×q
T=
2×π
p: Effective differential pressure MPa
q: Displacement per revolution cm3/rev OUTLET INLET (a)

R0233
T3-4-8 E215-E235

SWING DEVICE

VALVE CASING SECTION

Operation of anti-cavitation check plunger 351

Since the system using this type of motor is not

equipped with a valve having a counterbalance func-
tion, the motor is rotated beyond the oil feed rate in
some cases.
The system has check plunger (351) and sucks in
M PORT
deficient oil, in order to prevent cavitation from occur- (MAKE UP PORT)
ring due to oil deficiency.

DIRECTIONAL VALVE

R0234
Operation of relief valve

CONSIDER WHERE THE RELIEF VALVE IS

PRESSURIZED
The pressure at the P, R ports is equal to the tank
pressure at the beginning, as shown.
The relief valve begins to operates when the hydraulic
CHAMBER h
pressure that is determined by the product of the ORIFICE m SPRING (321) PISTON 1 (302)
pressure-receiving area A1 of plunger(301) and the
pressure P balances the hydraulic pressure that is
determined by the product of the pressure-receiving
P
area A2 of the plunger(301) and the pressure Pg of
chamber g.
R
Thereafter, the pressure of chamber g rises and the A4
PRESSURE- PLUNGER A3 A2
piston 1 (302) begins to stroke. The load to spring CHAMBER g
RECEIVING (301) ORIFICE n
(321) increases by this movement of the piston. AREA A1
As the result, the relief pressure P is raised and R0235
controlled in the pressure boost time t1 from P1 till Ps.
This process is explained in the following in the
relationships between the movements of the compo-
nents and the relief pressure:
1. If the P port of the relief valve is pressurized,
pressure is built up in chamber g via the restrictor
m of plunger (301).
The hydraulic pressure acting on plunger (301) CHAMBER h
ORIFICE m SPRING (321)
increases and when it balances the load Fsp of PIN (303) PISTON 1 (302)
spring (321), the relief valve performs relieving
action by the pressure P1.
This relationship is expressed as:
P

P1×A1=Fsp (min) 1+Pg1×A2

R
ORIFICE n CHAMBER g
where Fsp1: PLUNGER (301)
primary set load value of spring (321). R0236
E215-E235 T3-4-9

SWING DEVICE

2. The pressure of chamber g acts upon the pres-

CHAMBER h
sure-receiving area A3-A4 of piston 1 (302). When ORIFICE m SPRING (321) PIN (303) PISTON 1 (302)
the hydraulic pressure rises above the load of
spring (321), the piston 1 begins to move to the left.
On that occasion, since the machine turns to the
left while discharging the oil of chamber h arranged P
between piston 1 and adjust plug (401) into cham-
ber g via restrictor n provided in piston 1 (302), R
chamber h serves as a dumping chamber. ORIFICE n
PLUNGER (301) CHAMBER g
The load of the spring increases slowly till piston 1
reaches the end of the adjust plug. The relief R0237

pressure P rises smoothly.

3. The machine does not travel to the left further when ORIFICE m SPRING (321) PIN (303) PISTON 1 (302)
piston 1 (302) arrives at the end of adjust plug
(401). Therefore, the relief valve keeps its normal
relieving action whereby the relief pressure is held
at P2. P
In the processes 1. to 3. above, the relief pressure
changes as shown in Fig. below.
R

PLUNGER (301) ORIFICE n CHAMBER g

FUNCTION WHEN THE RELIEF VALVE R0238

PRESSURE IS REDUCED
Let us consider the pressure of the P port is reduced.
When the pressure at port P is reduced to zero, the
pressure of chamber g falls to the tank pressure level. (4)
PS
The result is that the plunger (301) which is now open
moves to the left and is seated on seat (341). At the (3)
same time, the piston 1 (302) moves to the right by the
P1 (2)
action of spring (321) and returns to the beginning
condition. (1)

t1
R0239
T3-4-10 E215-E235

SWING DEVICE

Operation of anti-reaction valve

NEUTRAL CONDITION
The figure illustrates the relationship between the
neutral condition of the anti-reaction valve and the
hydraulic circuits. Now, let us consider a braking BM AM
condition in which brake pressure generates on the
AM port side.
BV AV

ANTI-
REACTION
VALVE
ANTI-
REACTION
VALVE
R0240

k
322 313 321 311
R0241

WHEN BRAKE PRESSURE OCCURS m n

If pressure (P) generates at the AM port, it passes
through the passage l, the hole on the shaft of seat
(313) and the passage m of plunger (311) and is led P=PS
to the n chamber.
When the pressure P rises above a value (Ps) set by
spring (321), plunger (311) compresses spring (321)
and shifts it to the left.
Seat (313) compresses weak spring (322) as pushed 322 313 321 311
R0242
by plunger (311) and moves to the left.

AT ANTI-REACTION ACTION p t
When inertia load stops moving (point Y), brake
pressure (P) tries to fall.
P<PS
When P<PS, plunger (311) moves toward the right
return side by the action of spring (321). Seat (313)
tries to move to the right by the action of spring (322),
but since chamber p provides damping action by
orifice g, the return of the seat makes a time delay with k
regard to the return of the plunger. 322 313 g r 321 311
R0243
Consequently, seat t opens. This makes a passage
connecting the AM port and BM ports or both ports of
the hydraulic motor by way of ➝t➝r➝k. The result is P
that the pressures at the AM and BM ports become
equal (PB), falling into the condition at point Z in the PS
diagram. This prevents the hydraulic motor from
swing shock by the closing pressure of the AM port.
PB

Z
T
R0244
E215-E235 T3-4-11

SWING DEVICE

BRAKE SECTION

Operation

The cylinder (111) is jointed by drive shaft (101) and 111

a spline. Separator plate (743) is fixed in its circumfer-
712
ential direction by circular grooves provided in casing
(301).
Now, if the friction plate (742) splined to the outer
circumference of the cylinder is pressed against cas- 702
ing (301) via separator plate (743) and brake piston
712 743
(702) by the action of brake spring (712), frictional
force is created between friction plate (742) and
742
casing (301) and between separator plate (743) and
brake piston (702). The frictional force bounds the
702 301
drive shaft to brake the motor.
In the meantime, when brake release pressure ap- 743 742 301 101
plied to the oil chamber formed between brake piston R0245
(702) and casing (301) overcomes the spring force,
the brake is released as brake piston (702) moves till
friction plate (742) is separated from casing (301).
T3-4-12 E215-E235

SWING DEVICE

SWING REDUCTION UNIT

Operation

The swing reduction unit is used to reduce the rotating

RING GEAR (FIXED) PLANETARY SHAFT
speed which is transmitted by the hydraulic motor and
to convert it to the strong turning force (torque).
This swing speed reduction unit is equipped with
planetary speed reducing mechanism.
SPIDER
The planetary mechanism is made up of sun gear,
planetary pinion, planetary shaft, spider and ring
SUN
gear, as shown. GEAR
For the operation of the 1st stage planetary, the
hydraulic motor rotates #1 sun gear (19). Sun gear
(19) is engaged with planetary pinion (26) and rotates,
but since ring gear (16) is fixed, planetary pinion (26)
revolves about sun gear (19) with the planetary shaft
and spider (17).
PLANETARY PINION
The role of spider is to hold the planetary pinion and R0246
planetary shaft and transmits the power from the
planetary pinion to the spider through the planetary
shaft.
The #1 spider (17) is linked with #2 sun gear(15) by SWING MOTOR
the involute spline, and transmits the power to the 2nd
stage planetary mechanism. 26 19
For the operation of the 2nd stage planetary, the 16
power is transmitted to sun gear (15)➝planetary
pinion (23)➝spider(14) similarly to the 1st stage.
The #2 spider (14) is linked with pinion shaft (1) by the 17
involute spline, and pinion shaft(1) is engaged with 15
the swing gear fixed on the undercarriage (lower
frame) and rotates. 14

10

23
12

9 1

R0247
E215-E235 T3-5-1

TRAVEL DEVICE

OUTLINE

Characteristics

Item E215 E235

Reduction gear unit Epicycloidal, three-stage planetary type

Model 710 C3 K

Gearbox ratio 1 : 49,5

Travel motor Two speed, axial piston swash plate type

Model MAG 170 VP 2 MAG 170 VP 3

high speed 86.5 cm3/rev 97.1 cm3/rev

Displacement
low speed 129.3 cm3/rev 147.8 cm3/rev

Max. flow 210 L/min 241.5 L/min

Max. output torque (theoretical) 705.8 Nm at 343 bar 807.1 Nm at 343 bar

low speed 34 930 Nm 39 941 Nm

Max. gearbox output torque
high speed 23 369 Nm 26 233 Nm

static 470 Nm
Parking brake torque
dynamic 370 Nm

Min. pressure parking brake release 14 bar

cracking 310 bar at 1.2 L/min

Relief valve set pressure
total flow 353 bar at 40 L/min
T3-5-2 E215-E235

TRAVEL DEVICE

Hydraulic motor Planetary gearbox

Two speed hydraulic motor (axial piston swash plate Planetary gearbox, 3 stages, rotating housing type.
type) containing: The track drive is suitable to be used as track drive for
crawled machines equipped with open loop hydraulic
- Integrated counterbalance valve;
circuit.
- Crossover relief valve wich contains a shock ab-
sorber to smoooth acceleration and stopping;
- Negative multidisc parking brake built-in directly
driven from ythe motor oil pressure (no additional
hose is required);
- Double speed function, allowing the motor to be set
to a fast or slow speed.

Ports

Tin
P1 P1
Pm1

T Ps T
Pm2
P2 Pp P2

R0752

P1 PF 1”
Service port
P2 PF 1”
T PF 1/2” Drain port
Ps PF 1/4” 2 speed control port
Tin PF 1/4” Oil motor filling port
Pm1 PF 1/4”
Pm2 PF 1/4” Pressure gauge ports
Pp PF 1/4”
E215-E235 T3-5-3

TRAVEL DEVICE

Hydraulic circuit

Pm1 Tin

Pp

Gearbox

P1
P2

Pm2 Ps
R0753

Direction of rotation

When assembling the track drive on the machine and

connecting the hoses, follow instructions shown in
below sketch for proper direction of rotation.

P1

P2

R0754

Oil inlet port Oil outlet port Direction of rotation

P1 P2 Clockwise
P2 P1 Counterclockwise
T3-5-4 E215-E235

TRAVEL DEVICE

CONSTRUCTION

Hydraulic motor

7
20 9
21

3 5
8 8
12 4 7
1 5

1
9 A
4
3

5 2
6

23
22
15
16
17
13
14
13
14
13
2

7 14 12 13 15 10 8 19 18 8 21 20

3
1 24 25
2
6 2
4 5 4 9
5 4 5 12
3 3
6 2 2 11
2
18
24 17
16
23 3
18 22 22 2
10 23 1
9 2
24 11
10
11 7
4
1 5
13
14
19 7
17 19 6
18
A 19 1 2 15
3
8 5
4
2

2
2 3
4 1 3
5
6 6 4
5

R0756
E215-E235 T3-5-5

TRAVEL DEVICE

1 - Flanged hub 2-14 - Plug 118 ± 5 Nm

2 - Base plate assembly 2-15 - Washer
2-1 - Base plate 2-17 - Orifice 2.5 ± 0.5 Nm
2-2 - Cuonterbalance valve 2-18 - Orifice (Q.ty 2) 2.5 ± 0.5 Nm
2-2-1 - Spool 2-19 - Orifice (Q.ty 5) 2.5 ± 0.5 Nm
2-2-2 - Valve (Q.ty 2) 2-20 - Plug (Q.ty 4) 36.8 ± 2.5 Nm
2-2-3 - Spring (Q.ty 2) 2-21 - O-Ring (Q.ty 4)
2-2-4 - Body (Q.ty 2) 2-22 - Check valve (Q.ty 2)
2-2-5 - O-Ring (Q.ty 2) 2-23 - Spring (Q.ty 2)
2-3 - Spring seat (Q.ty 2) 2-24 - O-Ring (Q.ty 2)
2-4 - Spring (Q.ty 2) 3 - Motor shaft
2-5 - Spring seat (Q.ty 2) 4 - Cylinder block assy
2-6 - Flanged plug assy (Q.ty 2) 4-1 - Cylinder block
2-6-1 - Plug (Q.ty 2) 4-2 - Piston (Q.ty 9)
2-6-2 - O-Ring (Q.ty 2) 4-3 - Retainr plate
2-6-3 - Socket screw M12x40 (Q.ty 8) 108 ± 10 Nm 4-4 - Spherical retainer plate holder
2-6-4 - O-Ring (Q.ty 2) 4-5 - O-Ring
2-6-5 - Plug (Q.ty 2) 4-6 - Spring seat
2-6-6 - Ball (Q.ty 2) 4-7 - Spring
2-7 - Relief valve (Q.ty 2) 375 ± 20 Nm 4-8 - Spring seat
2-7-1 - Valve body (Q.ty 2) 4-9 - Pin (Q.ty 3)
2-7-2 - Valve (Q.ty 2) 5 - Swash plate
2-7-3 - Valve seat (Q.ty 2) 6 - Steel ball (Q.ty 2)
2-7-4 - Spring seat (Q.ty 2) 7 - Two speed control piston (Q.ty 2)
2-7-5 - Spring (Q.ty 2) 8 - Bearing
2-7-6 - Body (Q.ty 2) 9 - Bearing
2-7-7 - O-Ring (Q.ty 2) 10 - Grain
2-7-9 - Free piston (Q.ty 2) 11 - Socket bolt M14x40 (Q.ty 9) 205 ± 10 Nm
2-7-10 - O-Ring (Q.ty 2) 12 - Seal ring
2-7-11 - Backup ring (Q.ty 2) 13 - Brake disc (Q.ty 3)
2-7-13 - Spring seat (Q.ty 2) 14 - Steel disc (Q.ty 2)
2-7-14 - O-Ring (Q.ty 2) 15 - Brake piston
2-7-15 - Adjusting screw (Q.ty 2) 16 - O-Ring
2-7-16 - Counternut (Q.ty 2) 17 - O-Ring
2-7-17 - O-Ring (Q.ty 2) 18 - Two speed control spring (Q.ty 8)
2-7-18 - Backup ring (Q.ty 4) 19 - Pin (Q.ty 4)
2-8 - Conical plug (Q.ty 3) 10 ± 1 Nm 20 - Spring (Q.ty 2)
2-9 - Two speed valve 21 - Valve plate
2-10 - Spring 22 - O-Ring (Q.ty 4)
2-11 - Plug 118 ± 5 Nm 23 - O-Ring
2-12 - O-Ring (Q.ty 2) 24 - Name plate
2-13 - Spring seat 25 - Screw (Q.ty 2)

MOTOR DRAIN PRESSURE

Continuous running Less than 2 bar

Max. intermittent Less than 5 bar

Brake

The track drive is supplied with a safety negative disc ports of the hydraulic motor. For this reason, there is
brake fitted into the hydraulic motor (parking brake). no need of brake external pilot.
Parking brake release is automatically operated The brake technical data are shown on the track drive
when high pressure oil is supplied to one of the two installation drwing.

BRAKE TECHNICAL DATA

Min. pressure for release parking brake bar 11
Static parking brake torque Nm 581
T3-5-6 E215-E235

TRAVEL DEVICE

Gearbox

1
2

10 3
11 4
5
6
7
8
9

17
18 12
19 13
20 14
15
16

R0755

1 - Socket screw M10x25 (Q.ty 10) 75 Nm 11 - 3rd stage reduction planet assembly (Q.ty 5)
2 - End cover 12 - Spacer
3 - Plug M22x1.5 (Q.ty 2) 35 ± 5 Nm 13 - Ring nut M230x2
4 - Washer 14 - Screw
5 - O-Ring 15 - Washer (Q.ty 18)
6 - Plug 16 - Sprocket
7 - 1st stage sun gear 17 - Gearbox housing
8 - 1st stage reduction assembly 18 - Lifetime seal
9 - 2nd stage reduction assembly 19 - Centering ring
10 - Circlip 20 - Hydraulic motor
E215-E235 T3-6-1

SWIVEL JOINT

OUTLINE

General view

C D E

C
B

VIEW Z
E

Z
R0250

Specifications

Working pressure 34.3 MPa

High pressure ports
Max. impact pressure 51.5 MPa
A,B,C,D
Rated flow 255 L/min
Low pressure ports Working pressure 0.5 MPa
E Rated flow 50 L/min
Low pressure ports Working pressure 4.9 MPa
F Rated flow 30 L/min
Revolution 15 min-1
A,B,C,D PF1
Ports size E PF1/2
F PF1/4
Length (height) 355 mm
Weight 27.4 kg
T3-6-2 E215-E235

SWIVEL JOINT

CONSTRUCTION

G
2 A

G
1
E
C
B D

B
VIEW Y

5 F

3
9 12
8 E E

4
SECTION GG
R0251

1 - Body 6 - Seal assy (Q.ty 2)

2 - Stem 7 - O-Ring
3 - Thrust plate 8 - Socket bolt; M8 × 20 (Q.ty 2) 30.4 Nm
4 - Cover 9 - Socket bolt; M8 × 30 (Q.ty 4) 30.4 Nm
5 - Seal assy (Q.ty 5) 12 - Plug
E215-E235
SWIVEL JOINT
OPERATION
The swivel joint consists mainly of body (1) and stem
(2) that rotate mutually, thrust plate (3) preventing
both components from falling off, cover (4) closing
one side of body (1), seal (5) that partitions off the
circuits and seal assy (6) and O-Ring (7) that prevent
external leaks.
Four ports for the travel main circuits are provided on
body (1) and stem (2). Further, four oil passing
grooves are arranged in the inner surface of body (1),
with seal (5) fixed above and below the circumferen-
tial groove.
T3-6-3
The body (1) and the stem (2) rotate mutually. The oil
flowing in from body (1) or stem (2) keeps on flowing
to stem (2) or body (1) past the circumferential groove
between body (1) and stem (2); the oil flow is never
shut off because of rotation. Further, an oil groove for
lubrication that connects with the drain port is pro-
vided, in order to prevent the body (1) from seizure
with the stem (2).
This construction keeps on connecting the circuits
between the swing bodies by means of a swivel joint.
T3-6-4 E215-E235

SWIVEL JOINT

NOTE:
E215-E235 T3-7-1

CYLINDERS

OUTLINE

General view

B
gth
l en
ed A
te nd gth
ex en
lly e dl
Fu nd
e xte
F ully

Part No. and Manufacturing No.

Stamp position

R0252

Specifications

Center distance
Cylinder bore / of pins
Use Stroke Cushion Dry weight
Rod Dia. Full extend B /
Full retract A
mm mm mm kg

With cushion
Boom Ø 125 / Ø 85 1 240 3 000 / 1 760 177
on rod side

With cushion
Arm Ø 135 / Ø 95 1 490 3 520 / 2 030 251
on both sides

With cushion
Bucket Ø 120 / Ø 80 1 080 2 684 / 1 604 149
on rod side

Positioning Ø 150 / Ø 100 1 090 2 760 / 1 670 – 251

T3-7-2 E215-E235

CYLINDERS

CONSTRUCTION

Boom cylinders

27 26 12 24 25

B
105_0.5

110_0.5
0

0
PT 1/4
28

980

PS 1/8

30
29
30°

SLIT
31

28
M12X1.75 With hole
GREEN BLACK (1 place)

VIEW Y DETAIL 6 DETAIL B DETAIL C

9 8 7 6 4 5 3 11 10 2 1 13 14 15 17 16 18 19 20 21 22 23

C SLIT
Orientation of cut off part
of cushion bearing (13)

R0253

1 - Cylinder tube 17 - Backup ring (Q.ty 2)

2 - Piston rod 18 - Slide ring (Q.ty 2)
3 - Rod cover 19 - Slide ring (Q.ty 2)
4 - Bushing 20 - Shim
5 - Snap ring 21 - Piston nut; M65 × 3 5470 Nm
6 - Buffer ring 22 - Set screw; M12 56.9 ± 10.7 Nm
7 - U-Ring 23 - Steel ball
8 - Backup ring 24 - Pin bushing
9 - Wiper ring 25 - Wiper ring (Q.ty 2)
10 - O-Ring 26 - Pin bushing
11 - Backup ring 27 - Wiper ring (Q.ty 2)
12 - Socket bolt; M16 × 75 (Q.ty 12) 267 Nm 28 - Band assy
13 - Cushion bearing 29 - Band
14 - Cushion seal 30 - Capscrew; M10 × 43 (Q.ty 2) 31.5 Nm
15 - Piston 31 - Washer (Q.ty 2)
16 - Seal ring
E215-E235 T3-7-3

CYLINDERS

Arm cylinder

29 28 12 28 29
1596

B
105_00.5

110_00.5
PS 1/8
PT 1/4

30 32, 33
SLIT

35°

31 With hole
GREEN BLACK (1 place)

VIEW Y DETAIL 6 DETAIL B DETAIL C

9 8 7 6 3 4 5 11 10 2 1 13 14 15 16 17 18 19 20 21 22, 23 27
24

25 26

C SLIT
Orientation of cut off part
of cushion bearing (13)

R0254

1 - Cylinder tube 18 - Slide ring (Q.ty 2)

2 - Piston rod 19 - Slide ring (Q.ty 2)
3 - Rod cover 20 - Shim
4 - Bushing 21 - Piston nut; M70 × 3 10,280 Nm
5 - Snap ring 22 - Set screw; M12 56.9 ± 10.7 Nm
6 - Buffer ring 23 - Steel ball
7 - U-Ring 24 - Cushion bearing
8 - Backup ring 25 - Cushion seal
9 - Wiper ring 26 - Stopper (Q.ty 2)
10 - O-Ring 27 - Snap ring
11 - Backup ring 28 - Pin bushing (Q.ty 2)
12 - Socket bolt; M18 × 80 (Q.ty 12) 367 Nm 29 - Wiper ring (Q.ty 4)
13 - Cushion bearing 30 - Band assy
14 - Cushion seal 31 - Band
15 - Piston 32 - Capscrew; M10 × 43 (Q.ty 2) 31.5 Nm
16 - Seal ring 33 - Washer (Q.ty 2)
17 - Backup ring (Q.ty 2)
T3-7-4 E215-E235

CYLINDERS

Bucket cylinder

25 24 12 24 25

B
100_00.5

100_00.5
PS1/8

1055

PS1/8

27
45° SLIT

28, 29 With hole

GREEN BLACK (1 place)
26

VIEW Y DETAIL 6 DETAIL B DETAIL C

9 8 7 6 3 4 5 10 11 2 1 13 14 15 16 17 18 19 20 21 22 23

C SLIT
Orientation of cut off part
of cushion bearing (13)

R0255

1 - Cylinder tube 16 - Seal ring

2 - Piston rod 17 - Backup ring (Q.ty 2)
3 - Rod cover 18 - Slide ring (Q.ty 2)
4 - Bushing 19 - Slide ring (Q.ty 2)
5 - Snap ring 20 - Shim
6 - Buffer ring 21 - Piston nut; M62 × 3 7280 Nm
7 - U-Ring 22 - Set screw; M12 56.9 ± 10.7 Nm
8 - Backup ring 23 - Steel ball
9 - Wiper ring 24 - Pin bushing (Q.ty 2)
10 - O-Ring 25 - Wiper ring (Q.ty 4)
11 - Backup ring 26 - Band assy
12 - Socket bolt; M16 × 75 (Q.ty 12) 267 Nm 27 - Band
13 - Cushion bearing 28 - Capscrew; M10 × 43 (Q.ty 2) 31.5 Nm
14 - Cushion seal 29 - Washer (Q.ty 2)
15 - Piston
E215-E235 T3-7-5

CYLINDERS

Hydraulic cylinder construction

(for boom, arm and bucket cylinders)

By construction the hydraulic cylinder consists mainly

of cylinder tube assy (1), piston rod assy (2) that takes
out the motion of pistons reciprocating in the cylinder
tube assy, and cylinder head (3) that serves as both
a lid and a guide. Cylinder tube assy (1) is equipped
with a pin mount (clevis) that connects piston rod assy
(2) with other parts.
In addition to these main components, seal ring (16)
and back-up ring (17) are located between cylinder
tube assy (1) and piston rod assy (2); buffer ring (6),
U ring (7) back-up ring (8) and wiper ring (9) are
located between piston rod assy (2) and cylinder head
(3); and an O-Ring (10) and a back-up ring (11) are
placed between cylinder tube assy (1) and cylinder
head (3).

OPERATION
If pressurized oil is fed alternatively to the oil inlet and
outlet provided in the cylinder, force acts on the piston
which in turn causes the piston rod (2) to extend and
retract.

Operation of cylinder with cushion CUSHION RING (13) CHAMBER "A" PATH "B"
CUSHION ON ROD SIDE TANK
PISTON (15)
The cushion mechanism is provided to prevent the
generation of shock when the moving speed of piston ROD(2)
(15) is not reduced and strikes cylinder head (3). HEAD ROD
An oil in chamber "A" returns to the tank by passing SIDE SIDE
through paths "B" at a fixed flow rate in a intermediate
stroke state of pressing bottom side.
CILINDER HEAD(3)
CUSHION STROKE
R0256

Next, in a state of just before stroke end, cushion ring TANK

CLEARANCE "D"
(13) plunges into path "B".
At this time, an oil in chamber "A" passes clearance
"D" and mouth gap "C", an oil flow volume returning to
tank suddenly drops and the piston part movement
MOUTH GAP "C"
slows down.

R0257
T3-7-6 E215-E235

CYLINDERS

CUSHION ON HEAD SIDE CUSHION SEAL(24)

This construction is similar to the one of cushion on PATH "B" TANK CUSHION BEARING(23)
rod side. In a state of intermediate stroke pressing rod
side, an oil in chamber "A" returns to tank by passing
through path "B" at a fixed flow rate.
Next, in a state of just before stroke end, cushion
bearing (23) plunges into path "B". At this time, an oil
in chamber "A" path clearance "D" and cushion seal
(24) are mouth gap "C", an oil flow volume returning
to tank suddenly drops and the piston part movement
CLEARANCE "D"
slows down. CHAMBER "A"

R0258
E215-E235 T3-8-1

AIR CONDITIONER

CONSTRUCTION AND PIPING

Construction

1-9

1-1

4
1-8 1-2

1-3
2-1
1-4 1-6
2-2

1-5

2-10

2-7

2-5
2-9

2-6

2-8
5

R0260

1- Air-conditioner assy 2-2 - Bracket

1-1 - Air-conditioner unit 2-5 - S Hose; Ø 24.5 mm L = 4 100 mm
1-2 - Plate 2-6 - D Hose; Ø 9 mm L = 2 380 mm
1-3 - Capscrew 2-7 - L Hose; Ø 15.5 mm L = 5 350 mm
1-4 - Hose (Q.ty 2) 2-8 - L Tube; Ø 10.1 mm
1-5 - Clamp 2-9 - D Tube
1-6 - Sensor 2-10 - S Tube
1-8 - Clip (Q.ty 2) 3 - Compressor
1-9 - Cap 4 - Panel
2- Air dryer assy 5 - Condenser
2-1 - Receiver dryer 6 - Filter assy
T3-8-2 E215-E235

AIR CONDITIONER

Piping

NOTE - 1. Apply oil for refrigerant R134a to the O-Rings at all air-conditioner hose fittings.
2. Refrigerant volume: 960±100 g.

L HOSE Ø 15.5
17
S HOSE Ø 24.5
14
8 6
20
18
8
5 18 8
18

1 8 18
18 8
B
6 6
C
9
6

7
4
5

1
2 5

18
26
S HOSE
21

18 D HOSE
12
21 3
D HOSE
2 21
28
18
29 B 26
14 C 6
24
20

27 19
CONDENSOR 19
23 15
11
22 13
L TUBE 26
9
RECEIVER DRYER
20
L HOSE 10

16
19

18 30
25

R0301
E215-E235 T3-8-3

AIR CONDITIONER

1 - Water hose (Q.ty 2) 16 - Screw; M8 × 20

2 - Support (Q.ty 2) 17 - Screw; M6 × 25 (Q.ty 2)
3 - V Belt 18 - Washer (Q.ty 14)
4 - Connector ★ 19 - Washer (Q.ty 7)
5 - Clip (Q.ty 4) 20 - Washer (Q.ty 10)
6 - Clip (Q.ty 10) 21 - Capscrew; M10 × 25 (Q.ty 5) 39.2 Nm
7 - Connector ★ 22 - L Hose; L = 5 350 mm
8 - Capscrew; M10 × 20 (Q.ty 5) 23 - D Hose; L = 2 380 mm
9 - Clip (Q.ty 2) 24 - S Hose; L = 4 100 mm
10 - Capscrew; M6 × 20 (Q.ty 2) 25 - Capscrew; M10 × 55 (Q.ty 3) 39.2 Nm
11 - Capscrew; M8 × 16 (Q.ty 2) 26 - Clip (Q.ty 3)
12 - Capscrew; M6 × 45 (Q.ty 6) 4.4 Nm 27 - Grommet
13 - Capscrew; M8 × 130 (Q.ty 4) 27.5 Nm 28 - Screw
14 - Lock washer (Q.ty 8) 29 - Screw
15 - Lock washer (Q.ty 4) 30 - Bracket

NOTE - Apply Three-Bond #1110B to ★ mark.

Heater circuit

AIR CONDITIONER UNIT

ENGINE

IN OUT

OUT IN

R0302

Air conditioner circuit

AIR CONDITIONER UNIT

L HOSE

S HOSE
D HOSE

COMPRESSOR

CONDENSER

RECEIVER DRYER
R0303
T3-8-4 E215-E235

AIR CONDITIONER

MAIN COMPONENTS
Air-conditioner unit

38

69 37

60 7 26
60 19 5
36

63
61 20
9
63
1
61
25 21
61
30
14 61
59
35 61
60 4

29
61
18
28 17
10 31 61

4
23
22 33

24
65
34

65 23 61
32
65 11
61
22
61 16
12
15

65
64
22 8
2
58
61
23
65
22 63
57
19 61
27
1 61
3 5
63 40
6

13 6

55

53

R0305
E215-E235 T3-8-5

AIR CONDITIONER

11 - Actuator (Q.ty 3) 26 - Rod 67

12 - Expansion valve 27 - Rod 120
13 - Thermistor 28 - Damper AM assy
14 - Clamp (Q.ty 2) 29 - Damper CM assy
15 - Rod holder (Q.ty 2) 30 - Damper VE assy
16 - Sensor holder (Q.ty 2) 31 - Damper FA assy
17 - Clamp A 32 - Damper DE assy
18 - Evaporator 33 - Damper FO assy
19 - Casing 34 - Heater core
10 - Casing 35 - Controller
11 - Casing 36 - Relay 24-4PE
12 - Insulator 37 - Clamp C
13 - Insulator 38 - Band CV-250
14 - Packing VE duct (Q.ty 2) 40 - Harness
15 - Packing DE duct 53 - Flange plate
16 - Packing FO duct 55 - Sems bolt
17 - AHC. bracket 57 - O-Ring; 1/2
18 - Clamp 58 - O-Ring; 5/8
19 - Lever MAL1 (Q.ty 2) 59 - Tapping screw (Q.ty 6)
20 - Lever AM 60 - Tapping screw (Q.ty 13)
21 - Lever CM 61 - Screw (Q.ty 31)
22 - Lever M01 (Q.ty 4) 63 - Tapping screw (Q.ty 9)
23 - Lever M02 (Q.ty 4) 64 - Capscrew (Q.ty 2)
24 - Cam 65 - Tapping screw (Q.ty 5)
25 - Rod AC 69 - Cap
T3-8-6 E215-E235

AIR CONDITIONER

Intake unit

50 63
1 61

60
49
63 60

61

51 61

60 60
47

52
61
61

42 48
61
61

61

56
60

44 61

68

60
43
44
67

46

41
60
45
54

62
62 66
59

62

R0304
E215-E235 T3-8-7

AIR CONDITIONER

41 - Resister TKS-B215A0 52 - Damper IN

42 - Casing top 54 - Inner air sensor
43 - Casing bottom 56 - Gasket
44 - Unit bracket (Q.ty 2) 59 - Tapping screw (Q.ty 6)
45 - Cooling hose 60 - Tapping screw (Q.ty 13)
46 - Blower motor 24V 61 - Screw (Q.ty 31)
47 - Casing R 62 - Sems bolt (Q.ty 3)
48 - Casing L 63 - Tapping screw (Q.ty 9)
49 - Inner air filter 66 - Drain hose (L = 300mm) (Q.ty 2)
50 - Lever MAL2 67 - Clip 14C (Q.ty 2)
51 - Lever IN 68 - Canoe clip (Q.ty 2)

Receiver dryer

REFRIGERANT 2
INLET
REFRIGERANT
OUTLET

2-M6

R0306

1 - Pressure switch
2 - Sight glass
3 - Desiccant
4 - Suction pipe
5 - Filter
6 - Receiver tank
T3-8-8 E215-E235

AIR CONDITIONER

FUNCTION

Mechanism of cooling circuit

MECHANISM OF COOLING
In the cooling process, the refrigerant that flows
through the cooling circuit changes its phases from HFC-134a (R134a)
liquid to gas and vice versa during which process heat Chemical formula CH2FCF3
is transferred from the low temperature part (compart-
ment) to the high temperature part (outside of the Molecular weight 102.03
vehicle).
Boiling point –26.19 °C
Kind of Refrigerant Critical temperature 101.14 °C
Many kinds of refrigerants that change in that way are Critical pressure 4.065 MPa
available, but the following requirements are needed
for use in such applications: Critical density 511 kg/m3
• Latent heat of vaporization (heat of vaporization) is
Density of saturated 1206 kg/m3
large.
liquid (25 °C)
• It is easy to liquefy (condense). (It does not require
very high pressure for condensation.) Specific volume of saturated 0.0310 m3/kg
• It is easy to gasify (evaporate). (It evaporates vapor (25 °C)
sufficiently at not too low pressure, i.e. cools down
an object.) Latent heat of vaporization (0 °C) 197.5 kJ/kg
• It has small specific heat. (Since the refrigerant Flammability Non flammable
itself is cooled by the expansion valve, the loss
resulting from it must be held down to a minimum.) Ozone destruction coefficient 0
• It has a high critical temperature and a low solidifi-
cation point.
• It is stable chemically and does not corrode and
permeate into the circuit parts.
• It is free from toxicity, objectionable odor, flamma-
bility and explosiveness and excels in thermal
conductivity and electric insulation.
• It has small specific volume.
• It is easy to find out leakage.
Out of refrigerants meeting the above-mentioned
requirements, ones having characteristics that suit
the intended cooling unit are chosen and used. If a
refrigerant other that those designated is used, suffi-
cient refrigeration will not be performed or the equip-
ment in which the refrigerant is used may be broken.
Therefore, always use a designated refrigerant for the
cooling unit.
Table shows the principal characteristics of the PRESSURE
R134a refrigerant that is used in this machine. MPa
R134a
4

CHARACTERISTICS OF REFRIGERANT
3
In general, the fluid (general term of gas and liquid)
has the following qualities: LIQUID
1. As a gas under certain pressure is cooled down, it 2
begins to condensate at a certain temperature to GAS
take a liquid state. The temperature at which con-
1 TEMPERATURE
densation begins is unique to each substance
(°C )
(fluid) at a given pressure. The temperature deter-
mined by a given pressure is called saturation 0 0 15 18 35 50 100
temperature.
R0307
E215-E235 T3-8-9

AIR CONDITIONER

2. Inversely to 1. above, the pressure at which a gas PRESSURE

condenses for a temperature is determined. This MPa
pressure is called saturation pressure. R134a
4
Figure beside illustrates the relationships between
the saturation temperature and the saturation
pressure in the case of refrigerant R134a used in 3
the air-conditioner. At the temperature and the
LIQUID
pressure on the lower righthand side of the curve
2
in figure, the refrigerant take a gaseous state, while
at the temperature and the pressure on the upper GAS
lefthand side of the curve, the refrigerant takes a 1 TEMPERATURE
liquid state. (°C )
Let us think of a case where an air-conditioner is
operated in the midst of summer. As the refrigerant 0 0 15 18 35 50 100
evaporates, it absorbs evaporation heat from the
R0307
air of the compartment. In order to cool the inside
of the compartment down to 25 °C, the refrigerant
must transform (evaporate) from a liquid to a
gaseous state at a lower temperature. It can be
seen from the figure that R134a under a pressure
above the atmospheric pressure is capable of
cooling the inside of the compartment sufficiently.
(If a refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required tem-
perature is used, air is mixed into the circuits,
thereby deteriorating the performance of the cool-
ing unit.) In the process in which gaseous refriger-
ant is brought back to a liquid state, the refrigerant
is cooled and condensed by the outer air exceed-
ing 35 °C.
Accordingly the refrigerant is capable of condens-
ing at a pressure exceeding 1 Mpa, as seen from
the figure.

Cooling circuit

The figure illustrates the cooling circuit of the car air-

conditioner.
In this circuit diagram, the portion that cools the air of
INSIDE OF COMPARTMENT (CAB)
the compartment is the evaporator. The object air is
cooled off by utilizing the fact that the refrigerant takes
EVAPORATOR
heat off the surrounding area as evaporation heat as
it evaporates in the cooling circuit. Since the part at
which vaporization of the refrigerant takes place is the EXPANSION
BLOWER VALVE
evaporator, cooled air is constantly delivered to the
circumference of the evaporator by the blower fan. In
the meantime, liquid refrigerant (slightly wet vapor- INSIDE OF ENGINE ROOM

ized refrigerant) is fed into the evaporator, when S D

"cooling" effect is attained. For instance, in order to COMPRESSOR COOLING FAN
cool the air to 15 °C, the refrigerant can not absorb
evaporation heat from the air unless it evaporates at
a temperature lower that 15 °C. For that purpose, it
can be seen from the figure that the pressure of the
RECEIVER
refrigerant in the evaporator must be less than DRYER
0.51 MPa. CONDENSER

Furthermore, the cooling effect deteriorates unless

the feed rate of the refrigerant is controlled so that all R0308

of the refrigerant supplied to the evaporator vaporizes

and turns into dry vapor.
T3-8-10 E215-E235

AIR CONDITIONER

Consequently, the cooling circuit is so constructed

that the evaporator can cool down an object (air in this
case) sufficiently (i.e. so as to decrease the pressure
in the evaporator) and that an adequate amount of
refrigerant can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator is
held low by the throttling action of the expansion valve
and the suction action of the compressor. The com-
pressor acts as a pump that allows the refrigerant to
circulate. The compressive action of the compressor
and the heat exchange (heat radiation) action of the
condenser transform the refrigerant in a dry vapor
state back to a liquid state.

Component parts

EVAPORATOR
The evaporator is an important heat exchanger that
absorbs the heat of the compartment air (object) by
the utilization of the latent vaporization heat of the low-
temperature, low-pressure liquid-state refrigerant. EVAPORATOR
Therefore, it is necessary that satisfactory heat trans-
fer between the object and the refrigerant take place
in the evaporator.
O-RING
To that end, the evaporator is equipped with fins on
EXPANSION
the air side in order to increase the heat transfer area VALVE
of the air side and thereby perform excellent thermal
transfer between the refrigerant and the air.
SOKET
The humidity in the air condenses as the air cools BOLT
down and adheres to the outside of the evaporator as M5x40
water drops. The cooling effect deteriorates if the (2 PCS.)
water drops freeze. Therefore, how to discharge EVAPORATION
water is an important point. SENSOR
The amount of refrigerant supplied to the evaporator
is controlled by the expansion valve which is de-
scribed in the following. In order to attain proper R0309
control, it is necessary to reduce the pressure drop of
the refrigerant of the evaporator. Accordingly, reduc-
ing the pressure drop is one element that makes the
evaporator attain its full performances.

EXPANSION VALVE
In order for the evaporator to fulfill its performances,
a proper amount of low-pressure low-temperature
liquid refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant completes
vaporization early in the evaporator which results in
deterioration of the cooling effect. If the feed rate is too
high, unvaporized liquid refrigerant returns to the
compressor (liquid back). This not only deteriorates
the cooling effect, but also damages the compressor
valves.
E215-E235 T3-8-11

AIR CONDITIONER

The expansion valve feeds the flowing high-pressure

high-temperature liquid refrigerant to the evaporator
as low-pressure low-temperature liquid refrigerant DIAPHRAGM
(damp vapor of low dryness). The expansion valve
controls the feed rate of the refrigerant at the same
time.
The figure beside shows how the block type expan- EVAPORATOR REFRIGERANT
sion valve is constructed. The temperature sensing SIDE OUTLET
part is provided in the shaft of the expansion valve to
directly detect the refrigerant temperature at the outlet
SHAFT
of the evaporator.
The diaphragm contains R134a in saturated state.
The pressure in the diaphragm changes according to
the temperature detected by the sensor. The change
in the pressure causes the force acting upon the REFRIGERANT
diaphragm to vary accordingly. INLET
The high-pressure high-temperature liquid refriger-
ant that is fed from the receiver side reduces the BALL
pressure abruptly as it passes through the valve VALVE
(throttling action). On that occasion, part of the refrig- SPRING
erant evaporates by the very heat of the refrigerant
R0310
and cooled off. The result is that low-pressure low-
temperature damp refrigerant vapor is fed to the
evaporator.
The opening of the valve is determined by the equilib-
rium between the pressure (low) of the evaporator
side, the action of the adjust spring and the pressing
force of the diaphragm (the temperature of the refrig-
erant at the outlet of the evaporator to be sensed by
the thermowell). The feed rate is controlled automati-
cally so that under the pressure in the evaporator, the
refrigerant is properly overheated (3 ~ 8 degrees) and
goes out of the evaporator. This action is carried out
by sensing the refrigerant temperature at the outlet of
the evaporator as against the inlet pressure of the
evaporator and consequently controlling the feed rate
of the refrigerant.
This means that if the refrigerant pressure drop in the
evaporator is excessive, it is difficult to control the
overheating or the feed rate of the refrigerant. For this
reason, the smaller the pressure drop of the evapora-
tor, the better.
The expansion valve senses the pressure and the
temperature at the outlet of the evaporator and con-
trols the overheating of the refrigerant and the refrig-
erant supply to the evaporator more securely. The air-
conditioner of this machine adopts a block type ex-
pansion valve. R0311
T3-8-12 E215-E235

AIR CONDITIONER

COMPRESSOR
The compressor performs the following three func- D HOSE
tions in the cooling circuit:
1. Suction action
2. Pumping action
3. Compressive action S HOSE
1. The suction action, as combined with the throttling
action, works to decrease the refrigerant pressure
in the evaporator. This permits the refrigerant to
vaporize at low temperature in order to perform
cooling effect.
2. The pumping action serves to cause all the refrig-
erant to circulate in the cooling circuit. This enables
enables continuous cooling.
3. The compressive action, as combined with the
action of the condenser which is mentioned here-
under, transforms vaporized refrigerant back to a
liquid state again.
The saturation temperature gets higher as the
pressure increases. For instance, it becomes pos-
R0312
sible to cool down the refrigerant by the use of an
outer air of 35 °C and liquefy it. The compressive
action of the compressor works to turn low pres-
sure vaporized refrigerant to high pressure vapor
refrigerant. The condenser then serves to cool
down the refrigerant. However, since the
compressive action takes place only for a short
period, the refrigerant hardly exchanges heat with
outer air. That is to say, it takes a near form of
thermally insulated compression, so that the refrig-
erant discharged by the compressor turns into
high-temperature high-pressure vapor and is deliv-
ered to the condenser.

CONDENSER
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure by
the use of outer air and condenses the refrigerant.
The direction in which heat moves is from the refrig-
erant to air, the opposite to the case of the evaporator.
Fins are equipped on the outer air side to improve
thermal transfer. If the refrigerant is not cooled well by
the condenser, the air in the compartment can not be
cooled sufficiently by the evaporator. For that pur-
pose, it is necessary to secure ventilation required for
the cooling of the refrigerant.

R0313
E215-E235 T3-8-13

AIR CONDITIONER

RECEIVER DRYER
1. Receiver Tank
REFRIGERANT SIGHT GLASS
On the air-conditioner, the revolution of the com- INLET
pressor varies greatly which causes the proper
flow of refrigerant in the cooling circuit to vary. It is REFRIGERANT
the receiver tank that receives the variations. OUTLET
When the cooling circuit does not need much
refrigerant, the receiver tank stores extra refriger-
ant temporarily and supplies it when the cooling
circuit needs much refrigerant. The receiver tank
also stores an extra amount of refrigerant to be
used for filling balance and supplement small
amounts of leakage of the refrigerant through pen- R0314
etration into rubber hoses.
2. Dryer
If water is mixed in the cooling circuit, it deteriorates
the compressor valves and oil, corrodes the metal-
lic parts of the circuit or clogs the circuit as the water PRESSURE SWITCH
freezes in the expansion valve. It is desirable that
the amount of water mixed in the refrigerant should
be held below a concentration of 30ppm. The air-
conditioner uses a molecular sieve as desiccant
suited for the circuit, in order to absorb water
content that intrudes into the circuit when the dryer
is installed or when refrigerant is charged.
3. Sight Glass
This is a inspection window with which the refriger-
DESICCANT
ant level in the circuit is determined, the only means
of confirming the inside of the circuit visually.
4. Filter SUCTION PIPE
5. Pressure Switch
This machine employs pressure switches of high/
low pressure type.
The pressure switch protects the circuit by cutting
off the power supply to the compressor when high FILTER
pressure increases abnormally high (more than
3.14 MPa).
The pressure switch also detects the leakage of
refrigerant by cutting the power supply to the com-
pressor when the pressure of the circuit falls below
0.196 MPa.
RECEIVER TANK

R0315
T3-8-14 E215-E235

AIR CONDITIONER

NOTE:
OPERATIONAL PERFORMANCE TEST

R0077
OPERATIONAL PERFORMANCE TEST E215-E235

SECTION AND GROUP CONTENTS

Section 4 OPERATIONAL PERFORMANCE TEST

Group 1 Introduction
Group 2 Standard Performances
Group 3 Test Procedures
Group 4 Mechatro Controller Adjustment
SECTION 4 E215-E235

OPERATIONAL PERFORMANCE
TEST

CONTENTS

Group 1 - Introduction

How to Use the Maintenance Standard

and Cautions to Be Exercised ................. T4-1-1
Preparation for Performance Tests ........... T4-1-2

Group 2 - Standard Performances

Performance Inspection Standard

Table ....................................................... T4-2-1

Group 3 - Test Procedures

Measurement of Engine Speed ............... T4-3-1

Measurement of Hydraulic
Pressure ................................................. T4-3-2
Measuring Travel Performances ............... T4-3-7
Measuring Swing Performances ............ T4-3-11
Measuring Attachment Operating
Performances ........................................ T4-3-15
Measuring Performances of Swing
Bearing ................................................. T4-3-17

Group 4 - Mechatro Controller

Adjustment

Engine Control Input/Output .................... T4-4-1

Engine Control Installation ...................... T4-4-1
Engine Control Equipment ....................... T4-4-2
Mechatro Controller "A" and
"B" Adjustment ....................................... T4-4-3
E215-E235
INTRODUCTION
HOW TO USE THE MAINTENANCE
STANDARD AND CAUTIONS TO BE
EXERCISED
Application
WHEN THE MACHINE IS NEW
Confirm that the performances are in accordance with
standard specifications as compared to the perform-
ance standards.
AT SPECIFIC SELF INSPECTION (RULE BY
COUNTRY)
Use the data for the criterion, for the purpose of
correction, adjustment and replacement.
WHEN PERFORMANCES ARE DETERIORATED
Determine whether it is caused by a fault or end of
service life after long hours of operation, to be used for
safety and economical considerations.
WHEN MAIN COMPONENTS ARE REPLACED
For example, use data to restore performances of
pumps and others.
Terminology
STANDARD VALUES
Values to be used to condition or assemble a new
machine. Where special notes are not given, these
values represent standard specifications (machine
with standard attachments and standard shoes).
REFERENCE VALUES FOR REMEDY
Values at which readjustment is required. In order to
ensure performance and safety it is strictly prohibited
to use the machine over the specified values.
SERVICE LIMIT
This is the limit value at which reconditioning is
impossible without replacement of parts. If the value
is expected to exceed the service limit before next
inspection and correction are performed, replace the
parts immediately. The operation over the specified
values causes increase of damage and requires the
down time of machine, and also causes safety prob-
lems.
T4-1-1
Cautions to be Exercised at Judgment
EVALUATION OF MEASURED DATA
Disagreement of measuring conditions, variations of
data peculiar to a new machine, and measuring errors
are to be evaluated. Determine generally at what
levels measured values are located, instead of deter-
mining whether or not values fall within or run out of
the reference values.
DETERMINING CORRECTION, ADJUSTMENT
OR REPLACEMENT
Machine performances deteriorate with time as parts
wear and some deteriorated performances may be
restored to new levels. Therefore, determine correc-
tion, adjustment or replacement, depending upon the
operating hours, kind of work and circumstances in
which the machine is placed, and condition the ma-
chine performances to its most desirable levels.
Other Cautions to be Exercised
PARTS LIABLE TO DEGRADE
Rubber products, such as, hydraulic hoses,
O-Rings, and oil seals deteriorate with time; replace
them at regular intervals or at overhauls.
PARTS REQUIRING REGULAR REPLACEMENT
Out of critical hoses that are necessary to secure
safety, we designate Very Important Parts (V.I.P) and
recommend that they should be replaced regularly.
INSPECTION AND REPLACEMENT OF OILS
AND GREASES
In performing maintenance, it is necessary for the
user to familiarize himself with how to handle the
machine safely, cautions to be exercised and inspec-
tion/lubrication procedures. Refer to the operators
manuals as well.
T4-1-2 E215-E235

INTRODUCTION

PREPARATION FOR PERFORMANCE

TESTS

Observe the following rules in order to carry out

performance tests accurately and safely.

The machine

1. Repair any defects and damage found, such as oil

or water leaks, loose bolts, cracks and so on,
before starting to test.

Test area

1. Select a hard and flat surface.

2. Secure enough space to allow the machine to run
straight more than 20 m, and to make a full swing
SM0131
with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.

Precautions

1. Before starting to test, agree upon the signals to be

employed for communication among coworkers.
Once the test is started, be sure to communicate
with each other using these signals, and to follow
them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
SM3026

Make precise measurement

1. Accurately calibrate test instruments in advance

to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
E215-E235 T4-2-1

STANDARD PERFORMANCES

PERFORMANCE INSPECTION STANDARD TABLE

NOTE - The mode is already "W" mode when power is thrown. Unless otherwise specified, measure it on "H/M"
mode.

Measuring Position Standard Adjusting Measuring

Inspection Item Unit
Position Size Port
Value Point Condition

Cleanliness of hydraulic oil Hydraulic oil in tank NAS 8 or less Class — Sampling
Std. Measuring condition

Hydraulic oil temperature Tank surface 50 ± 5 —

°C Atmospheric temp.
Water temperature Radiator surface 75 ± 15 — 50 °C ~ -10 °C

Low idle 1000 ± 50

Engine speed

Hi idle Multi display on 2150 ± 30

the gauge cluster
min-1 Adjustment Turn off the air-
Auto-idle screen (Injection 1050 ± 50 conditioner for all
not required
pipe) measurements
Mode cancel 2330 ± 50

— —

Pilot primary pressure circuit G pump a4 4.9 ± 0.3 PR1 HI idle

P1 a1 Simultaneous
valve pressure

ATT
Main pump

+ 0.5
34.3 + 0 MR1 Operation of travel RH
Travel P2 a2 and LH and Boom up
Main relief

P1 a1
Boost + 1.0
MR1 ATT boost SW. ON
37.7 – 0.5
P2 a2 Boom up

— — — — — — —
+0
H 39.7 – 5.4 OR3 Boom up
Boom a1
+0
R 37.7 – 3.4 OR4 Boom down
High pressure circuit

+0
H 39.7 – 5.4 OR1 Bucket digging
Bucket a1
Over load relief valve pressure

+0
R 37.7 – 3.4 OR2 Bucket dump
PF1/4 +0
MPa
H 37.7 – 3.4 OR7 Arm in
Arm a2
+0
R 39.7 – 5.4 OR8 Arm out
Main pump

LH OR5 Swing LH
+ 4.9
Swing a2 27.9 – 1.0
RH OR6 Swing RH

Forward +0
OT1
RH a1 35.8 – 1.5
Simultaneous
Travel

Reverse OT2
Operation of travel
Forward +0
OT3 RH and LH
LH a2 35.8 – 1.5
Reverse OT4

— — — —
— —
— — — —
T4-2-2 E215-E235

STANDARD PERFORMANCES

Standard Measuring
Inspection Item Unit
Value Condition

Sprocket revolution 1st speed 32.7~29.3

H/M mode min-1
(RH,LH) 2nd speed 49.0~44.0
Up 3.0~3.6
Boom
Down 2.5~3.1
In 3.4~4.0
Arm
Out 2.7~3.3
Operating time of Digging 3.5~4.1
Operating speed

cylinder Bucket s (At no load)

Dumping 2.2~2.8
— —
—
— —
— —
—
— —
Swing speed STD speed 5.0~6.2 s / 1 rev
Rubber —
1st speed
Iron 17.5~19.5
Travel speed s / 20 m
nd
Rubber —
2 speed
Iron 12.1~13.3
Amount of travel
deviation
2nd speed 0~240 mm / 20 m

Parking brake drift 1 / 5 Gradient 0 mm / 5 min

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

Swing parking brake drift 1 / 5 Gradient 0 mm

Tip of the bucket tooth 95
Boom cylinder 7
ATT amount of drift mm / 5 min (At no load)
Arm cylinder 6
— —

Amount of horizontal play at the bucket tooth 30~50 mm

CAUTION
8 4
Over load relief valves OR1~OR8 described in
advance correspond to the following operations.
5 6 1 2
1. Bucket digging 2. Bucket dump
3. Boom up 4. Boom down 7 3
5. Swing left 6. Swing right LH RH
7. Arm in 8. Arm out CONTROL LEVER
R316
E215-E235 T4-3-1

TEST PROCEDURES

MEASUREMENT OF ENGINE SPEED

Warming up of engine
PICK UP

Start engine to raise the coolant temperature of en-

gine to 40 °C to 80 °C.
Engine water
temperature gauge The engine coolant tempera-
ture gauge is used to meas-
SPEED METER
ure. The range in white color
shows the temperature of
approx. 40 °C to 100 °C, so
confirm that the pointer indi-
cates the temperature within
the range of white color.
R0317

R0318

Measuring with diesel engine speed meter GAUGE CLUSTER

1. Install diesel engine speed meter pickup on and of

injection pipes on which the pickup can be easily
installed.
2. Check engine speed shown in Table in idling
speed.

6 LOW E/G
OIL PRESS

BUZZER STOP
Engine speed measured value through service SWITCH
diagnosis

1. Turn "ON" the starter switch with the buzzer stop

switch pressed.
2. A program No. and an actual engine revolution are
displayed as the No. 2 Item. SCREEN CHANGE SWITCH
3. The screen advances like No. 2, No.3....each time R0319
the "Screen change" switch on the gauge cluster is
pushed.
4. The screen returns like No. 25, No. 24....each time 2 No. 2
the buzzer stop switch is pressed. E/G SET 2150 No load set rpm
5. The display does not disappear unless the starter
MEAS 2150 Actual rpm
switch is turned to "OFF".
E/G PRS. LIVE LIVE/DEAD indication
MODE SW W W - H/M - A indication

Actual measurement of engine revolution by the

screen change switch
10 : 05 2200RPM
After the engine starts, the fol-
lowing items are displayed in
that order each time the screen
256 Hr AFT
change switch is pressed. E/G OIL CH
• Engine speed Press screen change switch
• Hours after the engine oil was four times and display
• replaced changes to clock.
R0320
Example of screen change
R0321
T4-3-2 E215-E235

TEST PROCEDURES

MEASUREMENT OF HYDRAULIC
PRESSURE

Preparing to measure hydraulic pressure

HYDRAULIC EQUIPMENT
6.9 MPa pressure gauge ................................1 unit
39.2~49 MPa Pressure gauge ........................ 2 unit
Pressure measuring equipment and
instrument for analysis .................................... 1 set

MEASURING CLEANLINESS OF HYDRAULIC OIL

WARNING
After releasing air in the hydraulic oil tank, open the
cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the
measured value is higher than the reference value,
replace the return filter or change the hydraulic oil.

Place to install pressure gauge

MAIN CIRCUIT
Replace plugs PF1/4 of main pump gauge ports a1,
a2 with plugs for pressure measurement, and attach
pressure gauge 49 MPa.

PILOT CIRCUIT
Replace pilot gauge plug a3 with plug PF1/4 for
pressure measurement, and attach pressure gauge
6.9 MPa.

NOTE - In normal condition, pressure may be meas-

ured by the below service diagnosis numbers. How-
a2 a3
ever, in faulty condition, the above pressure gauge
(a1)
must be installed and pressure adjustment is re- R0322

quired.
Main circuit No. 14
Pilot secondary pressure No. 9~13
E215-E235 T4-3-3

TEST PROCEDURES

Pressure adjustment position

MAIN CONTROL VALVE

Over load relief valve position on main control valve.

MAIN RELIEF VALVE

BOOM (H) BUCKET (H) (ATT & TRAVEL)
OR3 OR1

OPTION 2 ARM (H)

(PA02) OR7

View from the top of the machine

R0323

OPTION 2 ARM (R)

(PB02) OR8

BOOM (R) BUCKET (R)

OR4 OR2

View from the bottom of the machine

R0324
T4-3-4 E215-E235

TEST PROCEDURES

PILOT RELIEF VALVE

A3
The pilot relief valve PR1 is located on the gear pump
that is attached to the main pump.

a3

PR1

Dr3

B3

R0325

SWING OVER LOAD RELIEF

SWING LEFT SWING RIGHT
The swing motor is equipped with plugs PA, PB for OVER LOAD RELIEF OVER LOAD RELIEF
pressure measurement, but the measurement is car- OR5 OR6
ried out using gauge ports a1 and a2.

R0326
E215-E235 T4-3-5

TEST PROCEDURES

Procedure for adjusting relief valve

PILOT RELIEF VALVE

Adjust it with adjust screw (311).
: 24 mm Tightening torque: 29 Nm
: 6 mm

No. of turns of Pressure change

adjust screw MPa
LOCK NUT HEX24
1 turn Approx. 2.1
311
R0327

2-STAGE MAIN RELIEF VALVE (Common for travel

and ATT sections)
Start from the boosting side, first. Loosen nut (1), HEX32 HEX19
adjust the pressure with adjusting screw (2) and 1 2
tighten nut (1) after completion of the adjustment on
the boosting side.
Then, loosen nut (3), adjust the pressure on the
standard side with adjusting screw (4) and tighten nut
(3) after completion of the adjustment.
: 32 mm Tightening torque: 27~31 Nm
4 3
: 22 mm Tightening torque: 27~31 Nm HEX22
: 19 mm Adjust screw
: 6 mm R0328

No. of turns of Pressure change

adjust screw MPa

Boosting side 1 turn Approx. 17.6

STD side 1 turn Approx. 17.6

OVER LOAD RELIEF VALVE (Boom, bucket, arm

sections)
Loosen lock nut (1) and adjust it with adjust screw (2).
: 22 mm Tightening torque: 27~31 Nm
: 6 mm

No. of turns of Pressure change

adjust screw MPa
2 1
1 turn Approx. 17.6 HEX22

R0329
T4-3-6 E215-E235

TEST PROCEDURES

SWING OVER LOAD RELIEF VALVE

When the adjustment of pressure is required, loosen 1 2
lock nut (1) and adjust the pressure with cap (2).
: 30,38 mm Tightening torque: 118 Nm
: 12 mm

3
R

No. of turns of Pressure change R0330

adjust screw MPa

1 turn Approx. 10

TRAVEL OVER LOAD RELIEF VALVE

This valve was adjusted by valve maker. If adjustment
SHIM
is required, adjust with shim thickness.

R0331
E215-E235 T4-3-7

TEST PROCEDURES

MEASURING TRAVEL PERFORMANCES

Travel speed

PURPOSES
Measure the travel sprocket revolution and confirm
the performances between the hydraulic pump and
the travel motor of the travel drive system.

CONDITIONS
R0332
Hydraulic oil temperature: 45~55 °C
Crawler on the right and left sides are tensioned
evenly.

PREPARATION
Attach the reflection panel with a magnet to the travel
REFLECTION
motor cover. PANEL
Swing the swing frame through 90° as shown in
Figure and make the crawler on one side take off the
ground, using the attachment.

MEASUREMENT
Engine revolution: Hi idle
2-speed travel switch: 1-speed and 2-speed R0333
Measuring points: Right and left
Method, example 1:
Measure revolution with a stroboscope.
Method, example 2:
Measure the revolutions per minute visually.

Sprocket revolution Unit: min-1

Measurement Standard Reference value Service
item value for remedy limit
RH HM1 32.7~29.3 25.5~22.9 20.8~
&
LH HM2 49.0~44.0 38.2~34.3 31.2~
T4-3-8 E215-E235

TEST PROCEDURES

Deviation of travel

PURPOSE
Measure the amount of deviation at 20 m travel and
confirm the horizontal balance between the hydraulic
pump and the travel motor of the travel drive system.

CONDITION Approx. 30~40 cm

R0334
Hydraulic oil temperature: 45~55 °C
RH and LH crawler are tensioned evenly.
Plain, level and solid ground
Engine revolution: Hi idle

PREPARATION
1. Straight course more than 30 m.
2. Travel position in which the bottom of the bucket is
lifted by about 30 cm.
A
MEASUREMENT
20 m
1. Measure the max. deviation distance of the circular
arc in the 20 m length, excluding the preliminary
R0335
run of 3~5 m.
2. Operate the travel lever at the same time.

Travel deviation Unit: mm/20 m

Measurement Standard Reference value Service
position value for remedy limit
A 240 or less 480 720
E215-E235 T4-3-9

TEST PROCEDURES

Performances of parking brake

PURPOSE
Confirm that the parking brake holds a stopped con-
dition of the machine in a no-load travel position and
on a 1/5 gradient slope.

CONDITION 30 cm
A slope with 1/5 (Approx. 12°) gradient and a stopped
1/5 GRADIENT
condition in a no-load travel position (Approx. 12 deg)
R0336
PREPARATION
Place an angle meter on the shoe plate and confirm
that it makes an angle more than 12°.
Hang a perpendicular in parallel with the guide frame
rib on the track frame and put a mark (matching mark)
on the shoe plate.

MEASUREMENT
Five minutes after the engine stops, measure the C ANGLE METER
GUIDE FRAME
movement distance of the matching mark.
R0337

Parking brake Units: mm/5 min

Measurement Standard Reference value Service
position value for remedy limit
C 0 1 2
T4-3-10 E215-E235

TEST PROCEDURES

Drain rate of travel motor

PURPOSE
To measure the drain rate of the travel motor and to
confirm the performances of the travel motor.

CONDITIONS
Hydraulic oil temperature: 45~55 °C
Engine revolution: Hi idle

PREPARATION
1. Place a stopper under the RH and LH travel sprock- FORWARD ø22 PIPE
ets. 90 ø10
2. Stop the engine and vent pressure from the hy-
draulic circuit. 40
3. Connect a hose with the drain port of the travel
motor and take drain in a container. RIB "A"
150
STOPPER
"B"
MEASUREMENT AT TRAVEL LOCK
ø80
ROTARY DIRECTION
WARNING
R0338
Unless you observe the rotary force direction at
travel lock, rib "A" may be broken by stopper "B" in
some cases.

1. Start the engine and relieve pressure at the full

stroke of the travel lever.
2. Measure the drain rate for 30 seconds of relieving.

Drain rate of travel motor Unit: L/30 s

Measurement Standard Reference value Service
position value for remedy limit
Drain rate 7 14 21

R0339
E215-E235 T4-3-11

TEST PROCEDURES

MEASURING SWING PERFORMANCES

Swing speed

PURPOSE
Measure the swing time and confirm the perform-
ances between the hydraulic pump and the swing
motor of the swing drive system.

CONDITIONS
Hydraulic oil temperature: 45~55 °C
Plain, level, and solid ground
Engine revolution: Hi idle

PREPARATION
Bucket empty, arm cylinder fully retracted (Max.
reach), or arm cylinder fully extended (Min. reach)

MEASUREMENT
Swing the machine by bringing the swing lever to its
full stroke. Measure the time required to make two
turns after one turn of preliminary run and calculate
the time required for one turn.
R0340

Swing speed Unit: s/rev

Measurement Standard Reference value Service
position value for remedy limit
max.
Swing
5.0~6.2 6.4~7.9 8.4~
reach
speed min.
reach 5.0~6.2 6.4~7.9 8.4~

R0341
T4-3-12 E215-E235

TEST PROCEDURES

Performance of swing brake

PURPOSE
Confirm the braking torque performances by the
swing relief valve.

CONDITIONS
1.5 m
Hydraulic oil temperature: 45~55 °C
Plain, level and solid ground
Engine revolution: Hi idle R0342

PREPARATION
1. A height of 1.5 m at which the bottom of the bucket
matches the tip of the tooth on condition that the
bucket is empty, the arm cylinder is most retracted
and the bucket is used for digging.
2. Put a matching mark on the outer circumference of
the swing bearing of the upper frame side and of the
track frame side. Erect two poles (flags) at the front
and back of the extended line of the matching mark.

MEASUREMENT
Measuring the length of the arc over the
1. When operating in regular swing speed, by shifting outer circumference of outer race
lever to neutral position at pole position the swing
operation stops. Matching marks
2. Calculate the swing drift angle by the following on outer race B
equation, after the upper swing body stops, using
the amount of deflection (m) of the matching marks
on the swing race and the length (m) of the circum-
ference of the swing race:

Amount of deflection of Matching marks on inner race

Swing drift matching marks (m) R0343
angle (°) = × 360°
Circumferential length of
swing race (m)

Swing brake performance Unit: degree

Measurement Standard Reference value Service
position value for remedy limit
Swing 180° 55~75° 61~83° 90°
E215-E235 T4-3-13

TEST PROCEDURES

Performance of swing parking brake

PURPOSE
To confirm the mechanical performances of the swing
parking brake that is fitted to the inside of the swing
motor.

CONDITIONS 1/5
On a slope with 1/5 (Approx. 12°) gradient.
Stop the machine at right angles with the slope at the
height of 1.5 m at which the bottom of the bucket R0344

matches the tip of the tooth on condition that the

bucket is empty, the arm cylinder is most retracted
and the bucket is operated for digging.

PREPARATION
Measuring the length of the arc over the
Put the angle meter on the shoe plate and make sure outer circumference of outer race
that the angle is more than 12°.
Put a matching mark on the outer race side and on the Matching marks
on outer race C
inner race side.

MEASUREMENT
When five minutes has passed after the engine stops,
measure the length of the movement of the matching
marks.
Matching marks on inner race

R0345
Performance of swing
parking brake Unit: mm/5 min

Measurement Standard Reference value Service

position value for remedy limit
C 0 1 2
T4-3-14 E215-E235

TEST PROCEDURES

Drain rate of swing motor

PURPOSE
Measure the drain rate of the swing motor and confirm
the performances of the swing motor.

CONDITIONS
Hydraulic oil temperature: 45~55 °C R0346
Engine revolution: Hi idle

PREPARATION
1. Stop the engine.
2. Release pressure from inside the hydraulic circuit.
3. Disconnect the swing motor drain hose from its end
returning to the hydraulic oil tank and take oil in a
container.
4. Put a plug to the tank side.

MEASUREMENT; AT SWING LOCK

1. Start the engine and put the side faces of bucket
against the inside of the right or left shoe plates.
2. Relieve the swing motor at full stroke of the swing
motion.
3. Receive in a container the amount of drain accu-
mulated in 30 seconds of relieving.

Drain rate of
swing motor Unit: L/30 s R0347

Measurement Standard Reference value Service

item value for remedy limit
Drain rate 2.0 5.0 6.0
E215-E235 T4-3-15

TEST PROCEDURES

MEASURING ATTACHMENT OPERATING

PERFORMANCES

Operating time of cylinders

PURPOSE
Measure the operating time of the boom, arm and
bucket and confirm the performances between the
hydraulic pump and the cylinder of the attachment
drive system.

CONDITION
Hydraulic oil temperature: 45~55 °C
Engine revolution: Hi idle
Operating time excluding the cushion stroke

PREPARATION
Plain ground with the bucket empty

MEASUREMENT
Boom up and down
With the boom operating lever at full stroke, measure
the required operating time of the bucket between the
ground surface and its highest position.

WARNING 2
1
When lowering the boom, allow the bucket onto a
30 cm
soft ground or cushioning such as rubber tires;
never put the bucket against concrete or other solid R0348

material.

Arm in and out, bucket digging and dump

In a position in which the tooth of the bucket rises to
a level of about 30 cm above ground, measure the full
stroke operating time required with the arm and
bucket operating levers at full stroke. 3

4
R0349
Cylinder Operating time Unit: s
Measurement Standard Reference value Service
position value for remedy limit
1 3.5~4.1 4.5~5.7 5.7~
2 2.2~2.8 2.9~3.6 3.8~
3 3.0~3.6 3.8~4.6 5.0~ 8
4 2.5~3.1 3.2~4.0 4.2~
7 3.4~4.0 4.4~5.1 5.6~
8 2.7~3.3 3.5~4.2 4.5~ 7
30 cm

R0350
T4-3-16 E215-E235

TEST PROCEDURES

Oil tightness of cylinders

PURPOSE
Confirm that the cylinder oil tight by checking the
moving length of the cylinder rods.

CONDITION B
Hydraulic oil temperature; 45~55 °C
Plain, level and solid ground C
Immediately after cylinders are replaced, bleed off air
from the cylinders, before checking for oil tightness. A

CONDITIONS D
PREPARATION 1.5 m
Keep the tip of the bucket at 1.5 m height, with the
bucket empty and the arm cylinder is most retracted. R0351

MEASUREMENT
Measure the items five minutes after the engine is
turned off.

Oil tightness of cylinder Unit: mm/5 min

Measurement Standard Reference value Service
position value for remedy limit
A 7 11 14
B 6 9 12
C — — —
D 95 150 200
E215-E235 T4-3-17

TEST PROCEDURES

MEASURING PERFORMANCES OF SWING

BEARING

Axial play

PURPOSE
Measure the gap between the lower frame and the
bottom face of the swing bearing and estimate the
degree of wear of the swing bearing.

CONDITION
Plain, level and solid ground
The swing bearing mounting bolts are not loosened.
The swing bearing is lubricated well, not making
abnormal sound during turning.

PREPARATION
LOCATION OF BEARING
1. Install a dial indicator to the magnetic base and fix ATTACHING CAPSCREWS
it to the lower frame.

2. Direct the upper swing body and the lower frame SWING BEARING
toward the travel direction, bring the probe of the A
dial indicator in contact with the bottom surface of
the outer race on the swing body side and set the DIAL INDICATOR
reading at zero.
LOWER FRAME

R0352

MEASUREMENT 1
(Measuring position I and II)
1. Measure the travel of the outer race in the axial
direction in position I (The arm at 90°~110° and the
crawler front lifted about 30 cm) and in position II, 90~110°
using a dial indicator.

2. Take measurement three times on the right and the

left reapectively, and make the mean value a
measured value. 30 cm

POSITION I
R0353

Axial play of
swing bearing Unit: mm
Measurement Standard Reference value Service
position value for remedy limit
A 0.8~1.8 2.3~3.3 3.6

1.5 m

POSITION II
R0354
T4-3-18 E215-E235

TEST PROCEDURES

Tooth clearance

MEASUREMENT 2
(Measuring position III)
1. With the arm cylinder most retracted and the
bucket dump, lift the tip of the tooth of the bucket
about 10 mm and swing the tip of the bucket to the
right and the left by man power.
But in this case, the gap of the attachment is
included. 10 mm
POSITION III

Right and left R0355

movement of
then tip of bucket Unit: mm
Measurement Standard Reference value Service
position value for remedy limit
Bucket tiptoe 50 100 120
E215-E235 T4-4-1

MECHATRO CONTROLLER ADJUSTMENT

ENGINE CONTROL INPUT/OUTPUT

C-1 MECHATRO
ACCEL DIAL CONTROLLER

STARTER
SWITCH

GAUGE

GOVERNOR
CLUSTER

MOTOR

ENGINE
PUMP

ENGINE
SPEED
BUZZER WORK MODE SENSOR
STOP SW. SELECT SW.
R0356

ENGINE CONTROL INSTALLATION

B

LOW
MAX
13° 19°
39.5

(40)
(191)

)
(181
)
(198
7°) MAX
(37.
47.5°

1.2°

LOW
A

R0357

Tightening torque
23.5 ± 1.98 Nm
(20)

(12)

Tightening torque
10.7 ± 1.1 Nm
191
(12)

Tightening torque
10.7 ± 1.1 Nm Tightening torque
(20)

9.8 ± 1.0 Nm

Tightening torque
23.5 ± 1.98 Nm
Section A R0358
Section B R0359
T4-4-2 E215-E235

MECHATRO CONTROLLER ADJUSTMENT

ENGINE CONTROL EQUIPMENT

REDUCTION GEAR SECTION
OIL SEAL
Governor motor and C–1 controller MOTOR SECTION
OUTPUT SHAFT
1. By operating accel dial, the input voltage change is
sensed by CN12–2 pin of C–1 controller.
2. The C–1 controller computes the input voltage, and
outputs command to governor motor (M–2), and
CAM
incline governor lever of engine to the swing angle
corresponding to accel dial set value. LIMIT
3. The limit switch in the governor motor is the starting SWITCH
point of the governor motor.

Speed sensor
R0360
Installing place: engine flywheel housing

Work mode select switch

GAUGE CLUSTER

If the work mode select switch is pressed, a signal is

transmitted to the C–1 controller and changes the
work modes in the order of W➝H/M➝A and back
to W again.

Buzzer stop switch

When the error is detected by self-diagnosis, the C–1 MODE SELECT

controller sends alarm by sounding buzzer. And SWITCH
press buzzer stop switch to stop buzzer sounding.
Also, when the engine oil pressure has lowered or
(finish preheat), (draining hyd. press.) or (fail drain
hyd. press.) are displayed, buzzer sounds. But in this
case the buzzer sounding does not stop.
BUZZER STOP SWITCH

R0361
E215-E235 T4-4-3

MECHATRO CONTROLLER ADJUSTMENT

MECHATRO CONTROLLER "A" AND "B"

GAUGE CLUSTER
ADJUSTMENT
When the mechatro controller requires
adjustment
– After replacement of the following parts, if following
display appears on the multidisplay, the adjust-
ment of the mechatro controller is performed.
– When the mechatro controller is required to adjust.
1. When the mechatro controller is replaced, OK
2. When the governor motor is replaced WORK MODE
3. When the ROM DATA FAILURE is displayed on SELECT SWITCH
the multidisplay,
4. When the ROM DATA FAILURE and MECHATRO
SET ERROR are displayed alternately on the
multidisplay.

Preparation
BUZZER STOP SWITCH
1. Warm up engine.
R0362
2. Turn the air-con switch off.
3. Turn the starter switch off to stop the engine.

Adjustment
A ADJUSTMENT
Procedure Multidisplay Movement of governor motor
1. While keeping the work mode selector
switch on the cluster gauge pressed, turn
the starter switch ON, hold it in this condition
for 5 to 10 seconds, and release it.
10 : 05

R0363

2. The governor motor returns it to the starting A

point, and it stops at the point corresponding
to the accel dial set position.
10 : 05

Stop at the position set by accel dial

R0364

3. Keep the buzzer stop switch on the gauge A

S
cluster pressed for 5 to 10 seconds and
release it, and (STEP 1) is displayed on the
multidisplay, then wait until the next display
(STEP 2) appears.
CPU step 1 start
Automatically run
to engine stop
position (S)
R0365

S
4. After verification of the (STEP 2) display, go
to the engine room and adjust the rod Assy
standard length to (Bmm) in order to have Stop at S position
the clearance "A 0.1 mm" between the gov-
ernor lever and the engine stop set bolt. (TOOLS)
If governor motor was replaced, indicate • Spanner 17 mm
(STEP 2) display and insert rod assy. • Spanner 6 mm
• Dimension B......191 mm. • Thickness gauge
R0366
T4-4-4 E215-E235

MECHATRO CONTROLLER ADJUSTMENT

Procedure Multidisplay Movement of governor motor

5. Press the buzzer stop switch once, and wait S
A
until the (STEP 3) is displayed.

Automatically run to the engine

available position A
R0367

6. After verification of (STEP 3) display, starts A

the engine.Then, it is unaffected by the
actual accel dial position.

Stop at A position
R0364

7. Press the buzzer stop switch once, and the Lo A

(STEP 4) is displayed and the controller Hi Move from A position to
returns from the A position of governor to the Lo idling position, and
low idling position once, and then reads the self-travels from Lo
engine rpm to the high idling automatically. position to high idling
(Required time: about 2 minutes.) (H) position

R0368

Hi
8. After completion of the read out, wait until
the "CPU FINISH 2150RPM" is displayed on
the multidisplay. After the "CPU FINISH
2150RPM" is displayed, the controller re-
turns to the actual dial initial optional posi-
tion automatically. 2150RPM (Approx. 5 seconds) A
t Hi
NOTE - If the "CPU FINISH 2150RPM" is not
displayed, the adjustment has failed.Turn
the starter switch off, and perform the adjust-
ment again.
R0369

B ADJUSTMENT

9. When the screen "CPU FINISH 2150RPM"

is displayed after adjustment of engine, the
"CPU STEP 5 MEMORY" is displayed auto-
matically, the engine speed changes into
high idling and the pump is loaded, and then
"CPU FINISH ORPM" is displayed after 1
minute in high idling condition and adjust-
ment is terminated.

Adjustment End (Rechecking engine speed)

NOTE
1. The B adjustment is carried out by mechatro control-
ler after completion of A adjustment automatically.
2. The temperature control of hydraulic oil is neces-
sary to adjust it to the correct output, so special
attention must be paid to the hydraulic oil tempera-
ture.
3. When the adjustment failed, start it from A adjust-
ment after checking the relief pressure.
4. Usually the A adjustment and B adjustment must
be carried out sequentially.
1. Place starter switch to "START" position, and rise
the engine speed to the high idling.
2. Press screen change switch on gauge cluster once,
press engine speed display and auto accel release
switch, and the auto accel function is released.
3. By switching the work mode selector switch on gauge
cluster, the mode display changes, then check that
the engine speed indicated on multi display changes.
4. Press auto accel release switch on gauge cluster to
have auto accel, and check the decel speed.
5. Press screen change switch on gauge cluster 4
times to have "Time Display" and stop the engine.
TROUBLESHOOTING

R0077
TROUBLESHOOTING E215-E235

SECTION AND GROUP CONTENTS

Section 5 TROUBLESHOOTING
Group 1 Mechatro Control
Group 2 Hydraulic System
Group 3 Electrical System
SECTION 5 E215-E235

TROUBLESHOOTING

CONTENTS

Group 1 - Mechatro Control

Outline .................................................. T5-1-1

Trouble Diagnosis ................................. T5-1-3
Outline (Mechatro Control) ................... T5-1-4
Check Point for Mechatro System
(for Troubleshooting) ............................. T5-1-5

Group 2 - Hydraulic System

Trouble Diagnosis ................................. T5-2-1

Hydraulic Pressure Measurement
by Service Diagnosis ............................ T5-2-2
Troubleshooting .................................... T5-2-3

Group 3 - Electrical System

Trouble Diagnosis ................................. T5-3-1

Hydraulic Pressure Measurement
by Service Diagnosis ............................ T5-3-3
Troubleshooting .................................... T5-3-5
E215-E235 T5-1-1

MECHATRO CONTROL

OUTLINE
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred.
This manual describes how to solve the specific
phenomenon systematically as early as possible. For
troubleshooting concerning the inside of equipment,
refer to troubleshooting for each manual of equip-
ment.

Judgment of actual thing at site

R0131
GET TO THE SITE AS QUICKLY AS POSSIBLE Attending the field to verify actual thing
Verify model, serial number, situation of trouble and
field, and notify person of arrival time.

VERIFY BACKGROUND
OF TROUBLE OCCURRED
1. Model name and serial number
2. Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not unrea-
sonable.
3. Operating time by hour-meter
4. History of trouble occurred and additional works.
5. Recurrence of past trouble, or problems on the
additional works. R0132

Verifying background of trouble occurred

HOW TO DIAGNOSE TROUBLE
1. Verify defective part
2. Make the condition of trouble again
3. Where defective parts can not be verified, sur-
mise causes systematically.
4. Verify reasons for surmise
5. Report methods, procedure, and period for re-
pairing to user.

EXPLANATION OF THE CAUSE OF TROUBLE

R0133
1. Explain the cause of trouble to clients. For exam-
Confirm the symptoms of the trouble
ple, oil leak through piston is caused by flaws on
the piston rod. And the method of using the
machines should be explained so that the same
kind of trouble does not reoccur.
2. Treatment of damaged parts
The damaged parts to be claimed and returned
are evidence so they should be handled with
care. Protect them from entry of water, soils, etc.
into port of hydraulic unit, etc. and return them.
And also use care not to flaw and damage those
surfaces.
R0134

Diagnosing fail by means troubleshooting

T5-1-2 E215-E235

MECHATRO CONTROL
 Independent operation
E215-E235

Bucket dump
Bucket digging

Swing operation
TROUBLE DIAGNOSIS

Boom down operation

Actuator

Arm in inching operation

Arm in full lever operation

Arm out inching operation
Boom up inching operation

Arm out full lever operation

Boom up full lever operation

Travel LH / RH operation (1st speed)

Heavy duty arm in full lever operation

Travel LH / RH operation (2nd speed)

Operating condition
Hi pressure sensor (P1)
E
S

{
{
{
{
{
{
{
{
{
{
{
{
{
22
E
S

Hi pressure sensor (P2)

{
{
{
{
{
{
{
{
{
{
{
{
{
23
E
S

{
{
{
{
{
{
{
{
{
{
{
{
{

Low pressure sensor

1-10

Arm variable recirculation

A
V
S
P

{
{
{
solenoid proportional valve
P2 bypass cut
B
V
S
P

solenoid proportional valve

Travel straight
V
S
P

{
solenoid proportional valve
Electric

P1 bypass cut
V
S
P

{
{

solenoid proportional valve

Swing P/B
1
V
S

{
{
{
{
{
{
{
{

solenoid valve
Attachment power boost
2
V
S

{
{
{
{
{
{

solenoid valve
Travel 1-2 speed
3
V
S

{
solenoid valve
Safety lock lever
4
V
S

{
{
{
{
{
{
{
{
{
{
{
{
{

solenoid valve
P1 pump solenoid
V
S
P

{
{
{
{
{
{
{
{
{
P1

proportional valve
P2 Pump solenoid
V
S
P

{
{
{
{
{
{
{
{
{
P2

proportional valve
Boom
{
{
{
MECHATRO CONTROL

Arm
{
{
{
{
{

Bucket
{
{

Swing
{
{

Travel right
{
{

Travel left
{
{

P1 bypass cut valve

Control valve

P2 bypass cut valve

{

Travel straight valve

{

Boom conflux valve

Hydraulic

Arm conflux valve

{
{
{

Arm variable recirculation valve

{
{

Right travel motor

{
{

Left travel motor

Motor

Swing motor
{

{
{

Boom
{
{
{
{
{

Arm
Cylinder

{
{

Bucket
{

Boom lock valve

Other

{
{
{

Arm lock valve

T5-1-3
T5-1-4 E215-E235

MECHATRO CONTROL

OUTLINE (MECHATRO CONTROL)

OPERATING Pilot secondary pressure Pressure sensor Solenoid proportional valve

ATT Lever position High pressure Low pressure P1 Pump Arm variable
ATT TRAVEL Pump P2 Bypass cut Travel straight P1 Bypass cut
TRAVEL (Pump) (Pilot) P2 recirculation
ATT

Bucket digging

Bucket dump
Control lever Approx 3.0 MPa Approx 2.4 MPa
More than 4.5 V More than 4.5 V MIN 750 mA MAX 706 mA MAX 513 mA MAX 706 mA MIN 200 mA
Boom up at full stroke or more or more

Boom down

Swing left

Swing right

Arm in

Arm out
Approx 0.6 MPa Approx 0.6 MPa
Lever at neutral Approx 0.5 V Approx 0.5 V MAX 350 mA 200 mA 350 mA 200 mA 404 mA
or less or less
TRAVEL

Forward

Reverse

Operating condition: Engine speed is High idling.

E215-E235 T5-1-5

MECHATRO CONTROL

CHECK POINTS FOR MECHATRO

SYSTEM (FOR TROUBLESHOOTING)

Attaching position of sensor

PUMP RELATION

SE-23 - Press sensor: pump P2

PSV-P2 - Pump 2
proportional SOL
SE-22 - Press sensor: pump P1

PSV-P1 - Pump 1
proportional SOL

Pump assy
Pump high pressure sensor SE-22, SE-23
Pump proportional valve PSV-P1, PSV-P2 R0135

SOLENOID PROPORTIONAL VALVE BLOCK

SV-1 - Swing parking brake SOL

SV-3 - Two-speed select SOL

PSV-A - Arm variable recirculation proportional SOL

PSV-D - P1 by-pass cut proportional SOL

PSV-C - Travel priority proportional SOL

PSV-B - P2 by-pass cut proportional SOL

SV-2 - Power boost SOL

SV-4 - Operating lever lock SOL

R0138

Proportional block section PSV-A~PSV-D

T5-1-6 E215-E235

MECHATRO CONTROL

LOW PRESSURE SENSOR

FOR PILOT OPERATION
A Sensor block and Travel control valve

SE-11 - Press sensor: P2 OPT. (2-piece+N&B)

SE-10 - Press sensor: travel left

SE-9 - Press sensor: travel right

SE-20 - Press sensor: P1 OPT. (2-piece. 2-piece+N&B)

SE-11 - Press sensor: P2 OPT. (N&B)

R0136

SE-8 - Press sensor: arm out

SE-7 - Press sensor: arm in

SE-4 - Press sensor: boom down

SE-3 - Press sensor: boom up

SE-2 - Press sensor: bucket dump

SE-1 - Press sensor: bucket digging

Low pressure sensor SE-1~4, 7~11, 20 R0137

B Main control valve

Main control valve

UPPER HARNESS

SE-5: Pressure sensor: Swing

Low pressure sensor SE-5 R0139

E215-E235 T5-1-7

MECHATRO CONTROL

Components

SOLENOID PROPORTIONAL VALVE BLOCK

Arm variable recirculation

Atachment power boost

P2
P1

Safety lock lever

Travel 2-speed

Travel straight
P1 bypass cut

P2 bypass cut
Swing P/B

Tightening torque
7.0 Nm
P2 P1
T

(Directional valve) Emergency manual screw

Max. tightening torque 2.0 Nm and below Tightening torque
A8 A7 A6 A5 A4 A3 A2 A1 Slit width1.0 x depth 1.3 7.4 Nm

HYDRAULIC SYMBOL

P2 P1
P2
A8 A8 A7 A6 A5 A4 A3 A2 A1

2–Ø11

702 701 601 601 601 601 701 701

(–) SIDE (+) SIDE

LEAD WIRE LEAD WIRE

DIRECTIONAL VALVE
CONNECTOR
A8 A7 A6 A5 A4 A3 A2 A1

DETAIL OF DIRECTIONAL
VALVE CONNECTOR R0140

601 - Solenoid proportional reducing valve (Q.ty 4)

701 - Solenoid directional valve (Q.ty 3)
702 - Solenoid directional valve
T5-1-8 E215-E235

MECHATRO CONTROL

HIGH PRESSURE SENSOR

AMP MQS TYPE CONNECTOR 3 POLE (TYPE-B)

MATING CONNECTOR (FEMALE)
HOUSING: 2-967642-1
TERMINAL (GOLD PLATED): 965906-5
HARNESS SEAL: 967067-1

Terminal No. Connection

1 Common
2 Output (+)
3 Power supply (+)

22x25.4 HEX
PF3/8

O-ring P14 R0141

LOW PRESSURE SENSOR

Vout

PF1/4

Vcc GND

ELECTRIC CONNECTING DIAGRAM

(Ex. Construction of internal controller)

Vcc (CONTROLLER)
APT + 5 VDC
Vout A/D
GND
R0142
E215-E235 T5-2-1
HYDRAULIC SYSTEM

TROUBLE DIAGNOSIS (HYDRAULIC SYSTEM)

Hydraulic
2-
section
Component Pump Control valve Swing Travel motor Cylinder Other Proportional valve block Relief valve Unload propor-
motor valve valve tional
valve
block
SV1 SV2 SV3 SV4 A B C D
Main control valve Travel Swing

Travel straight proportional valve

P2 bypass cut proportional valve

P1 bypass cut proportional valve

Arm variable recirculation valve

Arm variable recirculation valve

Pilot valve (1-2 speed select)
Counterbalance check valve

Travel 1-2 speed SOL valve

Boom conflux spool valve

Swing parking SOL valve

Arm conflux spool valve

Power boost SOL valve

Counterbalance valve

Lever lock SOL valve

Check valve for relief
Travel straight spool

P2 bypass cut valve

P1 bypass cut valve

Travel unload spool

Pilot valve (travel)

ATT unload spool

Load check valve

Pilot valve (ATT)

Main relief valve

Right shockless

Right shockless
Reduction parts
Pilot relief valve

Bucket cylinder

Bucket digging

Left shockless

Left shockless
E/G revolution

Boom cylinder
Boom cylinder
Parking brake

Parking brake

Travel unload
Bypass valve

Bucket dump
Bucket spool

Arm cylinder
Travel spool
Swing spool
Boom spool

Boom down

ATT unload
Swivel joint
Lock valve
Pilot pump

Arm spool
Classification

P1 pump
P2 pump

Boom up

Arm out
Group No.

Arm in
Trouble

Motor
Device No. 1 2 3 4 5 6 7 8 9 10 11 14
No operation is possible { { { { { { {
Machine moves unexpectedly when lever is at
1 { { { { { { { { { { { { {
neutral
All actions { { { { { { { { { { { {
Bucket digging and dump { { { { { { { { { { { {
Speed is low

Down { { { { { { { { { { { {
Boom
Attachment operation

2 Up { { { { { { { { { { { { { { { {
Arm in conflux { { { { { { { { { { { { { { { {
Arm out conflux { { { { { { { { { { { { { {
All motions { { { { { { { { { { { { {
Power lacks

Bucket digging { { { { { { { { { {
3 Down { { { { { { { { { { { { {
Boom
Up { { { { { { { { { { { { { { {
Hydraulic systems

Arm in and out { { { { { { { { { { { { { { {

Bucket digging and dump { { { { { { { {
impossible
operation

Down { { { { { {
Fine

4 Boom
Up { { { { { { { { { { { {
Arm in and out { { { { { { { { { { { {
5 Travel 1, 2 speed change impossible { { { {
Travel operation

6 Travel independent speed is low { { { { { { { { { { { { { { { { { { { { { { {

7 Travel power is low { { { { { { { { { { { { { { { { { { { { { { {
Machine cannot travel straight or deviates in
8 { { { { { { { { { { { { { { { { { { {
one direction or zigzags
9 Machine does not stop still on a slope { { { { { { { {
10 Swing motion does not work { { { { { { { { { {
Swing operation

11 Swing speed is low { { { { { { { { { { { {

Swing power is low { { { { { { { { { { { {
12 Swing drifts very large { { { { { { { {
Fine operation impossible { { { { { { { { { {
13 Abnormal noise at swing { { { { { { {
T5-2-2 E215-E235

HYDRAULIC SYSTEM

HYDRAULIC PRESSURE MEASUREMENT BY SERVICE DIAGNOSIS

Main circuit pressure Secondary pilot pressure Solenoid primary pressure Solenoid proportional valve secondary pressure
(Att. operation No. 1 ~ 8 Travel operation 1 ~ 4 )

E/G Hi, E/G Hi, E/G Hi, E/G Hi, Operation is not working In operation E/G Hi, E/G Hi,
•
Full lever, at relief No load, at neutral Full lever, at relief No load, at neutral No. 5 Full lever operation
• •
• No load, at neutral
No. 14 No. 9 SOL. VALVE Swing P/B No. 20
PRESS. SENSOR Main pump P1,P2 PRESS. SENSOR 3 4 F–2 SWING-BRAKE Swing & arm digging PROPO-VALVE P1 bypass cut
C–1 PUMP P1 B–1 BOOM RAISE COMP. ON OFF indication D–1 P1 BYPASS
3.3 V 35 MPa 0.7 V 2.0 MPa 4.5 V 3.0 MPa 0.5 V 0 MPa MEAS. ON OFF indication
} 5.0 MPa COMP. 706 mA 2.8 MPa 200 mA 0 MPa
C–1 PUMP P2 B–2 BOOM LOWER RELEASE SW OFF ON/OFF indication MEAS. 706 mA 2.8 MPa 200 mA 0 MPa
3.3 V 35 MPa 0.7 V 2.0 MPa 4.5 V 3.0 MPa 0.5 V 0 MPa No. 6 No. 21
No. 15 No. 10 SOL. VALVE Travel 2-speed select PROPO-VALVE P2 bypass cut
PRESS. SENSOR OPT PRESS. SENSOR 7 8 F–3 1/2-TRAVEL D–2 P2 BYPASS
B–16 P1 OPT. B–3 ARM OUT COMP. OFF ON indication COMP. 706 mA 2.8 MPa 200 mA 0 MPa
4.5 V 3.0 MPa 0.5 V 0 MPa 4.5 V 3.0 MPa 0.5 V 0 MPa MEAS. OFF ON indication
} 5.0 MPa MEAS. 706 mA 2.8 MPa 200 mA 0 MPa
B–17 P2 OPT. B–4 ARM IN SWITCH OFF ON/OFF indication No. 22
4.5 V 3.0 MPa 0.5 V 0 MPa 4.5 V 3.0 MPa 0.5 V 0 MPa No. 7 PROPO-VALVE Travel straight
No. 11 SOL. VALVE Boost pressure select D–3 TRAVEL STRAIGHT
Conversion for pressure PRESS. SENSOR 1 2 F–1 POWER UP COMP. 528 mA 1.8 MPa 350 mA 0.7 MPa
1 MPa = 10.2 kgf/cm2 = 145 psi B–5 BUCKET DIG COMP. OFF ON indication MEAS. 528 mA 1.8 MPa 345 mA 0.7 MPa
4.5 V 3.0 MPa 0.5 V 0 MPa MEAS. OFF ON indication
} 5.0 MPa
No. 23
B–6 BUCKET DUMP SWITCH OFF ON/OFF indication PROPO-VALVE Arm variable
4.5 V 3.0 MPa 0.5 V 0 MPa D–6 A-RECIRCULAT recirculation
No. 12 COMP. 538 mA 1.7 MPa 404 mA 1.0 MPa
PRESS. SENSOR 6 5 MEAS. 538 mA 1.7 MPa 404 mA 1.0 MPa
B–7 SWING (R) No. 24
4.5 V 3.0 MPa 0.5 V 0 MPa PROPO-VALVE P1 pump
B–8 SWING (L) E–1 P1 PUMP
4.5 V 3.0 MPa 0.5 V 0 MPa COMP. 750 mA 3.0 MPa 350 mA 0.7 MPa
No. 13 MEAS. 750 mA 3.0 MPa 350 mA 0.7 MPa
PRESS. SENSOR 1,2 3,4 POWER
B–9 TRAVEL (R) SHIFT 0 mA
4.5 V 3.0 MPa 0.5 V 0 MPa No. 25
B–10 TRAVEL (L) PROPO-VALVE P2 pump
R0166 4.5 V 3.0 MPa 0.5 V 0 MPa E–2 P2 PUMP
COMP. 750 mA 3.0 MPa 350 mA 0.7 MPa
MEAS. 750 mA 3.0 MPa 350 mA 0.7 MPa
LH control lever RH control lever POWER
SHIFT 0 mA
5 Swing left 1 Bucket digging
•
NOTE - OPERATION:
• •
• No. 47
6 Swing right 2 Bucket dump
No. 20 ARM OUT or ARM IN relief operation PROPO-VALVE Travel unload
7 Arm in 3 Boom up No. 21 BOOM UP relief operation D–17 TRAVEL UNLOAD
8 Arm out 4 Boom down No. 22 ARM IN relief operation COMP. 665 mA 2.6 MPa 200 mA 0 MPa
No. 23 ARM IN operation lever turned to full MEAS. 665 mA 2.6 MPa 200 mA 0 MPa
(at 200mA arm in relief) No. 48
No. 24 during BUCKET DIGGING operation PROPO-VALVE ATT unload
LH travel lever RH travel lever
No. 25 during ARM IN operation D–18 ATT UNLOAD
3 Travel left reverse 1 Travel right reverse No. 47 e 48 TRAVEL full lever operation COMP. 665 mA 2.6 MPa 200 mA 0 MPa
4 Travel left forward 2 Travel right forward (right & left operation in the same time) MEAS. 665 mA 2.6 MPa 200 mA 0 MPa
E215-E235 T5-2-3

HYDRAULIC SYSTEM

TROUBLESHOOTING

No operation is possible

24V is alive between white/blue and black terminals of NO

To electric troubleshooting.
connector (CN-253F) of lever lock solenoid (SV-4).
YES

Is the main relief valve pres-

Only the hydraulic pilot sys- Pilot relief valve pres-
NO sure within a standard value? NO NO
tem (ATT and travel motion) sure is about 4.5MPa. Replace relief valve.
P1,P2; 34.3MPa
not operative?
(OPT)-P4; 24.5MPa. YES
YES Inspect or replace pump.
YES
Also inspect pump coupling.

Inspect if there is any other cause.

Machine does not operate if

Travel straight valve port PTb
pressure is about 0.7MPa.
YES
NO connector (CN-258F) for travel NO
To electric troubleshooting.
straight proportional valve
(PSV-C) is disconnected.
YES

Replace proportional valve NG Replace proportional valve

for travel straight. block.

The command value for un- At neutral position, pressure

NO NO
loading in operation other than sensor of attachment indi- To electric troubleshooting.
travel operation is 200mA. cates 0.5V.
YES YES

Is it OK after connector of un- At neutral position, the sec- Check unload proportional
YES NO
load proportional valve was ondary pressure for unloading valve for possible damage or
removed? is approx. 0.7MPa or less. replace it.
NO YES

The unload spool moves NO YES

smoothly by hand. There is flaw around the spool. Replace unload spool.
NO
YES

There is breakage on return NO Check unload valve or re-

spring, etc. place it.
YES

Check spring, cover and

stopper for possible dam-
age or replace them.

The primary pressure of pilot pump is NO

about 4.5MPa. Inspect or replace pilot pump and pilot relief valve.

YES

The pilot valve P port inlet pressure is NO

approx. 4.5MPa. Inspect or replace pilot line filter.

YES

The secondary pressure of pilot valve for

NO
ATT; approx. 2.9MPa. Inspect or replace pilot valve.
Travel; approx. 2.3MPa.
T5-2-4 E215-E235

HYDRAULIC SYSTEM

Machine moves unexpectedly when lever is at neutral

Machine stops moving unexpectedly if the con-

nector (CN-257F,CN-259F) for proportional YES
valve P1,P2 bypass cut (PSV-D, PSV-B) are To electric troubleshooting.
disconnected.
NO

Pump delivery pressure in no- The secondary pilot pressure of the system that
NO YES
load condition is approx. is moving unexpectedly is generated when the Inspect or replace pilot valve.
0.98MPa or lower. lever is in neutral.
YES NO

The spool returning spring of the circuit that is YES Inspect or replace spool assy
moving unexpectedly is broken. and pilot cover.
NO

The spool of the system that is

operating unexpectedly moves NO The outer circumference YES
smoothly by hand. of spool is scratched. Replace spool assy.
(Remove pilot cover.) NG
NO
YES
Replace control valve.
(Diagnosis No. 20, No. 21)

Pilot pressure at ports PCa, PCb

NO Inspect or replace the proportional valve
(P1, P2 bypass cut valve) is
approx. 0.5MPa. for bypass cut valve that is defective.
NG
YES
Inspect or replace propor-
tional valve block.

Return spring of bypass cut YES

Inspect or replace bypass cut
valve spool is broken. valve spool assy and pilot
cover.
NO

Bypass cut valve spool moves

NO Spool is scored on in- YES Replace bypass cut
smoothly by hand (together with
spection. valve spool assy.
P1 and P2 bypass cut valves).
NO NG
YES
Replace control valve.

When the lock valve, body seat and selector YES

Replace lock valve and cor-
YES
Boom or arm? parts were inspected, faults such as scratch rect body seat or replace
NO
were discovered. body or replace selector.
NO

Faults such as scratch are discovered in load YES Replace check valve, correct
check valve and seats in conflux passage and
body seat or replace body.
recirculation passage. (CCb,CCa, CAr)
NO

Spool of the circuit that oper-

YES
ates unexpectedly is scored Replace spool assy.
on inspection.
NO
Inspect the cylinder of the cir-
Inspect or replace overload Inspect or replace control
cuit that operates unexpect-
relief valve. valve.
edly and replace if faulty.
(Inside leak)
E215-E235 T5-2-5

HYDRAULIC SYSTEM

All ATT operations are slow

(Service Diagnosis No. 24, No. 25)

Command current readings of pump propor-

tional valve are at standard levels (below) dur- The sum of pump pressures
NO NO
ing operation. (P1+P2) during check operation To electric troubleshooting.
P1; approx. 750mA by bucket operation. is 28.0MPa.
P2; approx. 750mA by swing operation. YES
Inspect or replace boost
YES check, bypass check piping.

Do motions get normal if the coupler (PSV-C)

YES
for travel straight proportional valve is discon- To electric troubleshooting.
nected?
NO
NO Inspect or replace pilot pump
Primary pilot pressure is 4.5MPa. and pilot relief valve.
YES

Secondary pilot pressure at PTb port (travel YES Inspect or replace travel NG Inspect or replace propor-
straight) is approx. 0.7MPa. straight proportional valve. tional valve block.
NO

Inspect or replace travel

NO
Return spring of travel straight spool is broken. straight spool assy and pilot
cover.
YES

Travel straight spool moves smoothly by hand NO Outer circumference of travel YES Replace travel straight spool
(Remove the pilot cover). straight spool is scored. assy.
YES NO NG

Replace control valve.

The command value for un- At neutral position, pressure

NO NO
loading in operation other than sensor of attachment indi- To electric troubleshooting.
travel operation is 200mA. cates 0.5V.
YES YES

Is it OK after connector of un- At neutral position, the sec- Check unload proportional
YES NO
load proportional valve was ondary pressure for unloading valve for possible damage or
removed? is approx. 0.7MPa or less. replace it.
NO YES

The unload spool moves NO There is flaw around YES

smoothly by hand. the spool. Replace unload spool.
YES NO

There is breakage on return NO Check unload valve or re-

spring, etc. place it.
YES

Check spring, cover and

stopper for possible dam-
age or replace them.

Main relief pressure lies within standard level NO Inspect or replace main relief NG Replace control valve or
P1,P2; 34.3MPa. valve. pump.
YES

Replace pump proportional NG Inspect or replace pump regu-

valve. lator.
NG

Replace pump.
T5-2-6 E215-E235

HYDRAULIC SYSTEM

Only the bucket operation is slow

Is the motion normal if connector (CN-257F) for YES

P2 bypass cut proportional valve is discon- To electrical troubleshooting.
nected?
NO

Secondary pilot pressure at PBc, PAc ports NO

Inspect or replace pilot valve.
(bucket digging and dump ports) is 2.9MPa.
YES

(Service Diagnosis No.24)

Pump pressure during check operation
Command current readings of P1 pump propor- NO lies within standard value (below). YES
tional valve are within standard levels (below) P1; digging approx 8.0MPa To electrical troubleshooting.
during full lever operation. dump approx 16.0MPa
750mA in bucket operation. P2; approx 0.98MPa
YES NO Inspect or replace control
valve.

Relief pressure lies within standard levels Inspect overload relief valve
NO YES
(below) when bucket operation is changed. Relief pressures for both digging and on the faulty pressure side
34.3MPa. dump operations are abnormal. and replace valve if defective.
NO
YES

Confirm the check valve before

main relief valve for control NG
valve. Replace control valve.
Check the seat of it as well.
(CMR1,CMR2)

YES
Return spring for bucket spool is broken. Replace bucket spool assy.
NO

Bucket spool moves smoothly by hand. NO Outer circumference of bucket spool is YES
Replace bucket spool assy.
(Remove pilot cover.) scored.
NG
YES NO
Replace control valve.

Is the motion slow if coupler for travel straight NO To electric troubleshooting.

proportional valve is disconnected? (to "All motions are slow")
YES

Pilot pressure at port PTb (travel straight) is NO Inspect or replace travel NG Inspect or replace propor-
approx. 0.7MPa. straight proportional valve. tional valve block.
YES

YES
Inspect travel straight spool
Return spring for travel straight spool is broken. assy and pilot cover and re-
NO
place them if faulty.

NO Outer circumference of travel straight YES Replace travel straight spool

Travel straight spool moves smoothly by hand.
spool is scored. assy.
YES
NO NG

Replace control valve.

Is the motion slow if pump delivery ports P1 and NO

Inspect or replace pump.
P2 are exchanged?
YES
Replace control valve.

Inspect bucket cylinder for oil

tightness and replace if defec-
tive.
E215-E235 T5-2-7

HYDRAULIC SYSTEM

Only the boom up operation is slow

(Service Diagnosis No.21)

Control current of P2 bypass cut proportional NO

valve is approx. 706mA when full lever opera- To electric troubleshooting.
tion is performed for boom raise motion.
YES

Secondary pilot pressure at port PCa (P2 by- NO Inspect or replace P2 bypass cut propor- NG Inspect or replace
pass cut valve) is approx. 2.7MPa. tional. proportional valve block.
YES

Pilot pressure at PAb, PB1 ports (boom raise NO Inspect or replace ATT pilot
and boom conflux) is 2.9MPa. valve.
YES

(Diagnosis 24,25)

Command current readings for pump propor-

Does the pump delivery pressure lie at
tional valve lie within standard levels (below) NO normal levels during check operation? NO
during the above operation. To electric troubleshooting.
Normal values for P1 & P2;
P1; approx. 640mA.
approx. 15.0MPa
P2; approx. 640mA.
YES YES

Hasn't the weight changed by the change NO Change ATT to normal one
of ATT's? and reconfirm.
YES

Inspect or replace control

valve.

Relief pressure lies within standard level (be- NO NG Replace overload relief valve
low) when boom up lever is turned to the full. Adjust boom port relief pressure.
at port Ab (boom head side).
34.3MPa.
YES

Return spring for P2 bypass cut valve spool is YES Inspect or replace P2 bypass
broken. cut spool assy and pilot cover.
NO

P2 bypass cut valve spool moves smoothly by NO Outer circumference of P2 bypass cut YES Replace P2 bypass cut spool
hand. (Remove pilot cover.) valve spool is scored. assy.
YES NO NG

Replace control valve.

Return spring of boom spool is broken. YES Inspect or replace boom spool
(Remove pilot cover.) assy and pilot cover.
NO
NO YES
Boom spool moves smoothly by hand. Outer circumference of boom spool is
Replace boom spool assy.
(Remove pilot cover.) scored.
NO NG
YES
Replace control valve.

YES Inspect or replace boom spool

Return spring for boom conflux spool is broken.
assy and Pilot cover.
NO
NO Outer circumference of boom conflux YES Replace boom conflux spool
Boom conflux spool moves smoothly by hand.
spool is scored. assy.
YES NO NG

Replace control valve.

T5-2-8 E215-E235

HYDRAULIC SYSTEM

Without boom up, arm in and arm out are slow

(Diagnosis No. 22)

Pilot pressure at port PTb (travel straight) is YES Inspect or replace travel straight propor- NG Inspect or replace
approx. 0.7MPa. tional valve. proportional valve block.
NO
YES
Inspect or replace travel
Return spring for travel straight spool is broken. straight spool assy and pilot
cover.
NO

Travel straight spool moves smoothly by hand. NO Outer circumference of travel straight YES
Replace travel straight spool
(Remove pilot cover.) spool is scored. assy.
YES NO NG

Replace control valve.

Only arm in operation is slow

(Service Diagnosis No. 23)

Control current readings for arm recirculation NO

proportional valve are about 538mA when To electric troubleshooting.
W-mode arm in lever is turned to the full.
YES

Pilot pressure at arm variable recirculation is NO Inspect or replace arm variable NG Inspect or replace
port Pis approx. 1.8MPa. recirculation proportional valve. proportional valve block.
YES

Command current readings for pump propor-

tional valve lie within standard levels (below)
NO
during the above operation. To electric troubleshooting.
P1; approx. 350mA.
P2; approx. 750mA.
YES

Secondary pilot pressure at PAa, PLC2 ports NO

Inspect or replace pilot valve.
(arm in, lock valve release) is approx. 2.9MPa.
YES

Relief pressure lies within standard levels NO

Adjust or replace overload re-
when arm in is operated. lief valve on the arm head (H)
34.3MPa. side.
YES

Arm spool or recirculation spool return spring is YES Inspect or replace arm spool,
broken. recirculation spool and pilot
cover.
NO

Arm spool or recirculation spool moves Outer circumference of arm spool or YES Replace arm spool or
smoothly by hand. (Remove pilot cover.) recirculation spool is scored. recirculation spool assy.
YES NO NG

Replace control valve.

E215-E235 T5-2-9

HYDRAULIC SYSTEM

Only arm out operation is slow

NO
Hydraulic oil temperature is 50 °C or more. Heat oil and inspect.
YES
(Service Diagnosis No. 28)

Command current for P1 bypass cut propor- NO

tional valve is approx. 700mA when arm out To electric troubleshooting.
lever is shifted to the full.
YES

Secondary pilot pressure at port Pbc NO

Inspect or replace P1 bypass cut propor- NG Inspect or replace propor-
(P1 bypass cut valve) is approx. 2.7MPa. tional valve. tional valve block.
YES

Secondary pilot pressure at port PBa (arm out) NO

is approx. 2.9MPa or over. Inspect or replace pilot valve.

YES
(Service Diagnosis No. 24, 25)

Command current readings for pump propor-

tional valve lie within standard levels (below) NO YES
during the above operation. To electric troubleshooting.
P1; approx. 565mA.
P2; approx. 565mA.
YES

Relief pressure lies within standard level (be- NO Inspect or replace overload
low) when arm out is turned to the full. relief valve at port Ba (arm rod
34.3MPa. side).
YES
YES Inspect or replace arm spool
Arm spool return spring is broken.
assy and pilot cover.
NO

Arm spool moves smoothly by hand. NO Outer circumference of arm spool is YES
(Remove pilot cover.) scored. Replace arm spool assy.

YES NO NG

Replace control valve.

Return spring of P1 bypass cut valve spool is NO Inspect or replace P1 bypass

broken. cut valve spool assy and pilot
cover.
YES

P1 bypass cut valve spool moves smoothly by NO Outer circumference of P1 bypass cut YES Replace P1 bypass cut valve
hand. (Remove pilot cover.) valve spool is scored. spool assy.
YES NO NG

Replace control valve.

NO
Arm conflux spool return spring is broken. Inspect or replace arm conflux
spool assy and pilot cover.
YES

Arm conflux spool moves smoothly by hand. NO Outer circumference of arm conflux spool YES Replace arm conflux spool
(Remove pilot cover.) is scored. assy.
YES NO NG

Replace control valve.

T5-2-10 E215-E235

HYDRAULIC SYSTEM

All ATT operating power is poor

Each independent operating speed is within a NO Refer to "All ATT operations

standard value. are slow".
YES

Relief pressure lies within standard level NO Adjust main relief pressure of control NG Replace the relief valve of
P1,P2; 34.3MPa. valve. main control valve.
YES
NO NG Replace pilot pump and relief
Primary pilot pressure is approx. 4.5MPa. Adjust pilot relief pressure.
valve.
YES

YES
Inspect or replace travel
Travel straight spool return spring is broken. straight spool assy and pilot
cover.
NO

Travel straight spool moves smoothly by hand. NO Outer circumference of travel straight YES Replace travel straight spool
(Remove pilot cover.) spool is scored. assy.
YES NO NG

Replace control valve.

Inspect or replace control

valve or pump.

Bucket digging power is poor

No-load independent operating speed is within NO Refer to "Only the bucket op-
a standard value. eration is slow."
YES

Relief pressure lies within standard level (be- NO Adjust overload relief valve on bucket NG Replace overload relief valve
low) when bucket digging lever is turned to the
digging side. at port BC (bucket head side).
full. 34.3MPa.
YES

Secondary pilot pressure at port PBC (bucket NO

digging) is approx. 2.9MPa. Inspect or replace pilot valve.

YES
YES Inspect or replace bucket
Bucket spool return spring is broken. spool assy and pilot cover.
NO
NO YES
Bucket spool moves smoothly by hand. (Re- Outer circumference of bucket spool is Replace bucket spool assy.
move pilot cover.) scored.
NG
YES NO
Replace control valve.

Replace control valve or

pump.
E215-E235 T5-2-11

HYDRAULIC SYSTEM

Boom up operating power is poor

No-load independent operating speed is within NO Refer to "Only the boom up

a standard value. operation is slow".
YES

Relief pressure lies within standard level (be- Adjust or replace overload re-
NO NG
low) when boom up lever is turned to the full. Adjust main relief on control valve. lief valve at port Ab (boom
34.3MPa. head side).
YES

Secondary pilot pressure at boom raise PAb NO

Inspect or replace pilot valve.
port and boom conflux PB1 port is 2.9MPa.
YES

YES Inspect or replace boom spool

Boom spool return spring is broken.
assy and pilot cover.
NO

NO Outer circumference of boom spool is YES

Boom spool moves smoothly by hand. Replace boom spool assy.
scored.
YES NG
NO
Replace control valve.

YES Inspect or replace boom con-

Boom conflux spool return spring is broken.
flux spool assy and pilot cover.
NO

NO Outer circumference of boom conflux YES Replace boom conflux spool

Boom conflux spool moves smoothly by hand.
spool is scored. assy.
YES
NO NG

Replace control valve.

Inspect or replace control

valve or pump.
T5-2-12 E215-E235

HYDRAULIC SYSTEM

Arm in power is poor

No-load independent operating speed is within NO Refer to "Only arm in opera-

a standard value. tion is slow".
YES

Relief pressure during arm in for both P1 and P2 Adjust or replace overload re-
NO NG
pumps lies within standard levels. Adjust main relief on control valve. lief valve at port Aa (on arm
P1,P2; 34.3MPa. head side).
YES
(Service Diagnosis No. 23)

Control current readings for arm recirculation NO

To electric troubleshooting.
proportional valve are about 538mA when Refer to "Only arm in opera-
W-mode arm in lever is turned to the full. tion is slow".
YES

Pilot pressure at arm variable recirculation port NO Inspect or replace arm variable recircula- NG Inspect or replace propor-
Pis is about 1.8MPa tion proportional valve. tional valve block.
YES

Control current of arm recirculation proportional NO

To electric troubleshooting.
valve during arm in relief normal.
(approx. 200mA)
YES

Pilot pressure of port Pis (arm recirculation) NO Inspect or replace arm variable recircula- NG Inspect or replace propor-
during arm in operation is approx. 0.5MPa tion proportional valve. tional valve block.
when lever is turned to the full.
YES

Secondaly pilot pressure at arm in port PAa and NO

Inspect or replace pilot valve.
arm lock valve release PLC2 port is 2.9MPa.
YES
YES Inspect or replace arm spool
Arm spool return spring is broken.
assy and pilot cover.
NO

Arm spool moves smoothly by hand. NO Outer circumference of arm spool is YES
Replace arm spool assy.
(Remove pilot cover.) scored.
YES NG
NO

Replace control valve.

Inspect or replace arm vari-

Arm variable recirculation spool return spring is YES
able recirculation spool assy
broken. and pilot cover.
NO

Arm variable recirculation spool moves smooth- NO Outer circumference of arm variable recir- YES Replace arm variable recircu-
ly by hand. (Remove pilot cover.) culation spool is scored. lation spool assy.
YES NG
NO

Replace control valve.

Replace control valve or

pump.
E215-E235 T5-2-13

HYDRAULIC SYSTEM

Machine can not perform fine operation of bucket digging and dump

(Diagnosis No. 24)

Current value of P1 pump proportional Is the action okay if the propor- Replace pump propor-
NO YES
valve when lever is neutral is less than tional valve for P1 is ex- tional valve.
705mA. (engine high idle) changed by the one for P2?
YES NO

To electric troubleshooting.

Machine returns normal if connector of P1 bypass cut proportional valve YES

To electric troubleshooting.
(PSV-D) is disconnected.
NO
(Service Diagnosis No. 20)
(Service Diagnosis No. 14)
Secondary pilot pressure at
Non-load pressure of P1 pump is less Inspect or replace P1
NO port PCb (P1 bypass cut YES NG Inspect or replace propor-
than 0.98MPa when bucket digging bypass cut propor-
valve) YES
is approx. 0.7MPa tional valve block.
lever is at neutral. tional valve.
when lever is at neutral.
YES
NO

Inspect or replace P1 by-

P1 bypass cut spool return YES
pass cut spool assy and
spring is broken.
pilot cover.
NO

P1 bypass cut spool moves Outer circumference

NO YES Replace P1 bypass cut
smoothly by hand. (Remove of P1 bypass cut
spool assy.
pilot cover). spool is scored.
NG
YES NO

Replace control valve.

(Service Diagnosis No. 11)

Secondary pressure of pilot valve is

NO Inspect or replace pilot
approx. 0.8MPa when bucket close
valve.
lever is just shifted a little.
YES

Bucket spool return spring is broken.

YES Inspect or replace bucket
spool assy or pilot cover.
NO

Bucket spool moves smoothly by NO Outer circumference of bucket YES Replace bucket spool
hand. (Remove pilot cover.) spool is scored. assy.
YES NO NG

Replace control valve.

T5-2-14 E215-E235

HYDRAULIC SYSTEM

Machine can not perform fine operation of boom raise and lower motions

(Diagnosis No. 24)

Is the action okay if
Current value of P1 pump proportional valve when lever is neutral is less NO the proportional valve YES Replace pump propor-
than 350mA. (engine high idle) for P1 is exchanged tional valve.
YES by the one for P2?
NO

To electrical troubleshooting.

Machine gets normal if connector of P1 bypass cut proportional valve is YES

To electrical troubleshooting.
disconnected.
NO
(Service Diagnosis No. 20)

Secondary pilot pressure at

No-load pressure of P1 pump is less Inspect or replace
NO port PCb (P1 bypass cut YES NG Inspect or replace propor-
than 0.98MPa when boom lever is at proportional valve for
valve) isYES
approx. 0.7MPa. tional valve block.
neutral. P1 bypass cut valve.
YES
NO

Inspect or replace P1 by-

Return spring of P1 bypass cut YES
pass cut spool assy and pilot
spool is broken.
cover.
NO

Outer circumference
P1 bypass cut spool moves NO YES Replace P1 bypass cut
of P1 bypass cut
smoothly by hand. spool assy.
spool is scored.
NG
YES NO

Replace control valve.

(Service Diagnosis No. 9)

Secondary boom pilot pressure is

NO
approx. 0.54MPa when lever is just Inspect or replace pilot valve.
shifted.
YES

Return spring of boom spool is broken.

YES Inspect or replace boom spool
assy and pilot cover.
NO

NO Outer circumference of boom YES

Boom spool moves smoothly by hand. Replace boom spool assy.
spool is scored.
YES
NO NG

Replace control valve.

Does boom lock valve move smoothly NO

Inspect or replace lock valve.
by hand?
YES

Replace control valve.

E215-E235 T5-2-15

HYDRAULIC SYSTEM

Machine can not perform fine operation of arm in and out

(Diagnosis No. 25)

Is the action okay if
Current value of P2 pump proportional valve when lever is neutral is less NO the proportional valve YES Replace pump propor-
than 705mA. (engine high idle) for P1 is exchanged tional valve.
YES by the one for P2?

Machine gets normal if connector of P2 bypass cut proportional valve is YES To electrical troubleshoot-
disconnected. ing.
NO

Secondary pilot pressure at Inspect or replace

P2 pump unload pressure is less than NO NO NG Inspect or replace propor-
port PCa (P2 bypass cut proportional valve for
0.98 MPa when arm lever is at neutral. tional valve block.
valve) is approx. 0.7 MPa. P2 bypass cut valve.
YES
YES

Inspect or replace P2 by-

Return spring of P2 bypass cut YES
pass cut spool assy and
spool is broken.
pilot cover.
NO

P2 bypass cut spool moves Outer circumference

NO YES Replace P2 bypass cut
smoothly by hand. of P2 bypass cut
spool assy.
(Remove pilot cover) spool is scored.
NG
YES NO

Replace control valve.

(Service Diagnosis No. 10)

Secondary pressure is approx.
NO Inspect or replace pilot
0.9 MPa when arm lever is shifted a
valve.
little.
YES

YES
Return spring of arm spool is broken. Replace arm spool assy.
NO

NO Outer circumference of arm YES

Arm spool moves smoothly by hand. Replace arm spool assy.
spool is scored.
YES NO NG

Replace control valve.

Arm lock valve moves smoothly by NO Inspect or replace lock

hand. valve.
YES

Replace control valve.

Travel 1st and 2nd speeds can not be changed over

24V is alive across light green/black and black of NO

To electrical troubleshooting.
connector for travel 1-2 speed solenoid (SV-3).
YES

Pilot pressure of travel 1-2 speed select sole- Inspect or replace travel 1-2 speed select Inspect or replace propor-
NO NG
noid (SV-3) is excited. solenoid valve. tional valve block.
YES

Travel 1-2 speed select can not be done in NO Inspect travel motor (throttle in passage to 1-2 speed select valve, inclusion of
heavy duty condition on a slope or on a muddy
foreign matter in shuttle valve, etc.) or replace it.
land.
YES

Since the delivery rate of pump is small at heavy duty, the difference between 1st
and 2nd speeds gets smaller. This makes you feel sometimes that speed is not
changed. But this is normal.
T5-2-16 E215-E235

HYDRAULIC SYSTEM

Travel independent speed is low (in full lever operation)

Engine idling speed in travel operation NO Refer to Article "Machine

is within standard values. does not travel straight".
YES

At high loading, pump de-

Travel speed on steep slope and
muddy ground is slow.
NO
YES
livery rate becomes lower
developing the difference
of flow on both right and
left side, but it is normal.

The indicated current values of both

The secondary pressure of
pump proportional valves when NO NO
travel pilot valve is approx. Replace travel pilot valve.
traveling are within standard values.
2.4MPa or more.
P1, P2: Approx. 750 mA.
YES
YES

The pump pressure at engine

YES To electric troubleshoot-
idling for traveling is in the
ing.
range of 4.5 to 7MPa.
NO

The indicated current values of both

The secondary pressure of
travel unload and ATT pump propor- NO NO
travel pilot valve is approx. Replace travel pilot valve.
tional valves when traveling are within
2.4MPa or more.
standard values.
Both values: approx. 665 mA. YES
YES

To electric troubleshoot-
ing.

Is it OK after connector of unload pro- The secondary pressure for
YES
portional valve was disconnected? unloading is approx. 2.4MPa
or more. (Travel & ATT).
NO
YES
Check unload proportional
NO
valve for possible damage
or replace it.

The unload spool moves There is flaw around

Replace unload spool.
smoothly by hand. the spool.
YES

There is breakage on return YES

Check spring, cover and
spring, etc. stopper for possible dam-
age or replace them.
NO

Check unload valve for

(continue) possible damage or re-
place it.
E215-E235 T5-2-17

HYDRAULIC SYSTEM

(continue)

The control current values of

Is it OK after connector of travel
YES travel straight proportional NO
straight proportional valve was discon- To electric troubleshooting.
valve is 350 mA. (Full lever
nected?
position)
NO
YES

The secondary pressure

travel straight valve is approx. NO Check travel straight proportional valve for possible
0.7MPa or less. (Full lever damage or replace it.
position)
YES

There is breakage on return spring, YES Check travel straight spool Assy, cover and spring for
etc. of travel straight spool. possible damage or replace them.
NO

The travel straight spool moves NO There is flaw around the travel YES
smoothly by hand. Replace travel straight spool.
straight spool.
YES NO

Check control valve for possible damage or replace

it.

There is a breakage on return spring, YES

Replace travel spool.
etc. of travel spool.
NO

The travel spool moves smoothly by NO There is flaw around the travel YES Check travel spool Assy, cover and spring for possible
hand. spool. damage or replace them.
YES NO

Check control valve for possible damage or replace

it.

Relief pressure value when traveling NO Check travel motor relief valve for possible damage or
are within standard values. replace it.
YES

Check travel motor for possible damage or replace it.

T5-2-18 E215-E235

HYDRAULIC SYSTEM

Travel power is poor

Engine idling speed in travel operation NO Refer to Article "Travel Deviation" or "Travel speed is
is within standard values. poor".
YES

Travel speed on steep slope and NO

At high loading, pump delivery rate becomes lower
muddy ground is slow. resulting is slow travel speed and poor power, but it si
normal.
YES

The indicated current values of both

travel proportional valves when NO Refer to article "Travel Deviation, Travel speed is
traveling are within standard values. slow".
P1, P2: approx. 750 mA.
YES

The relief pressure for boom-

The relief pressure on both travels are NO NO Check main relief valve for possible damage or replace
up operation is within standard
within standard values. it.
values.
YES
YES

The indicated current values of both

travel unload and ATT proportional NO The secondary pressure of NO
valves when traveling are within stand- travel pilot valve is approx. Replace travel pilot valve.
ard values. 2.4MPa or more.
Both values: approx. 665 mA. YES
YES To electric troubleshooting.

The secondary pressure for

Is it OK after connector of unload pro- YES NO Check unload proportional valve for possible damage
unloading is approx. 2.4MPa
portional valve was disconnected? ore replace it.
or more. (Travel & ATT)
NO
YES

The unload spool moves NO There is flaw around YES

the spool. Replace unload spool.
smoothly by hand.
YES NO

Check unload valve for

There is breakage on return NO
possible damage ore re-
spring, etc. place it.
YES

Check spring, cover and

stopper for possible dam-
(continue) age ore replace them.
E215-E235 T5-2-19

HYDRAULIC SYSTEM

(continue)

The control current values of

Is it OK after connector of travel YES NO
travel straight proportional
straight proportional valve was discon- To electric troubleshooting.
valve is 350 mA.
nected?
(Full lever position)
NO
YES

The secondary pressure of

travel straight valve is approx. NO Check travel straight proportional valve for possible
0.7MPa or less. damage or replace it.
(Full lever position)
YES

There is breakage on return spring, YES Check travel straight spool assy, cover and spring for
etc. of travel straight spool. possible damage or replace them.
NO

The travel straight spool moves NO There is flaw around the travel YES
Replace travel straight spool.
smoothly by hand. straight spool.
YES NO

Check control valve for possible damage or replace

it.

There is breakage on return spring, YES Check travel spool assy, cover and spring for possible
etc. of travel spool. damage or replace them.
NO

The travel spool moves smoothly by NO There is flaw around the travel YES
Replace travel spool.
hand. spool.
YES NO

Check control valve for possible damage or replace

it.

Check travel motor relief valve

Check travel motor for possible damage or replace
for possible damage or re-
it.
place it.
T5-2-20 E215-E235

HYDRAULIC SYSTEM

Machine does not travel straight

The secondary pressure Check pump propor-

The indicated current value of of pump proportional tional valve for possi-
Travel idling speed of both crawlers NO
pump proportional valves at
YES NO
are within strandard values. valve is approx. 2.8MPa ble damage or replace
idling is within standard values. or more (P1, P2). it.
NO
YES

YES The pump operating pressure Replace pump regu-

at idling is 10MPa or less. lator.
NO

The secondary pressure of travel pilot NO Check travel pilot valve for possible
valve is approx. 2.4MPa or more. damage or replace it.
YES

Are the input values of travel pressure

NO
sensor on both sides in Services Diagno- To electric troubleshooting.
sis normal? Approx.: 2.4MPa.
YES

At high loading, pump delivery flow

Travel speed on steep slope and YES rate lowers developing difference
muddy ground is slow. of flow rates on both sides, but it is
normal.
NO

The indicated current values of both

travel unload and ATT unload propor-
tional valves when traveling are within
standard values. 665 mA for both.
NO
YES The secondary pressure of travel pilot valve is NO
Replace travel pilot valve.
Approx. 2.4MPa or more.
YES
To electric troubleshooting.

Is it OK after connector of unload pro- YES The secondary pressure for unloading is NO Check unload proportional valve for
portional valve was disconnected? approx. 2.4MPa or more. (Travel & ATT). possible damage or replace it.
NO YES

The unload spool moves NO There is flaw around the YES Replace unload
smoothly by hand. unload spool. spool.
YES NO

NO
Check unload valve
There is breakage on return for possible damage
spring, etc. or replace it.
YES

Check spring, cover

and stopper for possi-
ble damage or replace
(continue) them.
E215-E235 T5-2-21

HYDRAULIC SYSTEM

(continue)

Is it OK after connector of travel YES

The control current values of travel straight NO
straight proportional valve was discon- proportional valve are 350 mA. (Full lever posi- To electric troubleshooting.
nected? tion)
NO YES

NO Check travel straight proportional

The secondary pressure of travel straight valve
valve for possible damage ore replace
is Approx. 0.7MPa or less. (Full lever position)
it.
YES

There is breakage on return spring, YES Check travel straight spool assy, cover
etc. of travel straight spool. and spring for possible damage or
replace them.
NO

The travel straight spool moves NO YES

There is flaw around the travel straight spool. Replace travel straight spool.
smoothly by hand.
YES NO

Check control valve for possible dam-

age or replace it.

Check travel spool assy, cover and

There is breakage on return spring, YES
spring for possible damage or replace
etc. of travel spool. them.
NO

The travel spool moves smoothly by NO YES

There is flaw around the travel spool. Replace travel spool.
hand.
YES NO

Check control valve for possible dam-

age or replace it.

The relief pressure on both travel op- NO Check travel motor relief valve for pos-
erations are within standard values. sible damage or replace it.
YES

Check travel motor for possible dam-

age or replace it.
T5-2-22 E215-E235

HYDRAULIC SYSTEM

Travel straight (Operations at travel full lever + Some attachment full lever)

All independent operations and the swing and NO Refer to Troubleshooting for
travel independent operations are normal. abnormal operations.
YES

The control current value of travel straight NO

To electric troubleshooting.
proportional valve is 528 mA.
YES
Check proportional valve for the travel Check proportional valve
The travel straight pilot secondary pressure is NO
straight spool for possible damage or re- block for possible damage or
about 1.75MPa.
place it. replace it.
YES

Check travel straight spool

YES
There is breakage on return spring, etc. of assy, cover and spring for
travel straight spool. possible damage ore replace
NO them.

The travel straight spool moves smoothly by NO There is flaw around the travel straight YES
Replace travel straight spool.
hand. spool.
YES NO

Replace control valve.

Machine drifts on a slope (Machine can not be held on a slope)

Machine can not be held on a slope when YES Inspect or replace travel mo-
engine is off. tor.
NO

NO Inspect or replace control

Secondary pilot pressure for travel is 0MPa.
valve.
YES
YES Inspect or replace travel spool
Return spring of travel spool is broken.
assy and pilot cover.
NO
NO Outer circumference of travel spool is YES
Travel spool moves smoothly by hand. Replace travel spool.
scored.
YES NG
NO
Replace control valve.
E215-E235 T5-2-23

HYDRAULIC SYSTEM

Swing motion does not work

Machine moves if connector of swing parking is YES

To electric troubleshooting.
disconnected.
NO

Is the pilot pressure of parking SOL reduced to NO NG

Inspect or replace swing parking sole- Inspect or replace
0MPa when the secondary pressure of pilot
noid. proportional valve block.
valve is 0.7MPa?
YES

Secondary pressure of swing pilot valve is NO Dirt or something is stuck in the orifice of YES
2.9MPa for both ways. valve. Inspect or replace orifice.
YES NO

Inspect or replace pilot valve.

Orifice in spool cover of C/V or orifice on under YES

Inspect or replace orifice.
cover is restricted.
NO
NO
Is shuttle in spool cover normal? Replace spool cover.
YES

YES Inspect or replace swing spool

Return spring of swing spool is broken.
assy and pilot cover.
NO

Swing spool moves smoothly by hand. NO Outer circumference of swing spool is YES
scored. Replace swing spool assy.
(Remove pilot cover.)
YES NG
NO

Replace control valve.

Swing relief pressure lies within standard level. NO Inspect or replace swing mo-
27.9MPa. tor relief.
YES NG

Machine can be held on a slope during swing NO Inspect or replace swing re-
motion. duction unit and swing motor.
YES

Machine drifts very much when swing parking YES Inspect or replace swing mo-
is released (arm in action) on a slope. tor.
NO

Inspect or replace swing re-

duction unit and swing motor.
T5-2-24 E215-E235

HYDRAULIC SYSTEM

Swing speed is slow

Command current of pump proportional valve NO

at operating P1: Approx. 350 mA. To electric troubleshooting.
P2: Approx. 640 mA.
YES

Secondary pilot pressure for swing motion is NO YES

Dirt or something is stuck in the restrictor
approx. 2.9MPa when lever is turned to the full Inspect or replace orifice.
of spool cover.
in either direction. NG
NO
YES
Inspect or replace pilot valve.

NO
Is shuttle in spool cover normal? Replace spool cover.
YES

Orifice in spool cover of remote control piping is YES Inspect or replace orifice of
clogged with foreign matter. spool cover.
NO

Swing relief pressure lies within standard level. NO Inspect or replace swing mo-
27.9MPa. tor relief.
YES NG

Machine drifts very much when swing parking YES Inspect or replace swing mo-
is released (arm in action) on a slope. tor.
NO

YES Inspect or replace swing spool

Return spring of swing spool is broken. assy and pilot cover.
NO

NO Outer circumference of swing spool is YES

Swing spool moves smoothly by hand. Replace swing spool assy.
scored.
YES NG
NO

Replace control valve.

Is the motion slow if pump delivery ports P1 and NO Inspect or replace P2 pump
P2 are exchanged? proportional valve.
NG

Inspect or replace pump regu-

lator.
NG

Inspect or replace pump.

E215-E235 T5-2-25

HYDRAULIC SYSTEM

Swing power is poor

NO Refer to "Swing speed is

Swing speed lies within standard level.
slow".
YES

YES Inspect or replace P2 bypass

Return spring of P2 bypass cut spool is broken.
cut spool assy and pilot cover.
NO

NO Outer circumference of P2 bypass cut YES Replace P2 bypass cut spool

P2 bypass cut spool moves smoothly by hand.
spool is scored. assy.
YES
NO NG

Replace control valve.

Secondary pilot pressure for swing motion is NO Inspect or replace slow return
approx. 2.9MPa when lever is turned to the full valve.
in either direction.
YES

NO Inspect or replace spool

Is shuttle in spool cover normal?
cover.
YES

YES Inspect or replace orifice of

Orifice in piping or spool cover is clogged with
foreign matter. spool cover.
NO

NO Inspect or replace swing mo-

Swing relief pressure lies within standard level.
27.9MPa. tor relief.
YES NG

YES Inspect or replace swing mo-

Machine drifts very much when swing parking
is released (arm in action) on a slope. tor.
NO

The pressure at the P(PG) port of swing motor NO Inspect or replace propor-
Inspect or replace swing parking SOL NG
is 2.9MPa when swing lever is turned to the full tional valve block.
valve.
or during arm in action.
YES

YES Inspect or replace swing spool

Return spring of swing spool is broken.
assy and pilot cover.
NO

Swing spool moves smoothly by hand. NO Outer circumference of swing spool is YES
(Remove pilot cover). Replace swing spool assy.
scored.
NG
YES NO
Replace control valve.
T5-2-26 E215-E235

HYDRAULIC SYSTEM

Swing motion drifts very large

Swing relief pressure lies within standard level. NO Inspect or replace swing mo-
27.9MPa. tor relief valve.
YES

Machine can be held on a slope during swing NO Inspect or replace shockless

motion. valve.
YES NG

Inspect or replace swing re-

duction unit or swing motor.

Machine drifts very much when swing parking YES Inspect or replace swing mo-
is released (arm in action) on a slope. tor.
NO

Secondary pilot pressure in swing motion de- NO YES

creases within 0.2 second when swing lever is Dirt or something is stuck in the orifice. Inspect or replace orifice.
brought to neutral.
NO
YES
Inspect or replace pilot valve.

NO
Is shuttle in spool cover normal? Replace spool cover.
YES

Orifice in spool cover of remote control piping is YES Inspect or replace orifice of
clogged with foreign matter. spool cover.
NO

YES Inspect or replace swing spool

Return spring of swing spool is broken.
assy and pilot cover.
NO

Swing spool moves smoothly by hand. NO Outer circumference of swing spool is YES
Replace swing spool assy.
(Remove pilot cover) scored.
NG
YES NO
Replace control valve.
E215-E235 T5-2-27

HYDRAULIC SYSTEM

Machine can not perform fine swing operation

(Diagnosis No. 25)

Is the action okay if
Current value of P1 pump proportional valve when lever is neutral is less NO the proportional valve YES Replace pump propor-
than 705mA. (engine high idle) for P1 is exchanged tional valve.
YES by the one for P2?
NO

To electrical troubleshooting.

Machine gets normal if connector for P2 bypass cut proportional valve is YES
To electrical troubleshooting.
disconnected.
NO

Machine gets normal if connector for swing parking brake solenoid is YES
To electrical troubleshooting.
disconnected.
NO

Inspect or replace
Secondary pressure of swing pilot valve is approx. 0.6MPa, while pilot YES NG Inspect or replace propor-
swing parking brake
pressure of swing parking brake solenoid valve is 0MPa. tional valve block.
solenoid valve.
NO

Pilot pressure of port PCa

No-load pressure of P2 pump is Inspect or replace
NO (P2 bypass cut valve) is YES NG Inspect or replace propor-
approx. 0.98MPa or less when swing proportional valve for
approx. YES
0.7MPa when swing tional valve block.
lever is at neutral. P2 bypass cut valve.
lever is at neutral.
YES
NO

Inspect or replace P2 by-

Return spring for P2 bypass YES
pass cut spool and pilot
cut spool is broken.
cover.
NO

P2 bypass cut spool moves Outer circumference

NO YES Replace P2 bypass cut
smoothly by hand. of P2 bypass cut
spool assy.
(Remove pilot cover.) spool is scored.
NG
YES NO

Replace control valve.

(Service Diagnosis No. 5)

Inspect or replace
Secondary pilot pressure of parking brake solenoid valve is 0MPa when NO NG Inspect or replace propor-
swing parking brake
secondary pressure of pilot valve is approx. 0.6MPa. tional valve block.
solenoid valve.
YES

Secondary pressure of pilot valve at NO

startup isNOapprox. 0.8MPa. Inspect or replace pilot valve.
YES

Return spring for swing spool is bro- YES

Replace swing spool assy.
ken.
NO

NO Outer circumference of swing YES

Swing spool moves smoothly by hand. Replace swing spool assy.
spool is scored.
YES
NO NG

Replace control valve.

T5-2-28 E215-E235

HYDRAULIC SYSTEM

Swing parking brake is not held on a slope

(Service Diagnosis No. 5)

Command voltage of swing parking brake sole- YES

To electric troubleshooting.
noid is OFF.
NO
Replace swing motor parking brake lin- NG Inspect or replace swing mo-
ing. tor and reduction unit.

Abnormal noise is heard during swing motion

Abnormal noise occurs during swing relief ac- YES Inspect or replace swing mo-
tion. tor relief valve.
NO

Abnormal noise occurs when swing motion YES Inspect or replace swing mo-
stops. tor shockless valve.
NO
(Diagnosis No. 14)

Swing relief pressure lies within standard level. NO Relief pressure on the P2 side of main NO Inspect or replace main con-
27.9MPa. control valve is 34.3MPa during arm in or trol valve and relief valve.
out action.
YES
YES
Inspect or replace swing mo-
tor relief valve.
NG

Inspect or replace swing mo-

tor.

YES Inspect or replace swing spool

Return spring of swing spool is broken. assy and pilot cover.
NO

Swing spool moves smoothly by hand. (Re- NO Outer circumference of swing spool is YES
Replace swing spool assy.
move pilot cover) scored.
NO NG
YES
Replace control valve.

NO Inspect or replace swing mo-

Swing can be held on a slope. tor and reduction unit.
YES

Inspect or replace swing mo-

tor pinion gear, swing bearing
race and swing bearing.
E215-E235 T5-3-1
ELECTRICAL SYSTEM
TROUBLE DIAGNOSIS (ELECTRICAL SYSTEM)
C1 mechatro controller
Low pressure sensor Power supply & other signal Switch & relay

Engine coolant temperature high SW

Accel motor start point indexing SW

Wiper motor prevent spark relay

Bucket digging pressure sensor

Water separator restriction SW

Bucket dump pressure sensor

P1 side OPT pressure sensor

P2 side OPT pressure sensor

Boom down pressure sensor

Travel right pressure sensor

Fuel level sensor thermister

Engine oil pressure low SW
Travel left pressure sensor
Component

Swing parking release SW

Wiper motor reverse relay

Boom up pressure sensor

P1 pump pressure sensor

P2 pump pressure sensor
Arm out pressure sensor

Wiper motor reverse SW

Engine coolant level SW

Front working light relay

Safety lock lever switch
Arm in pressure sensor

Engine oil level sensor

Swing pressure sensor

Hydraulic oil level SW

ATT power boost SW

Engine speed sensor

Travel 1-2 speed SW

Air filter clogging SW

Key switch ON/OFF

Washer motor relay

Swing flasher relay

Key switch GLOW

Wiper motor relay

Alternator voltage

Wiper motor SW
Accel potentio

Extra switch
Connector No. CN-11 CN12 CN-13 CN-14
Classification

Trouble
Group No.

1 4 7 10 13 16 19 25 28 1 4 7 10 13 20 1 2 3 4 5 6 8 9 10 12 13 14 15 16 1 2 6 7 13 16 17 18 19 20 23
• • • • • • • • • • • • • • • •
Pin No. 2 5 8 11 14 17 20 26 29 2 5 8 11 14 21 24
• • • • • • • • • • • • • • •
3 6 9 12 15 18 21 27 30 3 6 9 12 15 22
No motions operate {
1 Machine moves unexpectedly when
{ { { {
lever is at neutral
All operation
Only bucket speed is slow
Speed is slow
Attachment operation

Only boom up speed is slow { { { {

2 Motions are slow except boom up
{ {
or arm out
Only arm in motion is slow {
Only arm out motion is slow {
operation Power is poor

All operation
Bucket digging
3
Electrical system

Boom up
Arm in
impossible

Bucket digging, dump { { { {

Fine

4 Boom up, down { { { {

Arm in, out { { { { { {
5 Travel 1-2 speeds can not be changed {
6 Travel independent speed is low { { { { { { { {
Travel operation

7 Travel power is poor

ATT travel combined and travel straight
8 are impossible
Travel deviates, zigzags { { { { { { { { { {
Machine drifts on a downhill and does not
9
stop still on a slope
Swing operation

10 Swing motion does not work { {

11 Swing speed is slow {
12 Swing power is poor {
Swing parking brake is not held on a slope { { {
13
Swing fine operation impossible
 Electrical system
Classification
Swing operation Travel operation Attachment operation
T5-3-2

9
8
7
6
5
4
3
2
1

13
12
11
10
Group No.
Fine
operation Power is poor Speed is slow
impossible

Trouble

Arm in

are impossible
Boom up
lever is at neutral

or arm out

Arm in, out

stop still on a slope

No motions operate

All operation
All operation

Swing power is poor

Swing speed is slow
Travel power is poor
Bucket digging

Boom up, down

Travel deviates, zigzags

Swing motion does not work

Bucket digging, dump

Swing fine operation impossible

Travel independent speed is low
Only bucket speed is slow

Only arm in motion is slow

Component

Only arm out motion is slow

Machine moves unexpectedly when

Only boom up speed is slow

Travel 1-2 speeds can not be changed

Pin No.

ATT travel combined and travel straight

Motions are slow except boom up

Machine drifts on a downhill and does not

Connector No.

Swing parking brake is not held on a slope

•
2
1
Accelerator motor A phase

3 Sealed grounding
•
5
4

{
{
P1 bypass cut proportional valve D
•
7
6

{
{
{ {
{ {
{ {
{
{ {
P2 bypass cut proportional valve B

{
{
{
{
Travel straight proportional valve C

Arm variable recirculation proportional valve A

{
• • •

Power supply +24V

{
9 11 13

Battery back up 24V

Accelerator motor B phase

CN-15

P1 pump proportional valve

• • •

P2 pump proportional valve

{
{ {
16 18 20
C1 mechatro controller

Travel 1-2 speed SOL

{
Swing parking SOL
Governor motor & proportional valve & SOL

ATT power boost SOL

Battery relay

Power supply grounding

•
3

Cluster gauge
CN-16

ATT unload proportional valve

{ {
{ {
{ {
{ {
{ {
{ {
{ {

Travel unload proportional valve

Others

CN-17

•
26 2 16 18 •

Handy checker
22
21
• • • • 20

Battery
ELECTRICAL SYSTEM

• 1 4
8 10 12 14 15 17 19 21 22 23 24 25 1 15 17 19 E E

{ {

Fuse box
A
V
S
P

Arm variable recirculation proportional valve

B
V
S
P

{ {
{
{
{
{
{

P2 bypass cut proportional valve

{
{
V
S
P

{
{
{
{

Travel straight proportional valve

P

V
S
P

{
{
{
{
{
{

P1 bypass cut proportional valve

V
S
P

P1 pump proportional valve

V
S
P

{ {
{ {

P2 pump proportional valve

C D P1 P2
1
V
S

{
{

Swing parking SOL

2
V
S

ATT power boost SOL

SV

3
V
S

Travel 2-speed SOL

{

Safety lock lever SOL

{

Travel 2nd speed SW

SW

Safety lock lever SW

4 3 11 3
V W W E
S S S S

{
{
{
{

Boom up pressure sensor

4
E
S

Boom down pressure sensor

8
E
S

Arm out pressure sensor

{
Electrical equipments

7
E
S

Arm in pressure sensor

{
{ {
{ {
{ {
{
{ {
{ {
1
E
S

Bucket digging pressure sensor

2
E
S

Bucket dump pressure sensor

5
E
S

Swing pressure sensor

{ { { { { { {

{
{
{
{
{ { { { { { {
{
{
{

Travel right pressure sensor

{
SE

Travel left pressure sensor

{

Accel potentio

P1 pump pressure sensor

P1 pump pressure sensor

{ {

Engine speed sensor

P2 side OPT pressure sensor

E E E E E E E E
S S S S S S S S

P1 side OPT pressure sensor

9 10 16 22 23 13 11 20
E215-E235
E215-E235 T5-3-3

ELECTRICAL SYSTEM

HYDRAULIC PRESSURE MEASUREMENT BY SERVICE DIAGNOSIS

Main circuit pressure Secondary pilot pressure

(Att. operation No. 1 ~ 8 Travel operation 1 ~ 4 )

E/G Hi, E/G Hi, E/G Hi, E/G Hi,

Full lever, at relief No load, at neutral Full lever, at relief No load, at neutral
No. 14 No. 9
PRESS. SENSOR Main pump P1,P2 PRESS. SENSOR 3 4
C–1 PUMP P1 B–1 BOOM RAISE
3.3 V 35 MPa 0.7 V 2.0 MPa 4.5 V 3.0 MPa 0.5 V 0 MPa
C–1 PUMP P2 B–2 BOOM LOWER
3.3 V 35 MPa 0.7 V 2.0 MPa 4.5 V 3.0 MPa 0.5 V 0 MPa
No. 15 No. 10
PRESS. SENSOR OPT PRESS. SENSOR 7 8
B–16 P1 OPT. B–3 ARM OUT
4.5 V 3.0 MPa 0.5 V 0 MPa 4.5 V 3.0 MPa 0.5 V 0 MPa
B–17 P2 OPT. B–4 ARM IN
4.5 V 3.0 MPa 0.5 V 0 MPa 4.5 V 3.0 MPa 0.5 V 0 MPa
No. 11
Conversion for pressure PRESS. SENSOR 1 2
1 MPa = 10.2 kgf/cm2 = 145 psi B–5 BUCKET DIG
4.5 V 3.0 MPa 0.5 V 0 MPa
B–6 BUCKET DUMP
4.5 V 3.0 MPa 0.5 V 0 MPa
No. 12
PRESS. SENSOR 6 5
B–7 SWING (R)
4.5 V 3.0 MPa 0.5 V 0 MPa
B–8 SWING (L)
4.5 V 3.0 MPa 0.5 V 0 MPa
No. 13
PRESS. SENSOR 1,2 3,4
B–9 TRAVEL (R)
4.5 V 3.0 MPa 0.5 V 0 MPa
B–10 TRAVEL (L)
R0166 4.5 V 3.0 MPa 0.5 V 0 MPa

LH control lever RH control lever

5 Swing left 1 Bucket digging
6 Swing right 2 Bucket dump
7 Arm in 3 Boom up
8 Arm out 4 Boom down

LH travel lever RH travel lever

3 Travel left reverse 1 Travel right reverse
4 Travel left forward 2 Travel right forward
T5-3-4 E215-E235

ELECTRICAL SYSTEM

Solenoid primary pressure Solenoid proportional valve secondary pressure

Operation is not working In operation E/G Hi, E/G Hi,

•

No. 5 Full lever operation

• •
• No load, at neutral
SOL. VALVE Swing P/B No. 20
F–2 SWING-BRAKE Swing & arm digging PROPO-VALVE P1 bypass cut
COMP. ON OFF indication D–1 P1 BYPASS
MEAS. ON OFF indication
} 5.0 MPa COMP. 706 mA 2.8 MPa 200 mA 0 MPa
RELEASE SW OFF ON/OFF indication MEAS. 706 mA 2.8 MPa 200 mA 0 MPa
No. 6 No. 21
SOL. VALVE Travel 2-speed select PROPO-VALVE P2 bypass cut
F–3 1/2-TRAVEL D–2 P2 BYPASS
COMP. OFF ON indication COMP. 706 mA 2.8 MPa 200 mA 0 MPa
MEAS. OFF ON indication
} 5.0 MPa MEAS. 706 mA 2.8 MPa 200 mA 0 MPa
SWITCH OFF ON/OFF indication No. 22
No. 7 PROPO-VALVE Travel straight
SOL. VALVE Boost pressure select D–3 TRAVEL STRAIGHT
F–1 POWER UP COMP. 528 mA 1.8 MPa 350 mA 0.7 MPa
COMP. OFF ON indication MEAS. 528 mA 1.8 MPa 345 mA 0.7 MPa
MEAS. OFF ON indication
} 5.0 MPa
No. 23
SWITCH OFF ON/OFF indication PROPO-VALVE Arm variable
D–6 A-RECIRCULAT recirculation
COMP. 538 mA 1.7 MPa 404 mA 1.0 MPa
MEAS. 538 mA 1.7 MPa 404 mA 1.0 MPa
No. 24
PROPO-VALVE P1 pump
E–1 P1 PUMP
COMP. 750 mA 3.0 MPa 350 mA 0.7 MPa
MEAS. 750 mA 3.0 MPa 350 mA 0.7 MPa
POWER
SHIFT 0 mA
No. 25
PROPO-VALVE P2 pump
E–2 P2 PUMP
COMP. 750 mA 3.0 MPa 350 mA 0.7 MPa
MEAS. 750 mA 3.0 MPa 350 mA 0.7 MPa
POWER
SHIFT 0 mA
•
NOTE - OPERATION:
• •
• No. 47
No. 20 ARM OUT or ARM IN relief operation PROPO-VALVE Travel unload
No. 21 BOOM UP relief operation D–17 TRAVEL UNLOAD
No. 22 ARM IN relief operation COMP. 665 mA 2.6 MPa 200 mA 0 MPa
No. 23 ARM IN operation lever turned to full MEAS. 665 mA 2.6 MPa 200 mA 0 MPa
(at 200mA arm in relief) No. 48
No. 24 during BUCKET DIGGING operation PROPO-VALVE ATT unload
No. 25 during ARM IN operation D–18 ATT UNLOAD
No. 47 e 48 TRAVEL full lever operation COMP. 665 mA 2.6 MPa 200 mA 0 MPa
(right & left operation in the same time) MEAS. 665 mA 2.6 MPa 200 mA 0 MPa
E215-E235 T5-3-5

ELECTRICAL SYSTEM

TROUBLESHOOTING
No motions operate

Is it OK after connector of unload proportional NO

To hydraulic troubleshooting.
valve was disconnected?
YES
(Service Diagnosis No. 47, No. 48)
(Service Diagnosis No. 13)
The current value of unload proportional valve
NO Is the voltage of travel pressure sensor at NO
in operations other than travel operation is Replace failed sensor.
neutral position 0.4-0.5 V?
approx. 200 mA.
NG
YES
YES

Check wiring of failed sensor

or pilot valve for possible dam-
age.

Is wiring to unload proportional valve nor- NO

Correct wiring.
mal?
YES

Replace proportional valve.

NG

Replace mechatro controller.

More than 1 sec. after lever stand is lowered.

24V is alive between OW and B of connector for YES

To hydraulic troubleshooting.
lever lock solenoid (SV-4).
NO

24V is alive on cable 86A of connector for timer YES

Harness between lever lock solenoid
(SV-1) and timer relay (R-20) is discon- Inspect harness.
relay (R-20).
nected.
NO

24V is alive on cable 87B of connector for timer YES Cable E31 of connector for timer relay (R- YES
Replace timer relay (R-20).
relay (R-20). 20) is at grounding level.
NO NO

Harness between timer relay (R-20) and

Inspect harness.
ground is disconnected.

Harness between timer relay (R-20) and

24V is alive on cable 87C of connector for lever YES
lever lock switch (SW-11) is discon- Inspect harness.
lock switch (SW-11).
nected.
NO

Lever lock switch (SW-11) is faulty. Replace switch.

24V is alive on cable 15B of connector for lever YES
lock switch (SW-11).
Lever lock switch (SW-11) is attached
Adjust and replace.
NO improperly.

24V is alive on cable 15 of connector on fuse box YES Harness between lever lock switch
(SW-11) and fuse box (E-4) is discon- Inspect harness.
(E-4).
nected.
NO

YES Inspect the shorted point of

Fuse No.15 is blown. Harness shorted to frame.
harness.
NO

Inspect if there is no discon-

nection in fuse box (E-1).
T5-3-6 E215-E235

ELECTRICAL SYSTEM

Machine moves unexpectedly when lever is at neutral

The machine operates unexpectedly if the con-

nector for the P1 bypass cut proportional valve YES
To hydraulic troubleshooting.
and P2 bypass cut proportional valve is discon-
nected.

NO
(Service Diagnosis No. 9,10,11,12,13)

Are all low pressure sensor readings (boom,

NO
arm, bucket, swing, travel and OPT) 0.4 to 0.5V Replace faulty sensor.
at neutral?
NG
YES
Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to P1 bypass cut propor-

NO
tional valve and P2 bypass cut proportional Correct electric wiring.
valve all right?

YES
Replace proportional valve.
NG

Replace mechatro controller.

E215-E235 T5-3-7

ELECTRICAL SYSTEM

All motions are slow

Is it OK after connector of unload proportional NO

valve was disconnected? To hydraulic troubleshooting.

YES
(Service Diagnosis No. 47, No. 48).
(Service Diagnosis No. 13).
The current value of unload proportional valve
in operations other than travel operation is
NO Is the voltage of travel pressure sensor at NO
Replace failed sensor.
approx. 200 mA. neutral position 0.4-0.5 V?
NG
YES
YES
Check wiring of failed sensor
or pilot valve for possible dam-
age.

Is wiring to unload proportional valve NO

Correct wiring.
normal?
YES

Replace proportional valve.

NG

Replace mechatro controller.

(Service Diagnosis No. 2)

Actual engine revolution reading is 0 or a false YES

Adjust speed sensor gap.
value by service diagnosis.
NG
NO
Replace speed sensor.
(Diagnosis No. 2)

Service diagnosis at neutral indicates that a set

YES
engine revolution differs more than 50 rpm from Adjust engine.
an actual value.

NO
(Diagnosis No. 24,25)

Current values of pump proportional valves

NO Is the electric wiring to each sensor all NO
during travel idling are approx. 750mA for both Correct electric wiring.
the right (P1) and the left (P2). right?
YES
YES
Replace proportional valve.
NG

(Diagnosis No. 22)

Replace mechatro controller.

Motions are slow even if connector of travel

straight proportional valve is pulled out. (Is the YES
To hydraulic troubleshooting.
current value of travel straight proportional
valve approx. 350mA?)
NO (Diagnosis No. 9,10,11,12,13)

Are all low pressure sensor readings (boom,

NO
arm, bucket, swing, travel and OPT) 0.4 to 0.5V Replace faulty sensor.
at neutral?
NG

YES
Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to travel straight propor- NO

Correct electric wiring.
tional valve all right?
YES
Replace proportional valve.
NG

Replace mechatro controller.

T5-3-8 E215-E235

ELECTRICAL SYSTEM

Only bucket motion is slow

(Service Diagnosis No. 11)

Is the voltage level of low pressure sensor for

NO
bucket action normal? (0.4 to 0.5V at Replace low pressure sensor.
neutral)(more than 4.5V at full lever).
NG
YES
Inspect electric wiring of faulty
sensor or pilot valve.

(Diagnosis No. 24)

Is the current value of pump proportional valve

during operation normal?
Dump:
P1; approx. 750mA, NO Is the electric wiring to above-mentioned NO
Correct electric wiring.
P2; approx. 400mA. sensor and proportional valve all right?
Digging:
P1; approx. 750mA, YES
P2; approx. 400mA. Replace P1 pump propor-
tional valve.
YES
NG

Replace mechatro controller.

(Diagnosis No. 22)

Motions are slow even if connector of travel

straight proportional valve is pulled out. (Is the YES
Motions are slow even if connector of P2 YES
current value of travel straight proportional bypass cut proportional valve is pulled To hydraulic troubleshooting.
valve approx. 350mA?) out.
NO
NO
(Diagnosis No. 9,10,12,13)

Are all low pressure sensor readings

NO
(boom, arm, bucket, swing, travel and Replace faulty sensor.
OPT) 0.4 to 0.5V at neutral? NG
YES
Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to P2 bypass cut NO

Correct electric wiring.
proportional valve all right?
YES
Replace proportional valve.
NG

Replace mechatro controller.

(Diagnosis No. 9,10,12,13)

Are all low pressure sensor readings (boom,

NO
arm, bucket, swing, travel and OPT) 0.4 to 0.5V Replace faulty sensor.
at neutral?
NG
YES
Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to travel straight propor- NO

tional valve all right? Correct electric wiring.

YES
Replace proportional valve.
NG

Replace mechatro controller.

E215-E235 T5-3-9

ELECTRICAL SYSTEM

Only boom up speed motion is slow

(Service Diagnosis No.9)

Is the voltage level of low pressure sensor for

boom up action normal? NO
Replace low pressure sensor.
(0.4 to 0.5V at neutral)(more than 4.5V at full
lever) NG

YES Check electric wiring.

(Diagnosis No.21)

Are the current values of P2 bypass cut propor- NO NO

Is the electric wiring to proportional valve
tional valve during boom up full lever operation Correct electric wiring.
all right?
normal or approx. 706mA.
YES YES
Replace proportional valve.
NG

Replace mechatro controller.

(Diagnosis No.24, No.25)

Are the command current value of pump pro- NO NO

Is the electric wiring to above-mentioned
portional valve during operation normal? Correct electric wiring.
sensor and proportional valve all right?
P1, P2: approx. 700mA~750mA.
YES YES
Replace pump proportional
valve.
NG

Replace mechatro controller.

(Diagnosis No.14)

Is the relief pressure by service diagnosis nor- YES

mal or approx. 35MPa. To hydraulic troubleshooting.

NO
Replace high pressure sensor
for pump pressure.
NG

Check electric wiring.

Machine motions are slow except boom up or arm out

(Service Diagnosis No.22)

Motions are slow even if connector of travel

straight proportional valve is pulled out. (Is the YES
To hydraulic troubleshooting.
current value of travel straight proportional
valve approx. 350mA?)
NO
(Diagnosis No.9,10,11,12,13)

Are all low pressure sensor readings (boom, NO

arm, bucket, swing, travel and OPT) 0.4 to 0.5V Replace faulty sensor.
at neutral? NG

YES Inspect electric wiring of faulty

sensor or pilot valve.

Is the electric wiring to travel straight propor- NO

tional valve all right? Correct electric wiring.

YES
Replace proportional valve.
NG

Replace mechatro controller.

T5-3-10 E215-E235

ELECTRICAL SYSTEM

Only arm in motion is slow

(Service Diagnosis No. 10)

Is the voltage level of low pressure sensor for

arm in action normal? NO
Replace low pressure sensor.
(0.4 to 0.5V at neutral) (more than 4.5V at full
lever). NG

YES Inspect electric wiring of faulty

sensor or pilot valve.
(Diagnosis No. 23)

Is the current value of arm variable recirculation NO NO

Is the electric wiring to proportional valve
proportional valve during arm in full lever opera- Correct electric wiring.
all right?
tion normal or approx. 538mA?
YES
YES
Replace proportional valve.
NG

Replace mechatro controller.

(Diagnosis No. 24, No. 25)

Are the command current value of pump pro-

NO Is the electric wiring to above-mentioned NO
portional valve during operation normal? Correct electric wiring.
sensor and proportional valve all right?
P1: 450mA or less
P2: approx. 750mA.
YES
Replace P2 pump propor-
YES
tional valve.
NG

Replace mechatro controller.

To hydraulic troubleshooting.
E215-E235 T5-3-11

ELECTRICAL SYSTEM

Only arm out motion is slow

(Service Diagnosis No. 10)

Is the voltage level of low pressure sensor for

arm out action normal? NO
Replace low pressure sensor.
(0.4 to 0.5V at neutral) (more than 4.5V at full
lever) NG

YES Inspect electric wiring of faulty

sensor or pilot valve.
(Diagnosis No. 20)

Are the current values of P1 bypass cut propor- NO NO

Is the electric wiring to proportional valve
tional valve during arm out full lever operation Correct electric wiring.
all right?
normal or approx. 706mA?
YES YES
Replace proportional valve.
NG

Replace mechatro controller.

(Diagnosis No. 24, No. 25)

Are the command current value of pump pro-

NO Is the electric wiring to above-mentioned NO
portional valve during operation normal? Correct electric wiring.
sensor and proportional valve all right?
P1, P2: approx. 700mA~750mA.

YES YES
Replace pump proportional
valve.
NG

Replace mechatro controller.

(Diagnosis No. 14)

Is the relief pressure by service diagnosis nor- YES

To hydraulic troubleshooting.
mal or approx. 35MPa.

NO
Replace high pressure sensor
for pump pressure.
NG

Check electric wiring.

T5-3-12 E215-E235

ELECTRICAL SYSTEM

ATT all motion power is poor

NO
Is the speed in each single operation normal? Refer to "All motions are slow".
YES

(Service Diagnosis No. 14)

Is the relief pressure by service diagnosis nor- YES

To hydraulic troubleshooting.
mal or approx. 35MPa.
NO

Is the relief pressure in actual pressure meas- NO

To hydraulic troubleshooting.
urement normal?
P1, P2: approx. 35MPa.
YES
Replace high pressure sensor
for pump pressure.
NG

Check electric wiring.

Bucket digging motion power is poor

Is the speed in empty bucket single operation NO Refer to "Only bucket motion
normal? is slow".
YES

To hydraulic troubleshooting.

Boom up motion power is poor

Is the speed in empty bucket single operation NO Refer to "Only boom up speed
normal? motion is slow".
YES

(Diagnosis No. 21)

Are the current values of P2 bypass cut propor-

NO Is the electric wiring to proportional valve NO
tional valve during boom up relief operation Correct electric wiring.
all right?
normal or approx. 706mA?

YES YES
Replace proportional valve.
NG

Replace mechatro controller.

To hydraulic troubleshooting.
E215-E235 T5-3-13

ELECTRICAL SYSTEM

Arm in motion power is poor

Is the speed in no load single arm operation NO Refer to "Only arm in motion is
normal? slow".
YES
(Service Diagnosis No. 23)

Are the current readings of arm variable

recirculation proportional valve normal by serv-
NO Is the electric wiring to proportional valve NO
ice diagnosis? Correct electric wiring.
all right?
Full lever: approx. 521mA.
Relief: approx. 200mA.
YES

YES Replace proportional valve.

NG

Replace mechatro controller.

(Diagnosis No. 22)

Are the current readings of travel straight pro- NO Is the electric wiring to proportional valve NO
portional valve normal by service diagnosis? Correct electric wiring.
all right?
Relief: approx. 513mA.
YES YES
Replace proportional valve.
NG

Replace mechatro controller.

(Diagnosis No. 20)

Are the current readings of P1 bypass cut pro- NO Is the electric wiring to proportional valve NO
portional valve normal by service diagnosis? Correct electric wiring.
all right?
Relief: approx. 706mA.
YES YES
Replace proportional valve.
NG

Replace mechatro controller.

To hydraulic troubleshooting.
T5-3-14 E215-E235

ELECTRICAL SYSTEM

Fine operation of bucket digging and dump motions can not be performed
(Diagnosis No. 24)

Is the current reading of P1 pump proportional

NO Is the electric wiring for the proportional NO
valve normal or approx. 400mA or less in high Correct electric wiring.
valve listed on the left normal?
idle neutral condition?

YES YES
Replace P1 pump propor-
tional valve.
NG

Replace mechatro controller.

Is the action normal if connector of P1 bypass NO

To hydraulic troubleshooting.
cut proportional valve is pulled out?

YES

(Diagnosis No. 9,10,11,12,13)

Are all low pressure sensor readings (boom,

NO
arm, bucket, swing, travel and OPT) 0.4 to 0.5V Replace faulty sensor.
at neutral?
NG
YES
Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to P1 bypass cut propor- NO

Correct electric wiring.
tional valve all right?

YES
Replace proportional valve.
NG

Replace mechatro controller.

E215-E235 T5-3-15

ELECTRICAL SYSTEM

Fine operation of boom up and down motions can not be performed

(Diagnosis No. 24)

Are the current readings of P1 pump propor-

NO Is the electric wiring for the proportional NO
tional valve normal or approx. 400mA or less in Correct electric wiring.
valve listed on the left normal?
high idle neutral condition?

YES YES
Replace P1 pump propor-
tional valve.
NG

Replace mechatro controller.

Is the action normal if connector of P1 bypass NO

To hydraulic troubleshooting.
cut proportional valve is pulled out?

YES

(Diagnosis No. 9,10,11,12,13)

Are all low pressure sensor readings (boom,

NO
arm, bucket, swing, travel and OPT) 0.4 to 0.5V Replace faulty sensor.
at neutral?
NG
YES
Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to P1 bypass cut propor- NO

Correct electric wiring.
tional valve all right?

YES
Replace proportional valve.
NG

Replace mechatro controller.

T5-3-16 E215-E235

ELECTRICAL SYSTEM

Fine operation of arm in and out motions can not be performed

(Diagnosis No. 25)

Is the current reading of P2 pump proportional

NO Is the electric wiring for the proportional NO
valve normal or approx. 400mA or less in high Correct electric wiring.
valve listed on the left normal?
idle neutral condition?

YES YES
Replace P2 pump propor-
tional valve.
NG

Replace mechatro controller.

Is the action normal if connector of P2 bypass NO

To hydraulic troubleshooting.
cut proportional valve is pulled out?

YES
(Diagnosis No. 9,10,11,12,13)

Are all low pressure sensor readings (boom,

NO
arm, bucket, swing, travel and OPT) 0.4 to 0.5V Replace faulty sensor.
at neutral?
NG
YES
Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to P2 bypass cut propor- NO

Correct electric wiring.
tional valve all right?

YES
Replace proportional valve.
NG

Replace mechatro controller.

Travel 1-2 speeds can not be changed

Are the voltages between 2P connectors for YES

To hydraulic troubleshooting.
travel 1-2 speed select solenoid 24V?
NO
(Diagnosis No.6)
Does actual readings change by turns
If travel 1-2 speed select switch is pushed in
YES each time the travel 1-2 speed select YES
service diagnosis, the display is turned "ON" Replace mechatro controller.
switch is turned ON and OFF in service
and if it is release, the display is turned "OFF".
diagnosis?
NO
NO

Replace travel 1-2 speed se-

lect SOL.
NG

Inspect harness between

mechatro controller and SOL.
(Diagnosis No.6)

If two female plugs connecting the switch with

the body harness are connected, the display YES Replace travel 1-2 speed se-
indicates "ON" and if they are disconnected, lect SOL.
the display changes to "OFF".
NO

Check main electric wiring.

NG

Replace mechatro controller.

E215-E235 T5-3-17

ELECTRICAL SYSTEM

Travel independent speed is low

Is it OK after connector of unload proportional NO

To hydraulic troubleshooting.
valve was disconnected?
YES
(Service Diagnosis No. 47, No. 48)
(Service Diagnosis No. 13)
Are the current values of both travel unload and
NO Is the voltage of travel pressure sensor at NO
ATT unload proportional valves when traveling Replace failed sensor.
normal? Approx. 665mA for both. full lever position 3.5V or higher?
NG
YES
YES

Check wiring of failed sensor

or pilot valve for possible dam-
age.

Is wiring to unload proportional valve NO

normal? Correct wiring.

YES

Replace proportional valve.

NG

Replace mechatro controller.

(Diagnosis No. 24, No. 25)

Are the current readings of pump proportional

NO Is the electric wiring to above-mentioned NO
valves during both travel actions normal? Correct electric wiring.
P1 and P2: approx. 750mA. sensor and proportional valve all right?
YES
YES
Replace pump proportional
valve.
NG

Replace mechatro controller.

(Diagnosis No. 22)

Motions are slow even if connector of travel

YES
straight proportional valve is pulled out. (Is the
current value of travel straight proportional To hydraulic troubleshooting.
valve approx. 350mA?)
NO

(Diagnosis No. 9,10,11,12,13)

Are all low pressure sensor readings (boom, NO

arm, bucket, swing, travel and OPT) 0.4 to 0.5V Replace faulty sensor.
at neutral?
NG
YES
Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to travel straight propor- NO

Correct electric wiring.
tional valve all right?

YES
Replace proportional valve.
NG

Replace mechatro controller.

T5-3-18 E215-E235

ELECTRICAL SYSTEM

Travel power is poor

Is it OK after connector of unload proportional NO

To hydraulic troubleshooting.
valve was disconnected?
YES
(Service Diagnosis No. 47, No. 48)
(Service Diagnosis No. 13)
Are the current values of both travel unload and
NO Is the voltage of travel pressure sensor at NO
ATT unload proportional valves when traveling Replace failed sensor.
normal? Approx.665mA for both full lever position 3.5V or higher?
NG
YES
YES

Check wiring of failed sensor

or pilot valve for possible dam-
age.

Is wiring to unload proportional valve NO

normal? Correct wiring.

YES

Replace proportional valve.

NG

Replace mechatro controller.

NO Refer to "Travel independent

Is the speed normal in travel idling action?
speed is low".
YES

Travel power is poor even if connector of travel

YES
straight proportional valve is pulled out. (Is the To hydraulic troubleshooting.
current value of travel straight proportional
valve approx. 350mA?)
NO
(Diagnosis No. 9,10,11,12,13)

Are all low pressure sensor readings (boom,

NO
arm, bucket, swing, travel and OPT) 0.4 to 0.5V Replace faulty sensor.
at neutral? NG

YES
Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to travel straight propor- NO

Correct electric wiring.
tional valve all right?

YES
Replace proportional valve.
NG

Replace mechatro controller.

E215-E235 T5-3-19

ELECTRICAL SYSTEM

Machine does not travel straight. (Check ATT and travel actions at full lever stroke.)

For abnormal operations, re-

All independent operations and the swing and
travel independent operations are normal.
YES
fer to troubleshooting corre-
NO
sponding to respective failed
operation according to the ab-
normal phenomenon.

(Service Diagnosis No. 22)

Are the current values for travel straight propor- YES

To hydraulic troubleshooting.
tional valve approx. 538mA?
NO
(Diagnosis No. 9, No. 13)

Are the low pressure sensor voltage readings in

service diagnosis during these actions normal? NO
Neutral: 0.4~0.5V Replace faulty sensor.
Full lever: more than 4.5V NG

YES Inspect electric wiring of faulty

sensor or pilot valve.

Is the electric wiring to travel straight propor- NO

Correct electric wiring.
tional valve all right?

YES
Replace proportional valve.
NG

Replace mechatro controller.

T5-3-20 E215-E235

ELECTRICAL SYSTEM

Travel deviates, zigzags

(Service Diagnosis No. 24, No. 25)

Is the current value of pump proportional

NO YES
Travel idling speed is within reference values. valve for service diagnosis at idling op- To hydraulic troubleshooting.
eration normal? P1, P2: Approx. 750mA.
YES
NO
(Service Diagnosis No. 14)

Is pump working pressure at engine NO Replace high-pressure sen-

idling 10MPa or less? sor for pump.
NG
YES

Check wiring for possible

damage.
(Service Diagnosis No. 13)

Is the voltage of travel pressure sensor at NO

full lever position 3.5V or higher? Replace low-pressure sensor.
NG
YES
Check wiring of failed sensor
or pilot valve for possible dam-
age.

All high loading pump delivery

rates becomes lower develop-
The travel speed on steep slope and muddy YES
ing the difference of flow on
ground is slow.
both right and left sides, but it
NO
is normal.

Is it OK after connector of unload proportional NO

valve was disconnected? To hydraulic troubleshooting.

YES
(Service Diagnosis No. 47, No. 48)

Are the current values of both travel unload and

NO Is wiring to unload proportional valve NO
ATT unload proportional valves when traveling Correct wiring.
normal? Approx. 665mA for both. normal?
YES
YES
Replace proportional valve.
NG

Replace mechatro controller.

Is it OK after connector of travel straight propor- NO

To hydraulic troubleshooting
tional valve was disconnected?
YES

(Service Diagnosis No. 22)

Are the current values of travel straight propor- NO Is wiring of travel straight proportional NO
tional valve in both operations approx. 350mA? Correct wiring.
valve normal?

YES YES

Replace proportional valve.

NG

Replace mechatrocontroller.

To hydraulic troubleshooting.
E215-E235 T5-3-21

ELECTRICAL SYSTEM

Machine drifts on a slope at parking

To hydraulic troubleshooting.

Swing motion does not work

Swing motion works if 2P connector of swing NO

To hydraulic troubleshooting.
parking SOL is disconnected.
YES
(Diagnosis No. 12)

In service diagnosis, the low pressure sensor

NO
voltage readings during swing motion are: Replace faulty sensor.
Neutral: 0.4~0.5V,
NG
Full lever: more than 4.5V.
YES Inspect electric wiring of faulty
sensor or pilot valve.

Replace mechatro controller.

T5-3-22 E215-E235

ELECTRICAL SYSTEM

Swing speed is slow

(Service Diagnosis No. 12)

Are the voltage readings of low pressure sen-

NO
sor for swing action normal for both the right Replace low pressure sensor.
and left directions?
NG
Neutral: 0.4~0.5V,
Full lever: more than 4.5V. Inspect electric wiring of faulty
YES sensor or pilot valve.

(Diagnosis No. 24, No. 25)

Are the command current value of pump pro-

portional valve during operation normal? NO Is the electric wiring to above-mentioned NO
Correct electric wiring.
P1: 400mA or less, sensor and proportional valve all right?
P2: approx. 623mA.
YES
YES Replace P2 pump propor-
tional valve.
NG

Replace mechatro controller.

Is the swing speed slow even if the 2P connec-

YES
tor for swing parking solenoid is disconnected? To hydraulic troubleshooting.
(Use care to swing operation.)

NO
Refer to "Swing motion does
not work".

Swing power is poor

NO
Is the swing speed normal? Refer to "Swing speed is slow".
YES
(Diagnosis No. 14)

Is the swing relief pressure by service diagno-

YES
sis normal or approx. 28MPa? To hydraulic troubleshooting.
NO

NO
Are actual relief pressure readings normal? To hydraulic troubleshooting.
YES

Replace high pressure sensor

for pump pressure.
NG

Check electric wiring.

E215-E235 T5-3-23

ELECTRICAL SYSTEM

Swing parking brake is not held on a slope

Are the voltages between 2P connectors for YES

To hydraulic troubleshooting.
swing parking solenoid 24V?
NO (Diagnosis No. 5)

Is the display of swing parking solenoid "ON" in YES Is the swing parking solenoid status "ON" YES
service diagnosis? Replace mechatro controller.
in service diagnosis?
NO
NO
Replace swing parking SOL.
NG

Inspect harness between

(Diagnosis No. 9,10,12) mechatro controller and SOL.
Are the low pressure sensors for swing, arm in,
arm out and boom up actions normal? YES
Replace mechatro controller.
Neutral: 0.4~0.5V.
Full lever: more than 4.5V.
NO
Replace faulty sensor.
NG

Inspect electric wiring of faulty

sensor or pilot valve.

Fine operation of swing motion can not be performed

(Diagnosis No. 25)

Are the current readings of P2 pump propor- NO Is the electric wiring for the proportional NO
tional valve normal or approx. 400mA or less in Correct electric wiring.
valve listed on the left normal?
high idle neutral condition?
YES YES
Replace P2 proportional
valve.
NG

Replace mechatro controller.

In the action normal if connector of P2 bypass NO

To hydraulic troubleshooting.
cut proportional valve is pulled out?
YES
(Diagnosis No. 9,10,11,12,13)

Are all low pressure sensor readings (boom,

NO
arm, bucket, swing, travel and OPT) 0.4 to 0.5V Replace faulty sensor.
at neutral?
NG
YES
Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to P2 bypass cut propor- NO

Correct electric wiring.
tional valve all right?
YES

Replace proportional valve.

NG

Replace mechatro controller.

T5-3-24 E215-E235

ELECTRICAL SYSTEM

NOTE:
REPAIR INSTRUCTIONS

R0077
REPAIR INSTRUCTIONS E215-E235

SECTION AND GROUP CONTENTS

Section 1 GENERAL INFORMATION

Group 1 Precautions for Disassembly and Assembly
Group 2 Tightening Torque

Section 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Air Conditioner
Group 3 Counterweight
Group 4 Main Frame
Group 5 Pump Device
Group 6 Control Valve
Group 7 Swing Device
Group 8 Pilot Valve
Group 9 Solenoid Valve Unit

Section 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Swivel Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Tracks

Section 4 FRONT ATTACHMENT

Group 1 Front Attachment
Group 2 Cylinders
SECTION 1 E215-E235

GENERAL INFORMATION

CONTENTS

Group 1 - Precautions for Disassem- Group 2 - Tightening Torque

bly and Assembly
Torque Chart ........................................ W1-2-1
Precautions for Disassembly and Piping Joint .......................................... W1-2-4
Assembly ............................................. W1-1-1
E215-E235
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
PRECAUTIONS FOR DISASSEMBLY
AND ASSEMBLY
Preparations for Disassembly
• Clean the Machine
Thoroughly wash the machine before bringing it into
the shop. Bringing a dirty machine into the shop
may cause machine components to be contami-
nated during disassembling/assembling, resulting
in damage to machine components, as well as
decreased efficiency in service work.
• Inspect the Machine
Be sure to thoroughly understand all disassem-
bling/assembling procedures beforehand, to help
avoid incorrect disassembling of components as
well as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
- The machine model, machine serial number, and
hour meter reading.
- Reason for disassembly (symptoms, failed parts,
and causes).
- Clogging of filters and oil, water or air leaks, if any.
- Capacities and condition of lubricants.
- Loose or damaged parts.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the area
for disassembling work.
Precautions for Disassembly and Assembly
• Precautions for Disassembly
- To prevent dirt from entering, cap or plug the
removed pipes.
- Before disassembling, clean the exterior of the
components and place it on a work bench.
- Before disassembling, drain gear oil from the reduc-
tion gear.
W1-1-1
- Be sure to provide appropriate containers for drain-
ing fluids.
- Use matching marks for easier reassembling.
- Be sure to use the specified special tools, when
instructed.
- If a part or component cannot be removed after
removing its securing nuts and bolts, do not attempt
to remove it forcibly. Find the cause(s), then take
the appropriate measures to remove it.
- Orderly arrange disassembled parts. Mark and tag
them as necessary.
- Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
- Inspect the contact or sliding surfaces of disassem-
bled parts for abnormal wear, sticking, or other
damage.
- Measure and record the degree of wear and clear-
ances.
• Precautions for Assembly
- Be sure to clean all parts and inspect them for any
damage. If any damage is found, repair or replace
it.
- Dirt or debris on the contact or sliding surfaces may
shorten the service life of the machine. Take care
not to contaminate any contact or sliding surfaces.
- Be sure to replace O-Rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
- Be sure that liquid-gasket-applied surfaces are
clean and dry.
- If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part to remove
the agent.
- Utilize matching marks when assembling.
- Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
- Keep a record of the number of tools used for
disassembly/assembly. After assembling is com-
plete, count the number of tools, so as to make sure
that no tools are missing.
W1-1-2 E215-E235

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

Bleeding Air from Hydraulic System

When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and instal-
lation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:

• Bleeding Air from Hydraulic Pump

IMPORTANT - If the engine is started with air trapped

in the hydraulic pump housing, damage to the pump
may result. Be sure to bleed air before starting the
engine.

- Remove the air bleeding plug from the top of the

pump and fill the pump housing with hydraulic oil.
- After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the engine
and run at slow idle speed.
- Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
- After bleeding all the air, securely tighten the plug.

• Bleeding Air from Travel Motor / Swing Motor

- With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic oil.

• Bleeding Air from Hydraulic Circuit

- After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light loads
for 10 to 15 minutes. Slowly start each operation
(never fully stroke the cylinders during initial opera-
tion stage). As the pilot oil circuit has an air bleed
device, air trapped in the pilot oil circuit will be bled
while performing the above operation for approx. 5 SM1000
minutes.
- Reposition the front attachment to check hydraulic
oil level.
- Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
E215-E235 W1-1-3

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

Floating Seal Precautions A

1. In general, replace the floating seal with a new one.

If the floating is to be reused, follow these proce-
dures:

1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of card-
board to protect surfaces.

2) Check the seal ring face (A) for scuffing, scoring, B SM1001

corrosion, deformation or uneven wear.

3) Check O-Ring (B) for tears, breaks, deformation

or hardening.

2. If incorrectly assembled, oil leakage or damage will

occur. Be sure to do the following, to prevent
trouble.

1) Clean the floating seal and seal mounting bores

with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with com-
pressed air. RIGHT

2) Clean the floating seal and seal mounting bores,

as dust on them tends to enter the floating seal WRONG
when installing it.

3) Check that the O-Ring is not twisted, and that it

is installed correctly on the seal ring. SM1002

4) After installing the floating seal, check that seal

RIGHT WRONG
ring surface (C) is parallel with mating face (A) by
measuring the distances (a) and (b), as illus- A
trated. a a
If these distances differ, correct the O-Ring (B)
seating. C

b b
a=b a≠b
SM1003
W1-1-4 E215-E235

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

Discharging R134a fluid from

the air conditioning system

For a correct discharge of the air conditioning system,

please call the nearest FIAT KOBELCO Dealer to
comply with current legislation involving the storage
and disposal of R134a refrigerant fluid.
E215-E235 W1-1-5

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

Charging R134a fluid into

the air conditioning system

The change of refrigerant in the air conditioner requires

a "vacuum generation procedure" and a "gas charging
procedure".

- The "vacuum generation procedure" consists in

removing moisture from the air conditioner circuit.
In the event even a small quantity of moisture
remains in the system, it would freeze in the small
orifices of the expansion valve when in operation.
This causes a clogging of the circuit or the formation
of rust, with a series of operational troubles. prior to
filling the circuit with refrigerant, apply the vacuum
and cause the boiling and vaporisation of the mois-
ture. In this manner, moisture is eliminated from the
system.

- The "gas charging procedure" consists in the filing

the circuit with refrigerant, after applying a vacuum.
the filling of the gas is not only depending upon the
cooling performance of the air conditioner, but it
influences also the useful working life of the circuit
components. An excessive overloading increases
considerably the pressure of the system and dam-
ages the cooling performance. On the contrary, a
too low charging, results in an insufficient circula-
tion of lubricant oil in the compressor, causing the
wear of the moving parts of the compressor.

WARNING
The gas filling operation involves the handling of
highly compressed gases; it is dangerous to handle
the gas without complying strictly with the relevant
procedures. The procedures and the protections
described in this manual for the filling of refrigerant
gas must be strictly adhered to.
W1-1-6 E215-E235

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

PROCEDURE FOR THE GENERATION

OF VACUUM
1. Close high pressure valve (3) and low pressure
valve (1) on manifold (2).
2
2. Connect the red charging pipe (5) and the blue one 1 3
(6) to compressor service valves (8) "D" and "S" as
described in the figure. 6 5

WARNING 4
Never exchange by mistake the high pressure pipe D
with the low pressure pipe when connecting them.
Install the pipe firmly until a click noise is heard.
Connect the quick release joint of the charging pipe S
with the service valve of the compressor. If the
charging pipe is connected in the opposite direction,
8 7
mini-valve (9) of the compressor fails to open. R0110

3. Connect the central valve of the manifold with

charging pipe (4) of the vacuum pump (7).
S

IMPORTANT - Some types of manifold are not D

equipped with an open/close valve in the central part.
8 9 R0111

4. Open high pressure valve (3) and low pressure

valve (1) of manifold (2).

5. Start the vacuum pump and let it operate 30 minutes

to generate the vacuum.

6. At the end of the vacuum phase for the prescribed

time (vacuum value: lower than 1.33 kPa) close the
high pressure valve and the low pressure valve of
the manifold.

7. Cut-off the vacuum pump.

8. Close the high pressure valve and the low pressure

valve on the manifold and check, after five minutes,
that the pressure gauge dial does not return to O.

NOTE - In the event the pressure gauge moves toward

O, this indicates the presence of a leakage. Tighten
again the connecting joints and apply the vacuum
again, verifying that there are no further leakages.
E215-E235 W1-1-7

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

PROCEDURE FOR THE CHARGING OF THE GAS

1. After applying the vacuum repeatedly, exchange
charging pipe (3) of the manifold, from the vacuum
pump to the service bottle.
1
2. Open the valve of service bottle (2). Close the high
and low pressure valves of the manifold. Press
central bleeding valve (1) of the side service open-
ing on the low pressure side of the manifold using a
screwdriver to bleed the air from the charging pipe
using the pressure of the refrigerant. Proceed with
this operation until a whistle is heard coming from
the bleeder.
2

R0112
3. Open high pressure valve (2) of the manifold and
charge the refrigerant to a pressure of 0.097 MPa.
Once the charge is completed, close high pressure
valve (2) of the manifold and service valve (3).

WARNING
1 2
Never start operating the compressor under any
circumstance. The starting of the compressor
causes the blowing of the service bottle.

D
4. Check that there are no leakages of gas in the cycle, 3
using a gas leakage tester. Retighten and eliminate
all points of leakage.

IMPORTANT - To check for gas leakages, always use

R0113
a tester for R134a. Do not use a type for obsolete
gases since they are insufficiently responsive.

5. Check that high pressure valve (2) and low

pressure valve (1) of the manifold and service
valve (3) of the bottle are closed.

6. Start the engine running it at 1500 ± 100 rpm and 1 2

open fully the door and windows of the cab.

7. Activate the air conditioner, setting it at maximum

ventilation speed and at lowest temperature.
D
8. During the charging of the gas, set the discharge
3
pressure of the compressor to 1.36 ~ 1.57 MPa.

R0114
W1-1-8 E215-E235

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

9. Open low pressure valve (1) of the manifold and

4
service valve (3) of the bottle and fill with refriger-
ant until all air bubbles in sight window (4) of the
dryer disappear.
Total quantity of gas to be charged: 1.05 ± 0.1 kg.

10. Once the refrigerant change operation is termi-

nated, close low pressure valve (2) of the manifold
and the service valve of bottle (3).

IMPORTANT - Do not open the high pressure valve of

the manifold under any circumstance nor place the
R0115
service bottle upside down.

11. The level of refrigerant is correct only once the air

conditioner is activated and through the inspection
sight window, just a few air bubbles are seen and,
afterward, a white colour slightly milky is seen.

IMPORTANT - When the air conditioner operates with

an insufficient quantity of refrigerant, this has a nega-
tive effect on the compressor; on the contrary, when
the refrigerant is charged with an excessive quantity,
the cooling performance is lost. Also, the pressure of
the system increases abnormally.

12. Disassemble the manifold disconnecting the

charging pipes from the compressor, as indicated
here below.
a. Press the quick release coupling of the charg-
ing pipe on the low pressure side against the
service valve of the compressor so that the
refrigerant doers not escape leaking when loos-
ening the connection. As soon as the nut has
been removed, disconnect the charging pipe
from the service valve.
b. Wait for the pressure in the high pressure site to
decrease, indicated on the pressure gauge, to
a value of 0.98 MPa.
c. Disconnect the red charging pipe from the high
pressure side, in the same manner as de-
scribed for the low pressure.
E215-E235 W1-2-1

TIGHTENING TORQUE

TORQUE CHART

WARNING
Use tools appropriate for the work to be done.
Makeshift tools and procedures can create safety
hazards. For loosening and tightening nuts and
bolts, use the correct tools. Avoid bodily injury
caused by slipping wrenches.

Bolt Types

Tighten nuts or bolts correctly to torque specifica-

tions. Two kinds of bolts, hexagon bolts T and
socket bolt, each made of different material, are SM1004

used. Make sure to employ the correct bolts and

tighten them to specification when assembling the
machine or components.

Hexagon T Bolt Socket Bolt

SM1005

Specified Tightening Torque Chart

Bolt Wrench Hexagon T Bolt,

Dia. Size Wrench Socket
Size bolt
(Nm)

M8 13 6 29.5
M10 17 8 64
M12 19 10 108
M14 22 12 175
M16 24 14 265
M18 27 14 390
M20 30 17 540
M22 32 17 740
M24 36 19 930
M27 41 19 1 370
M30 46 22 1 910
M33 50 24 2 550
M36 55 27 3 140
W1-2-2 E215-E235

TIGHTENING TORQUE

IMPORTANT
1. Apply lubricant (i. e. white zinc B dissolved into
spindle oil) to nuts and bolts to stabilize their friction
coefficients.
2. Torque tolerance is ±10%.
3. Be sure to use bolts of correct length. Bolts that are
too long cannot be tightened, as the bolt tip comes
into contact with the bottom of the bolt hole. Bolts
that are too short cannot develop sufficient
tightening force.
4. The torques given in the chart are for general use
only.
Do not use these torques if a different torque is
given for a specific application.
5. Make sure that the nut and bolt threads are clean
before installing. Remove dirt or corrosion, if any.

Bolt Tightening Order

When tightening two or more bolts, tighten them

alternately, as shown, to ensure even tightening.

Equally tighten upper

and lower alternately Tighten diagonally Tighten from center and diagonally

1 12 9 4 1 6 7 14
1,4 6 3

2,3 4 5
2 13 8 5 2 3 10 11

SM1006
E215-E235 W1-2-3

TIGHTENING TORQUE

Service Recommendations for Split Flange

IMPORTANT
1. Be sure to clean and inspect sealing surfaces.
Scratches / roughness cause leaks and seal wear. SM1007
Unevenness causes seal extrusion. If defects can-
not be polished out, replace the component.
WRONG
2. Be sure to use only specified O-rings. Inspect O-
rings for any damage. Take care not to file O-ring
surfaces. When installing an O-ring into a groove,
use grease to hold it in place.

3. Loosely assemble split flange halves. Make sure

that the split is centrally located and perpendicular
to the port. Hand-tighten the bolts to hold the parts
SM1008
in place. Take care not to pinch the O-ring.

4. Tighten bolts alternately and diagonally, as shown,

to ensure even tightening.

5. Do not use air wrenches. Using an air wrench often

causes tightening of one bolt fully before tighten the
others, resulting in damage to O-rings or uneven
tightening of bolts.

SM1009
Nut and Bolt Lockings
RIGHT WRONG
• Lock Plate

IMPORTANT - Do not reuse lock plates. Do not try to

bend the same point twice.

Bend along edge sharply Do not bend it round

• Cotter Pin
RIGHT RIGHT WRONG
IMPORTANT - Do not reuse cotter pins. Match the
holes in the bolt and nut while tightening, not while
loosening.

• Lock Wire
Bend along edge sharply
SM1010
IMPORTANT - Apply wire to bolts in the bolt-tightening
direction, not in the bolt-loosening direction.
RIGHT RIGHT WRONG

RIGHT WRONG
Loosen
Tighten

SM1011
W1-2-4 E215-E235

TIGHTENING TORQUE

PIPING JOINT

Pipe Thread Connection / Union Joint Tightening 1 4 3 5 2

Torque Specifications

Union Joint

Metal sealing faces (4) and (5) of adaptor (1) and hose
(2) fit together to seal pressure oil. Union joints are
used to join small-diameter lines.

Joint Body
SM1012
IMPORTANT
1. Do not over-tighten union nut (3). Excessive force
will be applied to metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be sure to tighten
union nut (3) to specifications.
37°

2. Scratches or other damage to sealing surfaces (4)

37°
or (5) will cause oil leakage at the joint. Take care
not to damage them when connecting /disconnect-
ing.
Male Union Joint Female Union Joint

SM1013

Wrench Size Tightening Torque

Type
Union Nut Joint Body (Nm)

37° Union Joint 19 17 29

22 19 39
27 22 78.5
36 30, 32 157
41 36 205
50 46 323.6

NOTE - Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.
E215-E235 W1-2-5

TIGHTENING TORQUE

O-Ring Seal Joint

O-Ring (6) seats against the end face of adaptor (7) to

7 6 9
seal pressure oil.

IMPORTANT
1. Be sure to replace O-Ring (6) with a new one when
reconnecting.

2. Before tightening union nut (9), confirm that O-Ring

8 10 Joint body
(6) is seated correctly in O-Ring groove (8). Tighten-
ing union nut (9) with O-Ring (6) displaced will SM1014

damage O-Ring, resulting in oil leakage.

3. Take care not to damage O-Ring groove (8) or

sealing face (10). Damage to O-Ring (6) will cause
oil leakage.

4. If union nut (9) is found to be loose, causing oil

leakage, do not tighten it to stop the leak. Instead,
replace O-Ring (6) with a new one, then tighten
union nut (9) after confirming that O-Ring (6) is
securely seated in place.

Wrench Size Tightening Torque

Union Joint
Nut Body (Nm)
19 17 29.4
22 19 68.6
27 22 93
30 27 137.3
36 30 175
41 36 205
50 46 320
W1-2-6 E215-E235

TIGHTENING TORQUE

Screwed-In Connection PT PF

30°

IMPORTANT - Many types of screwed-in connec-

tions are used for hose connections.
Be sure to confirm that the thread pitch and thread type
(tapered or straight) are the correct type before using
any screw-in connection. Male Tapered Thread Male Straight Thread
SM1015

Male Tapered Thread

Wrench Tightening Torque
Joint Body (Nm)
17, 19 34
22 49
27 93
36, 32 157
41 205
50 320
60 410

Seal Tape Application Internal Thread

Seal tape is used to seal clearances between male and

female threads, so as to prevent any leakage between
threads. Clearance External Thread
Be sure to apply just enough seal tape to fill up thread SM1016
clearances. Do not overwrap.

Leave one to two pitch threads uncovered

• Application Procedure

Confirm that the thread surface is clean, free of dirt

or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening Torque SM1017

Low-pressure-hose clamp tightening torque differs

depending on the type of clamp. T-Bolt Type Worm Gear Type
See below for correct tightening torque of each type of
low-pressure-hose clamp.

T-Bolt Type Band Clamp:

4.4 Nm (0.45 kgf m)
Worm Gear Type Band Clamp:
5.9 a 6.9 Nm (0.6 a 0.7 kgf m)

SM1018 SM1019
E215-E235 W1-2-7

TIGHTENING TORQUE

Connecting Hose WRONG RIGHT

WARNING
1. When replacing hoses, be sure to use only
genuine parts. Using hoses other than genuine
hoses may cause oil leakage, hose rupture or
separation of fitting, possibly resulting in a fire on
the machine. SM1020
2. Do not install hoses kinked. Application of high
oil pressure, vibration, or an impact to a kinked
hose may result in oil leakage, hose rupture or
separation of fitting. Utilize print marks on hoses WRONG RIGHT
when installing hoses to prevent hose from being
installed kinked. Rubbing Against Each Other
3. If hoses rub against each other, wear to the
hoses will result, leading to hose rupture.
Take necessary measures to protect hoses from
rubbing against each other.
Take care that hoses do not come into contact SM1021

with moving parts or sharp objects.

WRONG RIGHT

Clamp Clamp

Rubbing

SM1022

WRONG RIGHT

Rubbing

Clamp
SM1023
W1-2-8 E215-E235

TIGHTENING TORQUE

NOTES:
SECTION 2 E215-E235

UPPERSTRUCTURE

CONTENTS

Group 1 - Cab Group 7 - Swing Device

Removal and Installation of Cab ........... W2-1-1
Group 2 - Air conditioner
Removal and Installation
of Air Conditioner ................................. W2-2-1
Disassembly and Assembly of
Air Conditioner ..................................... W2-2-2
Removal and Installation of
Swing Device ....................................... W2-7-1
Disassembly and Assembly
of Swing Motor ..................................... W2-7-4
Disassembly and Assembly
of Swing Reducer ............................... W2-7-12
Maintenance Standard ....................... W2-7-21

Group 8 - Pilot Valve

Group 3 - Counterweight Removal and Installation of
Right and Left Pilot Valve ..................... W2-8-1
Removal and Installation of
Counterweight ...................................... W2-3-1 Removal and Installation of Travel
Pilot Valve ............................................ W2-8-3
Disassembly Right and Left
Group 4 - Main Frame Pilot Valve ............................................ W2-8-6
Assembly Right and Left
Removal and Installation of Pilot Valve .......................................... W2-8-12
Main Frame .......................................... W2-4-1 Disassembly Travel Pilot Valve ........... W2-8-16
Assembly Travel Pilot Valve ............... W2-8-19
Maintenance Standard
Group 5 - Pump Device
Right and Left Pilot Valve ................... W2-8-22
Removal and Installation of
Pump Device ....................................... W2-5-1
Disassembly and Assembly Group 9 - Solenoid Valve Unit
of Pump Device ................................... W2-5-2
Removal and Installation of
Maintenance Standard ....................... W2-5-11 Solenoid Valve Unit .............................. W2-9-1
Disassembly and Assembly Disassembly and Assembly
of Regulator ....................................... W2-5-12 of Solenoid Valve ................................. W2-9-2
Disassembly and Assembly
of PTO Gear Casing ........................... W2-5-20

Group 6 - Control Valve

Removal and Installation of
Control Valve ........................................ W2-6-1
Control Valve Disassembly ................... W2-6-2
Control Valve Assembly ..................... W2-6-33
Maintenance Standard ....................... W2-6-38
E215-E235 W2-1-1

CAB

REMOVAL AND INSTALLATION OF CAB

Removal of cab

1. Remove the operator's seat complete with longi-

tudinal travel slide, removing securing screws
(12) (Q.ty 4) complete with spring washers. Dis-
connect the seat heater switch cable.
: 6 mm

2. Remove securing screws (16) (Q.ty 4) complete

with washers and lift hooks (14) to remove panels
(17 and 19) to reach the conditioner unit.

3. Disconnect the connectors of loudspeakers (5)

from panels (17 and 19), from power outlet (15)
and pressure discharge button (18).

4. Disconnect connections (9 and 10) of the monitor,

ceiling light (7) and wiper interlock switch (8).

5. Disconnect the ground wires from the cab struc-

ture loosening securing screw (6).
: 10 mm

6. Remove securing screws (4) (q.ty 3) complete

with washers to remove panel (2). Disconnect the
connectors from hourmeter (3).

7. Disconnect washer liquid hose (11).

8. Extract air duct (13) pushing it toward the rear side

of the cab until it is free from the mounting and
remove it.

9. Install tool no. 380001057 with two C profiles

arranged on the cab structure.

WARNING
Approximate mass of the cab: 270 kg
380001057

10. Remove screws (1) (Q.ty 8).

: 19 mm

11. Lift carefully the cab from the operator's compart-

ment.

R0001
W2-1-2 E215-E235

CAB

5
6

4 8

9
10
3
2

11
1

4 13 12

16 16
Partial view from "A"

17

15

14

14
18

14

19
R0002
E215-E235 W2-1-3

CAB

Installation of cab

WARNING
380001057
Approximate mass of the cab: 270 kg

1. Lift the cab structure using tool no. 380001057 and

place it in the operator's compartment.

2. Secure the cab to the operator's compartment

using screws (1) (Q.ty 8).
: 19 mm
: 100 ± 15 Nm R0001

3. Connect flex air duct (13) to the rigid duct, pushing

it forward.

4. Connect washer liquid hose (11).

5. Connect the connections to hourmeter device (3)

and secure panel (2) using securing screws (4)
(Q.ty 3).

6. Connect the grounding cable to the cab structure

using securing screw (6).
: 10 mm
: 28.5 ± 3 Nm

7. Connect connectors of the monitor (9 and 10),

ceiling light (7) and wiper interlock switch (8).

8. Connect to panels (17 and 19) the connections of

loudspeakers (5), power socket (15) and pres-
sure discharge button (18).

9. Secure panels (17 and 19) acting on locking

hooks (14) and tightening securing screws (16)
(q.ty used 4) complete with washers.

10. Connect the seat heating switch cable and install

the operator's seat complete with longitudinal
travel slide using securing screws (12) (Q.ty 4)
complete with spring washers.
: 6 mm
: 29.5 Nm
W2-1-4 E215-E235

CAB

NOTES:
E215-E235 W2-2-1

AIR CONDITIONER

REMOVAL AND INSTALLATION OF

AIR CONDITIONER

Preliminary operations Installation of air conditioner

Prior to and during the removal and installation proc- 1. Place the air conditioning unit on the operator's
ess of the air conditioning unit, make sure that the compartment.
following conditions are complied with:
2. Arrange the unit securing the screws (Q.ty 6)
1. This air conditioning unit is filled with a type R314a
: 13 mm
refrigerant. Thus, make sure, prior to performing
: 10.8 Nm
removal and re-installation operations, that no re-
frigerant is present inside the air conditioning sys-
3. Install the air ducts, front protection panel, all the
tem. Implement the operations described in Proce-
connectors between the operator's seat and the air
dure: "Discharging R134a fluid from the air condi-
conditioning unit, the controller securing plate, the
tioning system" at page W1-1-4.
front bracket and the fluid pipes with the relevant
O-Rings.
2. Do not keep open the connections of the ducts on
the compressor and the portions of the refrigeration
4. Charge the conditioning system with refrigerant
system.
fluid as described in Procedure: "Charging R134a
fluid into the air conditioning system" at page
3. Prevent the lubricant from adhering to painted
W1-1-5.
surfaces and plastic made parts. In the event
lubricant is spilled, clean it at once.

4. The dryer is filled with material absorbing moisture in

the circuit. Consequently, the valves on the opening
of the ducts must be removed immediately before
connecting the ducts.

5. Prior to performing any operation, cut-off the engine

and disconnect all the electric power sources of the
systems relative to the air conditioner.

Removal of air conditioner

1. Remove the air ducts, the front protection panel, all

the connections between the operator's compart-
ment and the conditioning unit, the controller mount-
ing plate, the front bracket and the fluid pipes with
the relevant O-Rings.

2. Remove the screws (Q.ty 6) securing the condition-

ing unit to the operator's compartment.
: 13 mm

3. Lift and remove the air conditioning unit.

W2-2-2 E215-E235

AIR CONDITIONER

DISASSEMBLY AND ASSEMBLY OF

AIR CONDITIONER

1. Disassembly the blower unit

a. Remove the connectors (1) connected to the
inner/outer air select motor actuator, the blower
motor and the blower controller. Also remove the 1
harness (2) from the blower casing.
b. Draw out the inner air filter (3) from the intake
casing. Remove the four cross-recessed screws
(4) from the top of the intake casing (5), using a 2
screwdriver. Then remove the intake casing. 1
1
1 R0003
c. Remove three cross-recessed screws (6) fasten-
ing the blower casing (7) with the unit casing.
Then separate the blower unit from the air-
conditioner unit (8).

3
2. Assembly blower unit
4
a. Assembly is the reverse order of disassembly.

3. Disassembly the blower motor

5
a. Disconnect the cooling hose (9) that is con-
nected between the blower motor (10) and the
blower casing (11).
b. Remove three cross-recessed screws (12) fixed 6
from the bottom of the blower unit casing. Then
draw out the blower motor.

8 7
IMPORTANT - Do not separate the fan from the blower R0004
motor.

4. Assembly the blower motor

a. Assembly is the reverse order of disassembly. 11

5. Disassembly the blower controller

a. Remove two cross-recessed screws (13) fixed
from the bottom of the blower unit casing and
draw out the blower controller (14).
10

14
IMPORTANT - Do not disassemble the blower control- 9
ler in any circumstances.

12
6. Assembly the blower controller 13 R0005

a. Assembly is the reverse order of disassembly.

E215-E235 W2-2-3

AIR CONDITIONER

7. Removing the heater core

a. After discharging the cooling water, disconnect
the heater hose from heater core (1). 1
b. Remove one cross-recessed screw (2) each for
the bracket (3 and 4) fixing the heater core to the 4
unit and for the pipe clamp. Then remove the
bracket and the pipe clamp and draw out the
heater core from the unit casing.
2

8. Assembly the heater core 3 2 R0006

a. Assembly is the reverse order of disassembly.

9. Removing the upper and lower parts of the air-

conditioner unit casing
a. Draw out the connectors for the mode motor
actuator and the evaporation sensor.
5
b. Separate the rod (5) from the rod holder (6) that
is fixed to the lever (7) on the mode motor 11
6
actuator (8). 9
c. Remove three cross-recessed screws (9) fas- 7
tening the mode motor actuator that install the
bottom of the unit casing (10) to the back of the 9 10
unit casing (11). Then separate the mode motor
actuator. 9 8 R0007

d. Remove eleven cross-recessed screws (12)

that install the bottom of the unit casing (13) to
the top of the unit casing (14).

e. Draw out the top of the unit casing upwards,

using care so the evaporator sensor cord (15) is 14
not arrested by the casing.
On that occasion, do the work with the heater
core off the unit casing.

10. Assembly upper and lower parts of the air condi-

tioner unit casing.
a. Assembly is the reverse order of disassembly.

15

13

12

R0008
W2-2-4 E215-E235

AIR CONDITIONER

11. Disassembly the evaporator and the expansion

valve
1
a. Remove the evaporator assy (1) from the bot-
tom of the casing, together with the casing
insulator and the expansion valve (2).
b. Remove the upper and lower casing insulators 5
from the evaporator assy and draw out the 2
evaporator sensor (3) with the sensor holder.
c. Remove the socket head cap screws M5x40 (4)
(Q.ty 2) from the evaporator. Then separate the 4
expansion valve from the evaporator.
: 4 mm
3
R0009

12. Assembly the evaporator and the expansion vlave

a. Assembly is the reverse order of disassembly.
When attaching O-Rings (5), use care so the
O-Rings are not caught.
b. Attach new O-Rings to evaporator.
c. Then install the expansion valve to it with head
cap screws (M5x40) (Q.ty 2).
: 4 mm
: 7 Nm

13. Installing the evaporator sensor

a. Install the evaporation sensor (1) as shown in
figure.

1
R0010
E215-E235 W2-2-5

AIR CONDITIONER

14. Disassembly the motor actuator

a. Replacing the mode motor actuator (1).

Remove the connector fixed to the motor actu-
ator.
Remove the rod (3) linking the motor actuator
with the mode cam, from the rod holder (2). 2
Remove three cross-recessed screws (4) fixing
the motor actuator. Separate the motor actuator 3
from the unit, together with the rod holder and 4
the lever (5). Remove the rod holder and the 5
lever from the motor actuator.
4

4 1 R0011

b. Replacing the air mix motor actuator 8 6

Disconnect the connector connected with the 9
motor actuator. 10
Separate the rod (6) linking the motor actuator 7
(7) with the lever (8) from the rod holder (9).
Remove three cross-recessed screws fasten-
ing the motor actuator. Then remove the motor
actuator with the rod holder and the lever MAL1
(10) from the unit. Remove the rod holder and
the lever from the motor actuator.
R0012

c. Replacing the inner/outer air select motor actu-

ator (11).
Disconnect the connector connected with the
motor actuator. 12
Separate the motor actuator with lever (12) from
the unit.
Remove the lever from the motor actuator.

11 R0013
15. Assembly the motor actuator

a. Assembly is the reverse order of disassembly.

W2-2-6 E215-E235

AIR CONDITIONER

NOTES:
E215-E235 W2-3-1

COUNTERWEIGHT

REMOVAL AND INSTALLATION OF

COUNTERWEIGHT

Removal of counterweight
2
WARNING
Approximate weight of counterweight: 4400 kg

1. Attach wire rope (2) to eye-bolts using shackles.

Take out slack of wire rope by applying tension
slowly with a crane or hoist.

R0014

2. Remove bolts (3).

Lift counterweight using a crane or hoist.
: 46 mm

R0015

3. Lower the counterweight on proper stand.

R0016
W2-3-2 E215-E235

COUNTERWEIGHT

Installation of counterweight

WARNING
Approx. weight of counterweight: 4400 kg

1. Attach lifting tools to counterweight. 4

Lift counterweight (4) and install it onto the frame.
Install bolts (3) and washers to counterweight and
3
tighten temporarily.

: 46 mm
R0017

2. Remove wire rope.

Tighten the bolts with a power wrench (6) and
torque wrench (7).

: 46 mm
: 1570 Nm

6 7 R0018
E215-E235 W2-4-1

MAIN FRAME

REMOVAL AND INSTALLATION OF MAIN FRAME

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.

Preparation Removal of main frame

1. Park the machine on a firm, level surface. 1. Remove the cab, performing the operations de-
scribed in the procedure at page W2-1-1.
2. Cut-off the engine. Press the valve located on the
hydraulic oil tank to release the residual pressure 2. Remove the counterweight performing the opera-
present inside the tank itself. tions described at page W2-2-1.
Please refer to the "Procedure: Releasing the
pressure from the Hydraulic System" at page W4-
2-12. 3. Remove the front equipment and the boom cylin-
der, performing the operations described in the
3. Remove hydraulic oil tank cap. Connect a vacuum procedure at pages W4-1-1 and W4-2-1.
pump to maintain negative pressure in the hydrau-
lic oil tank.
4. Remove the centre joint performing the operations
described in the procedure at page W3-3-1. Drain
NOTE - Be sure to run the vacuum pump continuously
the hydraulic oil from the relevant tank.
while working.
W2-4-2 E215-E235

MAIN FRAME

WARNING
Approximate weight of main frame:
5575 kg

5. Attach wire ropes to the front and rear of main

frame. See wire ropes taut using a crane. Use
chain blocks for easy adjustment of wire rope Rear
lengths and to level the frame. SM1142

IMPORTANT - Make sure rear slings do not touch

engine.

Front
SM1143

SM1144

6. Put matching marks on swing bearing and main

frame. Remove bolts (14) from the swing bearing.
: 30 mm

14
SM1380
E215-E235 W2-4-3

MAIN FRAME

7. Lift main frame slightly from undercarriage.

Level main frame by adjusting the chain blocks.

Remove main frame.

SM1146
W2-4-4 E215-E235

MAIN FRAME

Installation of main frame

13
WARNING
Massa approssimativa del telaio superiore:
5875 kg

1. Fasten hoist to front and rear of main frame.

Level main frame by adjusting chain blocks (13)
and lower main frame onto undercarriage.
Align the matching mark on the swing bearing with
that on the main frame.
SM1146

2. Install bolts (14) on the swing bearing and tighten

temporary.
Install main frame and tighten bolts to specification.
: 30 mm

Upperstructure side
: 563 ± 56 Nm

14
3. Install the centre joint performing the operations SM1380

described at page W3-3-1. Fill with hydraulic oil the

relevant tank.

4. Install the front equipment and boom cylinder per-

forming the operations described at pages W4-1-1
and W4-2-1.

5. Install the counterweight performing the opera-

tions described at page W2-2-1.

6. Install the cab performing the operations described

at page W2-1-1.

7. Fill the hydraulic oil tank with hydraulic oil to the

specified level.
Run the engine at slow idle. Check hose connec-
tions for any oil leakage.

SM1147
E215-E235 W2-5-1

PUMP DEVICE

REMOVAL AND INSTALLATION PUMP DEVICE

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.

Preparation

1. Park the machine on a firm, level surface.
2. Cut-off the engine. Press the valve located on the
hydraulic oil tank to release the residual pressure
present inside the tank itself.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal

1. Remove all protection panels and doors to give 2. Install the hydraulic pump device to the engine by
access to the Hydraulic Pump Device. means of related bolts.

2. Disconnect all electrical connectors. : 17 mm

: 431 ± 43.1 Nm
3. Remove all hoses and collector from hydraulic
pump device. 3. Install all hoses and collector to the hydraulic pump
device.
: 11, 19, 22, 30, 36 mm
: 19 mm
: 8, 10 mm : 29.4 Nm

4. Fasten the hydraulic pump device by means of : 22 mm

hoist and lifting ropes. : 39.2 Nm
: 30 mm
WARNING : 137.2 Nm
Hydraulic pump device weight: 131 kg : 36 mm
: 156.9 Nm
: 8 mm
5. Remove the fixing bolts of hydraulic pump device
: 64 Nm
and draw it from engine.
: 10 mm
: 17 mm : 108 Nm

4. Connect all electrical connectors.

Installation
5. Install all protection panels and doors.
1. Lift the hydraulic pump device by means of hoist
and ropes.

WARNING
Hydraulic pump device weight: 131 kg
W2-5-2 E215-E235

PUMP DEVICE

DISASSEMBLY AND ASSEMBLY OF PUMP DEVICE

REGULATOR

534
702
531 261 406
548 792
789 732 532 710 774
535
886 ENGINE
953 SIDE
806

724
728 717
113 468 313
127 808 124
954 546
123 407
824 271 901
710 717 312 490
262 490
325 111
406 251 885
717
401 116 886
124
127 314
141
157
156 710
151 153 885 725
152 466
211 5
214
212
4

435

6
7 R0699

4- Gear pump 407 - Socket bolt M6×30 (Q.ty 3)

5- Pto unit 435 - Socket bolt (Q.ty 2)
6- Unload valve 466 - VP plug PF 1/4 (Q.ty 2)
7- Socket bolt (Q.ty 8) 468 - VP plug PF 3/4 (Q.ty 4)
111 - Shaft (F) 490 - Plug NPTF 1/16 (Q.ty 27)
113 - Shaft (R) 531 - Tilt Pin M24×2 (Q.ty 2)
116 - 1st gear 532 - Servo piston M24×2 (Q.ty 2)
123 - Roller bearing (Q.ty 2) 534 - Stopper (Q.ty 2)
124 - Needle bearing (Q.ty 2) 535 - Stopper (Q.ty 2)
127 - Bearing spacer (Q.ty 4) 546 - Spacer (Q.ty 2)
141 - Cylinder block (Q.ty 2) 548 - Feed back Pin (Q.ty 2)
151 - Piston (Q.ty 18) 702 - O-Ring (Q.ty 2)
152 - Shoe (Q.ty 18) 710 - O-Ring (Q.ty 2)
153 - Plate (Q.ty 2) 717 - O-Ring (Q.ty 2)
156 - Spherical bushing (Q.ty 2) 724 - O-Ring (Q.ty 18)
157 - Cylinder spring (Q.ty 18) 725 - O-Ring (Q.ty 6)
211 - Shoe plate (Q.ty 2) 728 - O-Ring (Q.ty 4)
212 - Swash plate (Q.ty 2) 732 - O-Ring (Q.ty 2)
214 - Tilting bushing (Q.ty 2) 774 - Oil seal
251 - Swash plate support (Q.ty 2) 789 - Backup ring (Q.ty 2)
261 - Seal cover 792 - Backup ring (Q.ty 2)
262 - Cover 806 - Hex. nut M16 (Q.ty 2)
271 - Pump casing (Q.ty 2) 808 - Hex. nut M20 (Q.ty 2)
312 - Valve block 824 - Snap ring (Q.ty 2)
313 - Valve plate 885 - Valve plate pin (Q.ty 2)
314 - Valve plate 886 - Spring pin (Q.ty 4)
325 - Cover 901 - Eye bolt M10 (Q.ty 2)
401 - Socket bolt M20×210 (Q.ty 8) 953 - Set screw M16×30 (Q.ty 2)
406 - Socket bolt M8×20 (Q.ty 4) 954 - Set screw M20 (Q.ty 2)
E215-E235 W2-5-3

PUMP DEVICE

Disassembly

1. Proceed with disassembly operations in a clean 433

place.
Spread rubber sheet or cloth on work bench to
protect parts from damaging. 434
B3
2. Clean the parts removing dust and rust, etc. on
pump surface with wash oil.
728
435
3. Drain out the oil in the pump casing by removing
drain port plugs (466 and 468). 312 A3

: 19, 27 mm 311
732 850 467
4. Disassembly of Gear pump (4).
307 308 355
a. Remove the flange socket (435) (Q. ty 2). 310 434 466
309
b. Remove the plug (466), the adapter (467), the 725
R0700
adjusting screw (311) and the lock nut (312).

5. Disassembly of Unload valve (6).

351
a. Remove the socket bolt (7) (Q. ty 8). 331
322
b. Remove the plugs (151, 331, 351 and 352).
321
c. Draw out the springs (321 and 322). 361
151

362
352
R0751

6. Remove regulator and PTO gear casing by loosen-

ing the socket bolts (412, 413 and 435). REGULATOR

: 8 mm

R0701
W2-5-4 E215-E235

PUMP DEVICE

7. Loosen socket bolts (401) that fasten swash plate

support (251), pump casing (271) and valve block 312 271
(312).
401
: 17 mm

R0702

8. Place the pump level on a work bench with its

mounting surface of the regulator facing down. Then 312 271
separate pump casing (271) and valve block (312).

NOTE - When facing the mounting surface of the

regulator down, place a rubber board on a work bench
so as not to score the mounting surface.
When the pump casing has been separated from the
valve block, draw out the 1st gear (116) at the same
time.

R0703

9. Draw out cylinder (141) out of pump casing (271) in 271

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

NOTE - Use care so as not to score the sliding surface

of the cylinder, spherical bushing, shoe and the swash
plate.

R0704
E215-E235 W2-5-5

PUMP DEVICE

10. Remove socket bolt (406) and seal cover (261). 406
: 5 mm
261

NOTE - The seal cover may be drawn out with ease if

it is taken out by tightening bolts in the tapped holes
of the seal cover.
An oil seal is fitted to seal cover. Therefore, use care
so as not to score the oil seal.

R0705

11. Knock lightly on the mounting flange of swash 271

plate support (251) from the pump casing (271)
side and separate the swash plate support from
the pump casing.
251

R0706

12. Draw out shoe plate (211) and swash plate (212)
from pump casing (271).
271

212
(211)

R0707

13. Tap lightly the shaft end (111 and 113) by means
251
of a plastic hammer and draw out the shaft from
the swash plate support.

111
(113)

R0708
W2-5-6 E215-E235

PUMP DEVICE

14. Remove valve plate (313 and 314) from valve

block (312).

312

314 (313)

R0709

15. If necessary, remove stoppers (534 and 535), 531

servo piston (532) and tilting pin (531) from pump
casing (271), and remove needle bearing (124)
from valve block (312).

535 534
806
532
NOTE - When removing the tilting pin, use care so as
not to score the head of the tilting pin, using a jig.
It is hard to separate the tilting pin from the servo
piston in some cases as Loctite is coated on the
808
mating part between them. Use care so as not to score
the servo piston by applying unreasonable force.
124
Do not draw out needle bearings except when their 312
service life has ended. 271
Do not loosen hex nuts (806 and 808) of valve block
(312) and swash plate support (251). A set flow rate 251
changes.

R0710
E215-E235 W2-5-7

PUMP DEVICE

Assembly

1. Assembly is a reverse order of disassembly, but

notice the following:
- Repair scored parts at disassembly. Get re-
placements ready beforehand.
- Wash parts sufficiently in cleaning oil and dry
them with jet air.
- Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
- In principle, replace sealing parts such as O-
Rings and oil seals.
- Tighten socket bolts and plugs to specified
torques in this manual, using a torque wrench.
- Do not mix up front pump parts with rear pump
parts.

2. Attach swash plate support (251) to pump casing 271

(271) by tapping the swash plate support lightly with
a plastic hammer.

NOTE - When the servo piston, the tilting pin, the

stoppers have been removed, install them to the pump
casing beforehand.
When tightening servo piston and tilting pin, use a jig
so as not to damage the head of the tilting pin and
feedback pin.
Coat the screwed part with Loctite 262.
251

R0711

3. Install swash plate placing the pump casing with its

mounting surface of the regulator facing down. 251
271 (531)
Insert the tilting bushing of the swash plate into
tilting pin (531), and fit swash plate (212) to swash
plate support (251) properly.

NOTE - Confirm by your both hands that swash plate

moves smoothly.
The shaft be installed easily if grease is applied to the 212
sliding parts of swash plate and swash plate support.

R0712
W2-5-8 E215-E235

PUMP DEVICE

4. Install shaft (111) fitted with bearing (123), bearing

spacer (127) and snap ring (824), to swash plate
support (251).
251

NOTE - Do not knock on the shaft with a hammer or

somethings. 123
Fix the bearing by lightly tapping the outer race of it by
127, 824
means of a plastic hammer and set it exactly to the end
by using a steel rod and others.

111 R0713

5. Install seal cover (261) to pump casing (271) and fix

it with socket bolts (406).
: 6 mm 271

: 29.4 Nm 261

406
NOTE - Coat the oil seal in seal cover with a thin film
of grease.
Handle the oil seal with sufficient care so it is not
scored.

R0714

6. Assemble the piston cylinder sub compound to the

cylinder block (141), piston (151), shoe (152), plate
(153), spherical bushing (156) and cylinder spring 141 (151, 152)
(157).
Align the spherical bushing with the cylinder spline 156
and insert them into the pump casing.
153

R0715
E215-E235 W2-5-9

PUMP DEVICE

7. Install valve plate (313 and 314) to valve block (312)

by aligning pin.

312
NOTE - Do not mistake the suction and delivery sides
of the valve plate.

314 (313)

R0716

8. Install valve block (312) to pump casing (271) and

fasten them together with socket bolts (401). 312 271
: 17 mm 401
: 431.5 Nm

NOTE - Work will be promoted if assembly is started

from the rear pump.
Exercise care so as not to mistake the direction of the
valve block (312). Install it so the regulator comes up
as seen from the front side and the suction flange
comes on the right.
Insert the 1st gear into the valve block beforehand and R0717
connect it with the spline of the shaft.

9. Install regulator and PTO gear casing pinching

feedback pin of tilting pin in feedback lever of the
REGULATOR
regulator and PTO gear casing, install the regulator
and fasten socket bolt (412, 413 and 435).
: 6 mm
: 29.4 Nm
: 8 mm
: 33.3 Nm

IMPORTANT - Do not mistake the front regulator for

R0718
the rear regulator.
W2-5-10 E215-E235

PUMP DEVICE

10. Assembly of gear pump (4). 433

a. Replace systematically every O-Rings with
new ones.
b. Install the plug (466), the adapter (467), the 434
B3
adjusting screw (311) and the lock nut (312).
c. Install the flange socket (435) (Q. ty 2).
728
435
312 A3
311
732 850 467
307 308 355
310 309 434 466
725
R0700

11. Assembly of Unload valve (6). 351

a. Replace systematically every O-Rings with 331
new ones. 322
b. Install the springs (321 and 322). 321
c. Install the plugs (151, 331, 351 and 352). 151 361
d. Install the unload valve (6) to the hydraulic
pump device by means of socket bolts (4)
(Q. ty 8).

12. Install drain port plugs (466 and 468).

: 19 mm
: 36.3 Nm
362
: 36 mm 352
: 73.5 Nm R0751

13. Refill with hydraulic oil the pump device till to the
maximum allowed level.
E215-E235 W2-5-11

PUMP DEVICE

MAINTENANCE STANDARD
Unit: mm

Standard Recommended
Part name and inspection item dimension value for Remedy
(mm) replacement (mm)

Clearance between piston and 0.039 0.067 Replace piston or cylinder.

cylinder bore (D-d)
D

R0719

Gap between piston and caulked 0 ~ 0.1 0.3 Replace piston shoe assy.
part of shoe (δ)

R0720

Thickness of shoe (t) 4.9 4.7 Replace piston shoe assy.

R0721

Free height of cylinder spring (L) 41.1 40.3 Replace cylinder spring.

L
R0722

Combined height of retainer plate 23.0 22.0 Replace a set of spherical bushing
and spherical bushing (H-h) or retainer plate.

H
h
R0723

Repair standards for cylinder, valve plate and swash plate (shoe plate face)

Valve plate (sliding section).

Swash plate (shoe plate face).
Cylinder (sliding section).
Roughness of each surface.
Surface roughness requiring correction. 3-Z
Standard surface roughness
Less than 0.4 Z (lapping)
(correction value).
W2-5-12 E215-E235

PUMP DEVICE

DISASSEMBLY AND ASSEMBLY OF REGULATOR

732
627
626

625
624

623
621 612
622 611
733 874 728
897 645
732 875
631 613
875 646
898 652
644
651
836
655
654
653 439
814 656
643

755

438
630 722
629
924
763 801
801
925
628
756
413 412
418 079
496
496

496
755
542 734
545 601
543 875

614
I
543 755
545 858
541 496
439 724
438 755 755 875
641 730 725
615
708 887 466
733 8-724
755
858
642
753
727
467 801
R0750
E215-E235 W2-5-13

PUMP DEVICE

079 - Solenoid proportional reducing valve 645 - Adjust stem

412 - Socket bolt M8×50 (Q.ty 2) 646 - Pilot spring
413 - Socket bolt M8×70 (Q.ty 2) 651 - Sleeve
418 - Socket bolt M5×12 (Q.ty 2) 652 - Spool
438 - Socket bolt M6×20 (Q.ty 10) 653 - Spring seat
439 - Socket bolt M6×35 (Q.ty 3) 654 - Return spring
466 - Plug PF1/4 655 - Set spring
467 - Plug PF3/8×M6 656 - Block cover
496 - Plug (Q.ty 12) 708 - O-Ring
541 - Seat 722 - O-Ring (Q.ty 3)
542 - Seat 724 - O-Ring (Q.ty 8)
543 - Stopper (Q.ty 2) 725 - O-Ring
545 - Steel ball (Q.ty 2) 727 - O-Ring
601 - Casing 728 - O-Ring
611 - Feed back lever 730 - O-Ring
612 - Lever 732 - O-Ring (Q.ty 2)
613 - Lever 733 - O-Ring
614 - Fulcrum plug 734 - O-Ring
615 - Adjust plug 753 - O-Ring
621 - Compensating piston 755 - O-Ring (Q.ty 5)
622 - Piston case 756 - O-Ring
623 - Compensating rod 757 - O-Ring
624 - Spring seat 763 - O-Ring
625 - Outer spring 801 - Nut M8 (Q.ty 3)
626 - Inner spring 814 - Snap ring
627 - Adjust stem 836 - Snap ring
628 - Adjust screw 858 - Snap ring (Q.ty 2)
629 - Cover 874 - Pin Ø 4×11.7 L
630 - Lock nut M30×1.5 875 - Pin Ø 4×8 L (Q.ty 4)
631 - Sleeve 887 - Pin
641 - Pilot cover 897 - Pin Ø 4×19 L
642 - Rod 898 - Pin Ø 8.5×10 L
643 - Pilot piston 924 - Socket bolt M8×20
644 - Spring seat 925 - Adjust screw
W2-5-14 E215-E235

PUMP DEVICE

Disassembly

1. Proceed with disassembly operations in a clean

place.
Spread rubber sheet or cloth on work bench to
protect parts from damaging.

2. Clean the parts removing dust and rust, etc. on

regulator surface with wash oil.

3. Remove regulator remove socket bolts (412 and

413) and separate the regulator from the pump 079
439
body. 656 413
: 6 mm 412

4. Remove socket bolt (439) and separate the port 629

plate (656).
: 6 mm
438
5. Remove socket bolts (438) and remove cover (629).
: 5 mm 601
641
R0724

NOTE - The cover is equipped with adjust screws (628

and 925), adjust stem (627), lock nut (630), hex nut
(801) and set screw (924). Do not loosen those parts.
If they are loosened, preadjusted set pressure and flow
values change.

624, 625, 626

627
801
629 (628, 925)

630 924 R0725

E215-E235 W2-5-15

PUMP DEVICE

6. After removing the cover (629) sub assy, take out

outer spring (625), inner spring (626) and spring seat M4 BOLT 645
(624) from the compensating part. Then take out 644, 646
adjust stem (645), pilot spring (646) and spring seat
(644) from the pilot part.
601

NOTE - Adjust stem (645) comes out easily if an M4

bolt is used.

R0726

7. Remove socket bolt (439) and pilot cover (641).

Once the pilot cover comes off, separate set spring
(655) from the pilot section.
: 5 mm

439
641
655 R0727

8. Remove snap ring (814), spring seat (653), return

spring (654) and sleeve (651).

814 (653)

NOTE - Sleeve (651) is equipped with snap ring (836).

When removing snap ring (814), return spring (654) 654
comes out, use care so as not to lose it. 651 (839)

R0728

9. Remove snap ring (858) and take out fulcrum plug

(614) and adjust plug (615).
858

615

614

R0729
W2-5-16 E215-E235

PUMP DEVICE

NOTE - Fulcrum plug (614) and adjust plug (615) come

off easily if a M6 bolt is used.

614

R0730

10. Remove lever 2 (613) with tweezer.

NOTE - Do not draw out pin (875).

613 (875)

R0731

11. Draw out pin (874) and remove feedback lever

(611).
874

NOTE - Push out pin (874) from above with a slender

steel rod (Ø 4 x 100) so as not to interfere with lever
(612).
611

R0732

611
R0733
E215-E235 W2-5-17

PUMP DEVICE

12. Remove lever 1 (612).

612
611
874
NOTE - Do not draw out pin (875). 897
875
613
13. Draw out pilot piston (643) and spool (652). 875

14. Draw out piston casing (622), compensating pis-

ton (621) and compensating rod (623).

NOTE - Piston casing (622) comes out from the

opposite side of the piston casing if compensating rod
(623) is pushed out. 643
R0734

Assembly
623
1. Assembly is the reverse order of disassembly. Do
the work paying attention to the following: 622 621

- Repair those parts that were damages during 733

disassembly and prepare replacement parts be- 732
forehand. 631
- Clean parts thoroughly in cleaning oil, blow them 898 652
with jet air and assemble parts in a clean place. 651
836
- Always tighten screws and plugs to the specified 655
torque. 654
653
- Do not fail to coat the moving parts with clean 814
hydraulic oil, before assembly.
- Replace seals such as O-Ring.
R0735

2. Assemble compensating rod (623) into the compen-

sating hole of casing (601). 623
612
3. Put the pin mounted in lever 1 (612) into the groove 611
of the compensating rod. Then assemble the lever 874
to the pin that is pressed in the casing. 897
875 613
875

R0736
W2-5-18 E215-E235

PUMP DEVICE

4. Assemble spool (652) and sleeve (651) into the

spool hole of the casing.

NOTE - Make sure that the spool and the sleeve move
smoothly in the casing.
Beware of the direction of the spool.

Spool (652) Feedback

lever (611)

R0737

5. Assemble feedback lever (611). Then put pin (874)

into the pin hole of the feedback lever. Feedback
lever (611)
NOTE - The work is eased if the pin is put in the
feedback lever a little, beforehand.
Take care so as not to mistake the direction of the Lever 1 Lever 2 (613) side
feedback lever. (612) side

6. Assemble pilot piston (643) into the negative control

hole of the casing.

NOTE - Make sure that the pilot piston moves

R0738
smoothly.

7. Place pin (875) pressed in lever 2 (613) into the

groove of the pilot piston and assemble lever 2
(613).

613 (875)

R0739

8. Assemble fulcrum plug (614) so pin (875) pressed

in the fulcrum comes in the pin hole of lever 2 (613).
Then fit snap ring (858).

614 (875, 858)

R0740
E215-E235 W2-5-19

PUMP DEVICE

9. Insert adjust plug (615) and fit a snap ring (858).

652

NOTE - Use care so as not to mistake the holes into 814

which the fulcrum and adjust plug are inserted. 653
Operate the feedback lever and make sure that the gap
is not large and that the lever moves smoothly. 654

R0741

10. Assemble return spring (654) and spring seat (653)

into the spool hole and fit snap ring (814).

11. Assemble set spring (655) into the spool hole.

Place compensating piston (621) and piston cas-
ing (622) into the compensating hole and attach
pilot cover (641) with socket bolts (436).
: 5 mm
: 11.7 Nm

622 (621)
R0742

12. Put spring seat (644), pilot spring (646) and adjust
stem (645) into the pilot hole. Then assemble
spring seat (624), inner spring (626) and outer 644, 645, 646
spring (625) into the compensating hole.
626

NOTE - Do not mistake the direction of the spring seat. 625 (624)

R0743

13. Attach cover (629) fitted with adjust screws (628

and 925), adjust stem (627), lock nut (630), nut
(801) and socket bolt (924). Then fasten them with
socket bolts (438).
: 5 mm
: 11.7 Nm 624, 625, 626
627
801
629 (628, 925)

630 924 R0744

W2-5-20 E215-E235

PUMP DEVICE

DISASSEMBLY AND ASSEMBLY OF PTO GEAR CASING

414

117 128

126 435
826 886 711
326
128

414
115
827 886 262
728
125 468

118
125
825
435
435

R0745

115 - Idle shaft 435 - Flange socket M10×20 (Q.ty 4)

117 - 2nd gear 468 - VP plug PF3/4
118 - 3rd gear 710 - O-Ring
125 - Ball bearing (Q.ty 2) 711 - O-Ring
126 - Roller bearing 728 - O-Ring
128 - Bearing spacer (Q.ty 2) 825 - Snap ring
262 - Cover (Q.ty 2) 826 - Snap ring
326 - Gear casing 827 - Snap ring
414 - Socket bolt M10×20 (Q.ty 4) 886 - Pin (Q.ty 2)
E215-E235 W2-5-21

PUMP DEVICE

Disassembly

1. Proceed with disassembly operations in a clean

place.
Spread rubber sheet or cloth on work bench to
protect parts from damaging. 414

2. Remove the socket bolts (414). Then remove the

cover (262).
: 8 mm
: 33.3 Nm 262

R0746

3. Remove flange socket (435) and PTO gear casing.

: 8 mm
Hole for flange
socket (435)

PTO
Gear casing

R0747
W2-5-22 E215-E235

PUMP DEVICE

4. Remove snap ring (827) and idle shaft (115). Then

draw out 2nd gear (117), roller bearing (126) and Hole for
bearing spacer (128). idle shaft
(115)

NOTE - Roller bearing (126) can not be separated from 117

2nd gear (117). (126, 128)

R0748

5. Remove snap ring (825) and draw out 3rd gear (118)
and ball bearing (125).

NOTE - Ball bearing (125) can not be separated from 125

3rd gear (118).

118

R0749

Assembly

Assembly is a reverse order of disassembly, but

notice the following:
- Repair scored parts at disassembly. Get replace-
ments ready beforehand.
- Wash parts sufficiently in cleaning oil and dry them
with jet air.
- Do not forget to coat the sliding areas and bearings
with clean hydraulic oil.
- In principle. replace sealing parts such as O-Rings
and oil seals.
- Tighten socket bolts and plugs to specified torques
in this Manual.

Maintenance standard

In case a pitching (1 pit is more than 1mm, while the

area ratio is more than 5%) is seen on the gear tooth
surface of 2nd gear (117) and 3rd gear (118), replace the
gears. Replace the gears also in case they show
excessive damage.
E215-E235 W2-6-1

CONTROL VALVE

REMOVAL AND INSTALLATION OF CONTROL VALVE

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.

Preparation
1. Park the machine on a firm, level surface.
2. Cut-off the engine. Actuate the manual and pedal
pilot valves to release any residual pressure from
insidet he hydraulic system. Press the valve lo-
cated on the hydraulic oil tank to release any
residual pressure present inside the tank itself.
Refer to “Bleed Pressure from Hydraulic Circuit” on
page W4-2-12.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
NOTE - Be sure to run the vacuum pump continu-
ously while working.

Removal of Control valve
NOTE - Attach caps to hoses and pipes.
Attach labels or tags to hoses and pipes, to aid in
assembly.
1. Install control valve to frame and tighten the bolts.
2. Connect all hoses, pipes and connectors to the
control valve.
3. Install the panel protecting the control valve using
the relevant securing screws.

1. Remove the panel protecting the control valve, IMPORTANT - After completing installation:
removing the securing screws. - Check hydraulic oil level. Add oil if necessary.
- Run the engine. Check the engine components for
: 19 mm
any oil leakage.
: 108 Nm

2. Disconnect all hoses, pipes and connectors from

the control valve (2).
: 19 mm
: 29.4 ± 2.94 Nm
1
: 22 mm
: 68.6 ± 6.8 Nm
: 36 mm
: 176.5 ± 17.6 Nm
2
: 41 mm
: 205.9 ± 20.6 Nm

CAUTION
Control valve assembly weight: 180 kg

3. Remove the control valve securing screws (1) and

remove it.
: 19 mm 1
: 108 Nm
Installation of Control valve

NOTE - Refer to “Removal of Control valve” section

above for wrench sizes and tightening torques.
R0433
W2-6-2 E215-E235

CONTROL VALVE

CONTROL VALVE DISASSEMBLY

2 3 4 5 6 7 8

1
4

18 9

10
4
4 11 12 4 13 14 15

16

17

4 19
R0434

1 - Main relief valve 11 - Option 2 valve for breaker

2 - Travel straight valve 12 - Arm recirculation valve
3 - Travel right valve 13 - Arm valve
4 - Overload relief valve 14 - Boom conflux valve
5 - Bucket valve 15 - Swing valve
6 - Boom valve 16 - Travel left valve
7 - Selector valve - Lock valve 17 - Casing A
8 - P1 bypass valve 18 - Casing B
9 - Plate 19 - P2 bypass valve
10 - Arm conflux valve
E215-E235 W2-6-3

CONTROL VALVE

Preliminary operations

1. As all the hydraulic components are precisely

machined, it is essential to carry out disassembly
and reassembly in an especially clean location.

2. When handling the control valve, take special care

to prevent the entry of foreign matter, such as dust
or sand.

3. Cap each port of the control valve before removing

the valve from the machine. Before disassembly,
confirm that each cap is in place and then clean the
exterior of the assembly.

Disassembly

1. Place the control valve on a workbench.

NOTE - Disassemble the valve in a clean location,

and be careful not to damage flange surfaces or plate
mounting surfaces.
W2-6-4 E215-E235

CONTROL VALVE

1. Remove option valve block (P2) for breaker.

214 276
a. Loosen the socket bolts (276) (Q.ty 4) and
remove the option valve block (P2) for breaker.
: 10 mm
b. Loosen the socket bolts (P271) (Q.ty 2) and
remove the spring cover (P202) and the O-Ring
(P261).
: 6 mm
c. Draw out, from casing (214), the assy of option
spool (P301), the spring seat (P337) (Q.ty 2)
springs (P323 and P324), stopper (P333) and bolt
(P334) from casing.

NOTE - When drawing out the spool assy, use care so

R0435
as not to score casing (214).

d. Fix the option spool assy with vise via a protec-

tive plate (aluminum plate, etc.) and remove bolt
(P334). Then separate spring seat (P337),
springs (P323 and P324) and stopper (P333)
from option spool (P301).
e. Loosen socket bolt (P271) (Q.ty 2) and separate
spool cover (P204) and O-Ring (P262).
: 6 mm
f. Remove the overload relief valve port (P603)
from casing (214).
: 32 mm

NOTE - Regarding the disassembly of the overload

relief valve refer to the "Disassembly main relief
valve" and "Disassembly overload relief valve".

g. Loosen the plug (P551) and remove shutter

(P512) with spring (P522).
: 12, 14 mm
275
2. Loosen socket bolt (275)(Q.ty 4) and remove plate
P1 side (213). 213

: 10 mm

R0436
E215-E235 W2-6-5

CONTROL VALVE

273 273

A A

SECTION A-A

P202 PAo2
P334
P337
P324
P323
P333
P271
275
P301
276

Ao2
214
P561
P551

P522
P512
213
Bo2

276

275
PBo2
P262
P204
R0437

P213 - Plate P1 side P323 - Spring

P214 - Option P2 lock valve P324 - Spring
P275 - Socket bolt (Q.ty 4) P333 - Stopper
P276 - Socket bolt (Q.ty 4) P334 - Spacer bolt
P202 - Spring cover P337 - Spring seat (Q.ty 2)
P204 - Spring cover P512 - Poppet
P262 - O-Ring P522 - Spring
P271 - Socket bolt (Q.ty 2) P551 - Plug
P301 - Option P2 spool P561 - O-Ring
W2-6-6 E215-E235

CONTROL VALVE

3. Disassembling arm recirculation spool.

273
a. Loosen the socket bolts (273) (Q.ty 2) and
remove the spring cover (204) and the O-Ring
(262) for arm recirculation.
204
: 6 mm (262)

R0438

b. Draw out, from casing A (101), the assy of arm

recirculation spool (311), spring seat (332) 311(325,326,332,334,337) 101
(Q.ty 2), springs (325 and 326), stopper (337)
and bolt (334).

NOTE - When drawing out the spool assy, use care so

as not to score casing A (101).

R0439

c. Fix the arm recirculation spool assy with vise via

a protective plate (aluminum plate, etc.) and
remove bolt (334). Then separate spring seat
(332), springs (325 and 326) and stopper (337)
from arm recirculation spool (311).
: 10 mm
337 334

332
326
325
311

R0440
E215-E235 W2-6-7

CONTROL VALVE

273 273

A A

SECTION A-A

PCb Pis

204
334
332
337
326
325
332
262
311
Ab CAr

X1

CCa Ba

PA1 PCa
R0441

204 - Spring cover 326 - Spring

262 - O-Ring 332 - Spring seat (Q.ty 2)
273 - Socket bolt (Q.ty2) 334 - Socket bolt
311 - Arm recirculation spool 337 - Stopper
325 - Spring
W2-6-8 E215-E235

CONTROL VALVE

4. Disassembling bypass cut spool.

204(262) 273
a. Loosen socket bolt (273) (Q.ty 2) and separate
spring cover (204) and O-Ring (262) from the cut
spool.
: 6 mm

R0442

b. Draw out the assy of cut spool (309 and 310), 309(325,326,332,334,337) 102
spring seat (332) (Q.ty 2), springs (325 and
326), stopper (337) and bolt (334) from casing A
(101) or casing B (102).

NOTE - When drawing out the spool assy, take care

so as not to score casing A (101) or casing B (102).

R0469

c. Fix the bypass cut spool assy with vise via a

protective plate (aluminum plate, etc.) and re-
move bolt (334). Then separate spring seat
(332), springs (325 and 326) and stopper (337)
from bypass cut spool (309 and 310).
332
: 10 mm 334

337
326
325

309

R0470
E215-E235 W2-6-9

CONTROL VALVE

273 273

A A

SECTION A-A

PCb Pis

204
334
332 332
337

326
325
262
309
Ab CAr

X1

CCa Ba
310

262
332
325
326
337
332
334
PA1 PCa 204

R0471

204 - Spring cover 325 - Spring

262 - O-Ring 326 - Spring
273 - Socket bolt (Q.ty 2) 332 - Spring seat (Q.ty 2)
309 - Bypass cut spool (P1) 334 - Spacer bolt
310 - Bypass cut spool (P2) 337 - Stopper
W2-6-10 E215-E235

CONTROL VALVE

5. Disassembling the arm spool. 201(261) 273

a. Loosen socket bolts (273) (Q.ty 2) and remove
spring cover (201) for arm and O-Ring (261).
: 6 mm

R0472

b. Draw out the assy of arm spool (302), spring

302(321,322,331,333,336) 101
seat (331) (Q.ty 2), springs (321 and 322),
stopper (336) and bolt (333) from casing A
(101).

NOTE - When drawing out the spool assy, take care

so as not to score casing A (101).

R0473

c. Fix the arm spool assy with vise via a protective

plate (aluminum plate, etc.) and remove bolt
(333). Then separate spring seat (331), springs
(321 and 322) and stopper (336) from arm spool 331
(302). 333
322
336
: 10 mm 321
302

R0474
E215-E235 W2-6-11

CONTROL VALVE

273 273

A A

SECTION A-A
201
PAb PAa
333
331
336
322
321

331
261
CRb Aa
302

LCb LCa

Bb CRa

Pisc

PBb PBa

R0475

201 - Spring cover 322 - Spring

261 - O-Ring 331 - Spring seat (Q.ty 2)
273 - Socket bolt (Q.ty 2) 333 - Spacer bolt
302 - Arm spool assy 336 - Stopper
321 - Spring
W2-6-12 E215-E235

CONTROL VALVE

6. Disassembling the boom spool. 273 201(261)

a. Loosen socket bolts (273) (Q.ty 2) and remove
spring cover (201) for boom and O-Ring (261).
: 6 mm

R0476

b. Draw out the assy of boom spool (301), spring 301(321,323,331,333,336) 102
seat (331) (Q.ty 2), springs (321 and 322),
stopper (336) and bolt (333) from casing B
(102).

NOTE - When drawing out the spool assy, take care

so as not to score casing B (102).

R0477

c. Fix the boom spool assy with vise via a protec-

tive plate (aluminum plate, etc.) and remove bolt 333
(333). Then separate spring seat (331), springs
(321 and 322) and stopper (336) from boom
spool (301). 331
: 10 mm
332
336
321
d. Do not disassemble arm spool (301) further 301
unless there is special reason. In case it must be
disassembled for indispensable reason, do as
R0478
follows :
Place the middle of boom spool (301) in a vise
fitted with mouth pieces and remove plug 1
(B352) and plug 2 (B353).

: 10 mm

Take out plunger 1 (B315), plunger 2 (B316), B352,

plunger 3 (B317), spring B1 (B320), spring B2 B353 301(B315,B316,B317,
(B330) and spring B3 (B340) from boom spool B320,B330,B340)
(301).

IMPORTANT - Take care so as not to distort boom

spool (301) by overtightening it in the vise. R0479
E215-E235 W2-6-13

CONTROL VALVE

273 273

A A

SECTION A-A
201
333 PAb PAa
331
336
322
321
331
261

CRb Aa

LCb LCa

Bb CRa

Pisc
301

PBb PBa
R0480

201 - Spring cover 322 - Spring

261 - O-Ring 331 - Spring seat (Q.ty 2)
273 - Socket bolt (Q.ty 2) 333 - Spacer bolt
301 - Boom spool assy 336 - Stopper
321 - Spring
W2-6-14 E215-E235

CONTROL VALVE

7. Disassembling the boom conflux spool. 273 207(261)

a. Loosen socket bolts (273) (Q.ty 2) and remove
spring cover (207) for boom conflux and O-Ring
(261).
: 6 mm

R0481

b. Draw out the assy of boom conflux spool (305), 305(323,324,331,333,339)

spring seat (331) (Q.ty 2), springs (323 and
101
324), stopper (339) and bolt (333) from casing A
(101).

NOTE - When drawing out the spool assy, use care so

as not to score casing A (101).

R0482

c. Fix the boom conflux spool with vise via a 333

protective plate (aluminum plate, etc.) and re-
move bolt (333).Then separate spring seat 331
(331), springs (323 and 324) and stopper (339)
from boom conflux spool (305).
339
: 10 mm

324
305
323

R0483

d. Fix spring cover (207) in a vise and remove plug.

E215-E235 W2-6-15

CONTROL VALVE

273 273

A A

SECTION A-A

PB1
207
PAc
333
331
339
324
323
331
261

Ac CCb

LCc 305

Bc

PBc

R0484

207 - Spring cover 324 - Spring

273 - Socket bolt (Q.ty 2) 331 - Spring (Q.ty 2)
261 - O-Ring 333 - Spacer bolt
305 - Boom conflux spool 339 - Stopper
323 - Spring
W2-6-16 E215-E235

CONTROL VALVE

8. Disassembling bucket spool.

273 201(261)
a. Loosen socket bolts (273) (Q.ty 2) and remove
bucket spring cover (201) and O-Ring (261).
: 6 mm

R0485

b. Draw out the assy of bucket spool (304), spring

seat (331) (Q.ty 2) , springs (321 and 322), 304(321,322,331,333,336) 102
stopper (336) and bolt (333) from casing B
(102).

NOTE - When drawing out the spool assy, use care so

as not to score casing B (102).

R0486

c. Fix the bucket spool assy with vise via a protec- 333
tive plate (aluminum plate, etc.) and remove bolt
(333). Then separate spring seat (331), springs
(321 and 322) and stopper (336) from bucket 331
spool (304).
: 10 mm

322 336

304
321

R0487
E215-E235 W2-6-17

CONTROL VALVE

273 273

A A

SECTION A-A

PB1
201
333 PAc
331
336
322
321

331
261

Ac CCb

LCc

Bc

304

PBc

R0488

201 - Spring cover 322 - Spring

273 - Socket bolt (Q.ty 2) 331 - Spring seat (Q.ty 2)
261 - O-Ring 333 - Spacer bolt
304 - Bucket spool 336 - Stopper
321 - Spring
W2-6-18 E215-E235

CONTROL VALVE

9. Disassembling the swing spool.

273 202(261)
a. Loosen the socket bolts (273) (Q.ty 2) and
remove the spring cover (202) and the O-Ring
(261) for swing.
: 6 mm

R0489

b. Draw out the assy of swing spool (303), spring

seat (331) (Q.ty 2), springs (321 and 322), 303(321,322,331,333,336)
stopper (336) and bolt (333) from casing A 101
(101).

NOTE - When drawing out the spool assy, use care so

as not to score casing A (101).

R0490

c. Fix the swing spool assy with vise via a protec-

tive plate (aluminum plate, etc.) and remove bolt 333
(333). Then separate spring seat (331), springs
(321 and 322) and stopper (336) from swing 331
spool (303).
: 10 mm
336

322 321

303

R0491
E215-E235 W2-6-19

CONTROL VALVE

273 273

A A

SECTION A-A

PBs2

Pss
202
PAr PAs 333
331
336
322
321

Dra 331
261

Ar As

CP1 LCs

Br Bs

Drb

303

PBr PBs1
R0492

202 - Spring cover 322 - Spring

273 - Socket bolt (Q.ty 2) 331 - Spring seat (Q.ty 2)
261 - O-Ring 333 - Spacer bolt
303 - Swing spool 336 - Stopper
321 - Spring
W2-6-20 E215-E235

CONTROL VALVE

10. Disassembling the travel spool (left travel and

right travel).
a. Loosen the socket bolts (273) (Q.ty 2) and
remove the spring cover (203) and the O-Ring
(262) for travel. 273

: 6 mm

203(262)
R0493

b. Draw out the assy of travel spool (306), spring

306(327,328,332,334,338)
seat (332) (Q.ty 2), springs (327and 328),
stopper (338) and bolt (334) from casing A
(101) or casing B (102).

NOTE - When drawing out the spool assy, take care

so as not to score the casing A (101) or the casing B
(102).

102

R0494

c. Fix the travel spool assy with vise via a protec-

tive plate (aluminum plate, etc.). Remove bolt 334
(334) and separate spring seat (332), springs
(327 and 328) and stopper (338) from travel 332
spool (306).
338
: 10 mm

327

328 306

R0495
E215-E235 W2-6-21

CONTROL VALVE

273 273

203 203
SECTION A-A
334 334
332 PAr PAL 332
338 338
328 328
327 327
332 332
262 262
Dra

Ar AL

CP1 CP2

Br BL
306

Drb

306
PBr PBL

R0496

203 - Spring cover 328 - Spring

273 - Socket bolt (Q.ty 2) 332 - Spring seat (Q.ty 2)
262 - O-Ring 334 - Spacer bolt
306 - Left and right travel spool 338 - Stopper
327 - Spring
W2-6-22 E215-E235

CONTROL VALVE

11. Disassembling travel straight spool.

a. Loosen the socket bolts (273) (Q.ty 2) and
remove the spring cover (203) and the O-Ring
(262) for travel straight.
: 6 mm 273

203(262)

R0497

b. Draw out the assy of travel straight spool (307),

spring seat (332) (Q.ty 2), springs (327 and
329), stopper (340) and bolt (334) from casing
B (102).

NOTE - When drawing out the spool assy, take care

so as not to score the casing B (102).
102

307(327,329,332,334,337)
R0498

c. Fix the travel straight spool assy with vise via a

protective plate (aluminum plate, etc.). Re- 334
move bolt (334) and separate spring seat
(332), springs (327), (329) and stopper (340) 332
from travel straight spool (307).
337
: 10 mm

327

329 307

R0499
E215-E235 W2-6-23

CONTROL VALVE

273 273

A A

SECTION A-A
203 166 156
334
332 PAL
340
329
327
332
262

PL1

AL

CMR1
CP2

CMR2
BL

307

PTb PBL
R0500

156 - Plug 327 - Spring

166 - O-Ring 329 - Spring
203 - Spring cover 332 - Spring seat (Q.ty 2)
273 - Socket bolt (Q.ty 2) 334 - Spacer bolt
262 - O-Ring 340 - Stopper
307 - Travel straight spool
W2-6-24 E215-E235

CONTROL VALVE

12. Disassembling the arm conflux spool .

204(262) 273
a. Loosen socket bolts (273) (Q.ty 2) and remove
spring cover (204) and O-Ring (262) for arm
conflux.
: 6 mm

R0501

b. Draw out the assy of arm conflux spool (308),

308(325,326,332,334,332)
spring seat (332) (Q.ty 2), springs (325 and
326), stopper (337) and bolt (334) from casing B 102
(102).

NOTE - When drawing out the spool assy, use care so

as not to score casing B (102).

R0502

c. Fix the arm conflux spool assy (308) with vise

via a protective plate (aluminum plate, etc.) and
remove bolt (334). Then separate spring seat 334
(332), springs (325 and 326) and stopper (337)
from arm conflux spool (308).
332
: 10 mm

332
326
308

325

R0503
E215-E235 W2-6-25

CONTROL VALVE

273 273

A A

SECTION A-A

PCb Pis

Ab CAr

X1

CCa Ba

308
262
326
337
325 332
332
334
204
PA1 PCa
R0504

204 - Spring cover 326 - Spring

273 - Socket bolt (Q.ty 2) 332 - Spring seat (Q.ty 2)
262 - O-Ring 334 - Spacer bolt
308 - Arm conflux spool 337 - Stopper
325 - Spring
W2-6-26 E215-E235

CONTROL VALVE

13. Remove spool covers (Arm, boom, bucket, swing,

left travel and right travel, travel straight), loosen 273
socket bolts (273) (Q.ty 2) and remove spool cover
(205) and O-Ring (264). 205(264)

R0505

14. Disassembling the rod spool (312).

a. Loosen socket bolts (273) (Q.ty 2) and remove 312
spring cover (205) and O-Ring (264).
101
: 6 mm
b. Draw out rod spool (312).
c. Remove plug (156) from spool cover (205).

R0506
E215-E235 W2-6-27

CONTROL VALVE

273 273

A A

SECTION A-A
PB1
PAc

Ac CCb

LCc

312
Bc

PBc 264
205
264 205 166
156
R0507

166 - O-Ring 264 - O-Ring

156 - Plug 312 - Rod spool
205 - Spool cover
W2-6-28 E215-E235

CONTROL VALVE

15. Remove lock valve selector sub assy. Loosen

socket bolts (1) (Q.ty 4) and remove lock valve 1 211
selector (211).
: 5 mm

R0508

16. Remove the main relief valve (601) and overload

relief valve (602) from the casing.
: 32 mm

NOTE - Distinguish overload relief valve between

(602, 603 and 604) with a tag to prevent them from
being confused during reassembly.
601

R0509

602

R0510
E215-E235 W2-6-29

CONTROL VALVE

17. Remove check valve.

a. Remove the boom conflux check valve (CCb)
by loosing plug (551) and remove poppet (511)
and spring (521).
: 12 mm 551
(511,521)

NOTE - Remove the load check valve CP1, LCc,

LCb, CCa, CP2, LCa, LCs the same way.

R0511

b. Lock valve section (arm CRa and CRb boom.). 556(514,524)

Loosen plug (556) and remove poppet (514)
and spring (524).
: 12 mm

NOTE - Exercise care so as not to mistake them as

they all differ in kind from above.

c. Travel straight section (CT1). Remove plug

(552). Then remove poppet (512) and spring R0512
(522).
: 10 mm

d. Main relief valve section (CMR1,CMR2). Re-

move plug (552) and remove poppet (512) and
spring (522).
: 10 mm

552
(512,522)

R0513

e. Recirculation check valve (CAr).Remove plug 552(512,522)

(552) and remove poppet (512) and spring
(522). Remove the load check valve the same
way.
: 10 mm

NOTE - Those plugs that are not mentioned in the

foregoing disassembly procedure are blind for extra
holes and cast-on holes; do not remove them unless
necessary.
R0514
W2-6-30 E215-E235

CONTROL VALVE

18. Disassembling main relief valve.

671
a. Remove plug (103) and seat (541) by pulling 652
them by hand as C ring (121) is fixed. 673
613
b. Draw out spring (521) and plunger (512) from 664
inside seat (541). 661 163

c. Remove lock nut (671) and adjust screw (104) 614

from adjust screw (652) and remove stopper 103
(613), piston (614), spring (621) and poppet
(611). 104

: 22 mm 611
562 663
621
561 122
125 121
521
124 541
123 512

R0515

d. Loosen lock nut (673) of plug (103) and remove

adjust screw (104).

: 32 mm
e. Separate snap ring (121) and spacer (122)
from plug (103).

IMPORTANT - Do not disassemble the plug (103).

541(121) 103

R0516
E215-E235 W2-6-31

CONTROL VALVE

19. Disassembling overload relief valve.

671
a. Loosen plug (102), remove springs (521),
(522) and seat (541) out of body (101) and
draw out piston (301) and plunger (511) out of 612 651
seat (541).
661
: 30 mm 102
621
162
611
562 101
561
125 541
124
123 161
521 522

511
563
564 301 R0517

b. Separate lock nut (671) and adjust screw (651)

from plug (102) and remove spring seat (612),
spring (621) and poppet (611).
: 30 mm

IMPORTANT - Filter (125) and filter stopper (124) are 102

assembled with plug (102) by means of C ring (123).
Therefore, it can not be disassembled any further.

101
R0518
W2-6-32 E215-E235

CONTROL VALVE

Inspection after disassembly RELIEF VALVE

Thoroughly clean all disassembled parts with wash
oil, and dry them with jet air. Place each part on a
cleans heet of paper or cloth for inspection.
CONTROL VALVE
1. Inspect the entire surface of each part for burrs,
scratches, cuts, and other defects.
2. Confirm that the O-Ring groove surface of the
casing or the block is free from foreign matter,
dents or rust.
3. If the check valve seat of the casing or the block has
dents or damage on its surface, smooth it by
lapping.
1. Make sure that the poppet and the seat surface at
the tip of the seat are without fault and that the
contact surface is even all over.
2. Manually confirm that the main poppet slides
smoothly onto and off the seat.
3. Confirm that the outer circumference of the main
poppet and the inner circumference of its seat are
free from defects such as scratches.
4. Confirm that each spring is free from breakage,
deformation, and excessive wear.
5. Confirm that the orifices of the main poppet and its
seat are not clogged.

6. Replace all O-Rings with new ones.

NOTE - Take care not leave lapping compound be-
hind in the casing or block.
7. Remove any slight defects found during the above
inspection by lapping.
4. Confirm that O-Ring or the outer circumference of
the sliding part of a manual spool is free from 8. If any abnormal part is found, replace the relief
scratches, dents, and the like. Remove any small valve as an assy.
defects with an oil stone or lapping compound.

5. Manually confirm that all sliding and fitted parts

move smoothly. Confirm that all grooves and pas-
sages are free from foreign matter.

6. Replace any broken or deformed spring with new

one.

7. Of a relief valve malfunctions, repair it by following

the relief valve disassembly and reassembly pro-
cedures.

8. Replace all O-Ring with new ones.

E215-E235 W2-6-33

CONTROL VALVE

CONTROL VALVE ASSEMBLY 2. Assembling relief valve.

IMPORTANT - Here, only the assembly procedures
are described. Regarding drawings, refer to the disas-
sembly procedures.
Precautions on assembling
1. Confirm that O-Rings are free from defects caused
by poor handling.
2. Apply thin coat of grease or hydraulic oil to O-Rings
and their mating parts.
a. Tighten main relief valve (601) and port relief
valves (602), to the specified torques in correct
positions.
: 32 mm
: 69-78 Nm
IMPORTANT - Overload relief valves (602) are the
same in outer appearance. Therefore, reassemble
them in correct positions by looking at tags attached
at disassembly.

3. Do not stretch O-Rings to the extent that they 3. Assembling arm conflux spool.
become permanently set.
a. Put a protective plate (aluminum plate, etc.) to a
4. When installing O-Rings, do not roll them into vise. Hold the middle of arm conflux spool (308)
place. Twisted O-Rings do not easily untwist by in the vise, set spring seat (332) (Q.ty. 2),
themselves after installation, and can cause oil springs (325, 326) and stopper (332) and tighten
leaks. bolts (334) to the specified torque.
: 10 mm
Assembly
: 16-18 Nm
1. Assembling check valve.
a. Load check valve, conflux check valve, etc. Fit
NOTE - Before tightening bolts (334), coat them with
poppet (511) and spring (521), put O-Ring (164)
Loctite #262. Be careful so as not to distort arm
in plug (551).
conflux spool (308) by overtightening it in the vise.
: 12 mm
: 230-260 Nm b. Fix the arm conflux spool assy into casing B
b. Lock valve. Fix poppet (514) and spring (524), (102).
put O-Ring (164) in plug (556) and fasten it to the
specified torque. NOTE - Fix the arm conflux spool assy into casing B
: 12 mm (102) slowly and carefully and never force it in.

: 230-260 Nm
c. Attach spring cover (204) with O-Ring (262) to the
spring side of the arm conflux spool assy. Then
IMPORTANT - Plugs described in assembling opera-
fasten socket bolts (273) (Q.ty 2) to the specified
tions are look similar; use care of the parts combina-
torque.
tion and assembling position.
: 6 mm
c. Travel straight and main relief sections. Fit pop- : 25-34 Nm
pet (512), spring (522), put O-Ring (562) in plug
(552).
: 10 mm
: 130-150 Nm

IMPORTANT - Use care so special poppet (515) for

travel straight is fixed in a correct position.
W2-6-34
CONTROL VALVE
4. Assembling cut bypass spool.
a. Put a protective plate (aluminum plate, etc.) in a
vise and hold the middle of cut bypass spool
(309) (310) in the vise. Set spring seat (332)
(Q.ty. 2), springs (325 and 326) and stopper (337)
and fasten bolts (334) to the specified torque.
: 10 mm
: 16-18 Nm
NOTE - Before tightening bolts (334), coat them with
Loctite #262. Use care so as not to distort cut spool
(309, 310) by overtightening it in the vise.
b. Fit the cut bypass spool assy into casing A (101)
and casing B (102).
NOTE - When assembling the cut spool assy into
casing A (101), B (102), do it slowly with care, never
force it in.
c. Attach spring cover (204) with O-Ring (262) to
the spring side of the cut spool assy. Then fasten
socket bolts (273) (Q.ty 2) to the specified
torque.
: 6 mm
: 25-34 Nm
5. Assembling arm spool.
a. Put a protective plate (aluminum plate) in the
vise and hold the center of arm spool (302) in the
vise. Set spring seat (331) (Q.ty. 2), springs (321
and 322) and stopper (336) and tighten bolts (333)
to the specified torque.
: 10 mm
: 16-18 Nm
NOTE - When tightening bolts (333), coat them with
Loctite #262. Take care so as not to distort arm spool
(302) by overtightening it in the vise.
b. Fit the arm spool assy to casing A (101).
NOTE - When assembling the arm spool assy into
casing A (101), do it slowly and carefully, never force
it in.
c. Attach spring cover (201) with O-Ring (261) to
the spring side of the arm spool assy. Then
tighten socket bolts (273) (Q.ty 2) to the speci-
fied torque.
: 6 mm
: 25-34 Nm
E215-E235
6. Assembling boom spool.
a. Assemble plunger 1 (B315), plunger 2 (B316),
plunger 3 (B317), spring B1 (B320), spring B2
(B330) and spring B3 (B340) in boom spool
(301). Then tighten plugs (B352), (B353) to the
specified torque.
: 24 mm
: 88-98 Nm
NOTE - Use care so parts are assembled in correct
positions and make sure that each plunger slides
lightly in boom spool (301).
b. Put a protective plate (aluminum plate, etc.) in a
vise and hold the middle of boom spool (301) in
the vise. Set spring seat (331) (Q.ty 2), springs
(321 and 322) and stopper (336) and tighten bolts
(333) to the specified torque.
: 10 mm
: 16-18 Nm
NOTE - When tightening bolts (333), coat them with
Loctite #262. Be careful so as not to distort boom
spool (301) by overtightening it in the vise.
c. Install the boom spool assembly reassembled
above in casing B (102).
NOTE - When assembling the boom spool assy into
casing B (102), do it slowly and carefully, never force
it in.
d. Attach O-Rings (261) to the spring side of the
boom spool assy. Then fit spring cover (201) to
the assy and tighten socket bolts (273) (Q.ty 2)
to the specified torque.
: 6 mm
: 25-34 Nm
E215-E235 W2-6-35

CONTROL VALVE

7. Assembling boom conflux spool.
a. Fix spring cover (207) in a vise, put O-Ring (166)
in plug and fasten it to the specified torque.
: 27 mm
: 69-78 Nm
b. Put a protective plate (aluminum plate, etc.) and
hold the middle of boom conflux spool (305) in
the vise. Set spring seat (331),(Q.ty 2) springs
(323 and 324) and stopper (339) and tighten bolts
(333) to the specified torque.
: 10 mm
: 16-18 Nm
NOTE - When tightening bolts (333), coat them with
Loctite #262. Use care so as not to distort boom
conflux spool (305) by overtightening it in the vise.
c. Fix the boom conflux spool assy into casing A
(101).
c. Fit O-Ring (261) to the spring side of the bucket
spool assy and attach spring cover (201) to the
assy. Then tighten socket bolts (273) (Q.ty 2) to
the specified torque.
: 6 mm
: 25-34 Nm
9. Assembling swing spool.
a. Put a protective plate (aluminum plate, etc.) to
the vise and hold the middle of swing spool
(303). Set spring seat (331) (Q.ty 2), springs
(321 and 322) and stopper (336) and tighten bolts
(333) to the specified torque.
: 10 mm
: 16-18 Nm
NOTE - When tightening bolts (333), coat them with
Loctite #262. Be careful so as not to distort swing
spool (303) by overtightening it in the vise

NOTE - When assembling the boom conflux spool

b. Assemble the swing spool assy into casing A
assy into casing A (101), do it slowly and carefully,
(101).
never force it in.

d. Fit O-Ring (261) to the spring side of the boom NOTE - When assembling the swing spool assy into
conflux spool assy and attach spring cover (201) casing A (101), do it slowly and carefully, never force
to the assy. Then tighten socket bolts (273) (Q.ty it in.
2) to the specified torque.
: 6 mm c. Put O-Ring (261) to the spring side of the swing
spool assy and attach spring cover (202) to the
: 25-34 Nm assy. Then tighten socket bolts (273) to the
specified torque.
8. Assembling bucket spool.
: 6 mm
a. Put a protective plate (aluminum plate, etc.) to
the vise and hold the middle of bucket spool : 25-34 Nm
(304) in it. Set spring seat (331) (Q.ty 2), springs
(321 and 322) and stopper (336) and tighten bolts
(333) to the specified torque.
: 10 mm
: 16-18 Nm

NOTE - When tightening bolts (333), coat them with

Loctite #262. Be careful so as not to distort bucket
spool (304) by overtightening it in the vise.

b. Assemble the bucket spool assy into casing B

(102).

NOTE - When assembling the bucket spool assy into

casing B (102), do it carefully and slowly, never force
it in.
W2-6-36
CONTROL VALVE
10. Assembling travel spool.
a. Put a protective plate (aluminum plate, etc.) in
the vise and hold the middle of travel spool
(306) in it. Set spring seat (332) (Q.ty 2),
springs (327, 328) and stopper (338) and
tighten bolts (334) to the specified torque.
: 10 mm
: 16-18 Nm
NOTE - When tightening bolts (334), coat them with
Loctite #262. Be careful so as not to distort travel
spool (306) by overtightening it in the vise.
b. Assemble the travel spool assy into casing A
(101), B (102).
NOTE - When assembling the travel spool assy into
casings A (101), B (102), do it slowly and carefully,
never force it in.
c. Fit O-Ring (262) to the spring side of the travel
spool assy. Then attach spring cover (203) to
the assy and tighten socket bolts (273) to the
specified torque
: 6 mm
: 25-34 Nm
11. Assembling travel straight spool.
a. Put a protective plate (aluminum plate, etc.) in
the vise and hold the center of travel straight
spool (307) in it. Set spring seat (332) (Q.ty 2),
springs (327, 329) and stopper (340) and
tighten bolts (334) to the specified torque.
: 10 mm
: 16-18 Nm
NOTE - When tightening bolts (334), coat them with
Loctite #262. Be careful so as not to distort travel
straight spool (307) by over-tightening it in the vise.
b. Assemble the travel straight spool assy into
casing B (102).
NOTE - When assembling the travel straight spool
assy into casings B (102), do it slowly and carefully,
never force it in.
c. Fit O-Ring (262) to the spring side of the travel
straight spool assy. Then attach spring cover
(203) to the assy and tighten socket bolts (273)
to the specified torque.
: 6 mm
: 25-34 Nm
E215-E235
12. Assembling rod spool.
a. Fix spool cover (201) in a vise, put O-Ring
(166) in plug (156) and fasten it to a specified
torque.
: 27 mm
: 69-78 Nm
b. Assemble the rod spool (312) into casing A
(101).
NOTE - When assembling the rod spool (312) into
casing A (101), do it slowly and carefully; never force
it in.
c. Fit O-Ring (264) to the spool cover (205) to the
assy and tighten socket bolts (273) (Q.ty 2) to
the specified torque.
: 6 mm
: 25-34 Nm
13. Assembling spool covers (Arm, boom, bucket,
swing, travel (right, left) and travel straight).
a. Fit O-Ring (264) to spool cover (205) and
tighten socket bolts (273) (Q.ty 2) to the speci-
fied torque.
: 6 mm
: 25-34 Nm
14. Assembling main relief valve.
a. Fit spacer (122), C-Ring (121), O-Rings (163),
(561) and backup ring (562).
b. Fit piston (614) and O-Ring (661) to adjust
screw (104). Then fix stopper (613) to the
adjust screw and temporarily assemble it with
adjust screw (652) and locknut (671).
c. Fix poppet (611) and spring (621) to plug (103).
Then fix O-Rings (663, 664) with adjust screw
(104).
NOTE - Make sure that poppet (611) is snugly placed
in the seat of plug (103).
d. Assemble plunger (512) and spring (521) into
seat (541).
e. Assemble the seat (541) to the plug (103) assy
and fix it with C-Ring (121).
f. Pressure adjustment is performed in accord-
ance with "Maintenance Standard and Test
Procedure".
NOTE - Leave adjust screws (104), (652) temporarily
assembled.
E215-E235 W2-6-37

CONTROL VALVE

15. Assembling overload relief valve.
a. Assemble spring seat (612) with poppet (611),
spring (621) and O-Ring (661), into plug (102)
that is fitted with O-Rings (162), (561) and
backup ring (562). Then temporarily assemble
adjust screw (651) and locknut (671).
NOTE - Make certain that poppet (611) is snugly fitted
in the seat of plug (102).
d. Put O-Ring (P261) to the spring side of the
option spool assy, attach spring cover (P202)
to the assy and tighten socket bolts (P271)
(Q.ty 2) to the specified torque.
: 6 mm
: 25-34 Nm
e. Install spool cover (P204) with O-Ring (P262)
and fasten socket bolt (P271) (Q.ty 4) to the
specified torque.

b. Fit O-Ring (563) and backup ring (564) to seat
(541) and attach the seat to plunger (511) and
assemble piston (301) and springs (521, 522).
c. Assemble the seat (541) assy into body (101)
and tighten the plug (102) assy in par. 1) to the
specified torque.
f. Install overload relief valve (P603) to casing
(214) and fasten it to the specified torque.
: 32 mm
: 69-78 Nm
g. Fit O-Ring (P161) (Q.ty 3) into casing (214).

: 30 mm 17. Install plate P1 side (213) into casing (101) and

: 69-78 Nm fasten it by means of socket bolts (275) (Q.ty 4)
: 10 mm
NOTE - Confirm that springs (521, 522) are guided
: 108 Nm
properly.

d. Pressure adjustment is performed in accord-

ance with "Maintenance Standard and Test
Procedure" and adjust screw (651) is left tem-
porarily assembled.

16. Assembling option valve P2 for breaker.

a. Assemble poppet (P512) and spring (P522) to
casing (214) and fasten plug (P551) with
O-Ring (P561) to the specified torque.
: 12 mm
: 120-140 Nm
b. Put a protective plate (aluminum plate, etc.) in
the vise and hold the middle of option spool
(P301) in it. Set spring seat (P337) (Q.ty 2),
springs (P323), (P324) and stopper (P333)
and tighten bolts (P334) to the specified torque.
: 10 mm
: 16-18 Nm

NOTE - When tightening bolts (P334), coat them with

Loctite #262. Be careful so as not to distort option
spool (P301) by overtightening it in the vise.

c. Assemble the option spool assy into casing

(214).
W2-6-38 E215-E235

CONTROL VALVE

MAINTENANCE STANDARD

PART NAME INSPECTION ITEM CRITERION AND REMEDY

Casing 1. Look for scratches, rusting and 1. If any of the following parts are damaged,
corrosion. replace the casing:
· Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
· Part of sealing pocket through which
spool is inserted.
· Area of sealing part that is in contact
with O-Ring.
· Sealing and seating part of main or
overload relief valve.
· Defects of other parts that seem to
prevent normal function.

Spool 1. Look for scratches, galling,
rusting and corrosion.
2. Inspect ends that are sealed
with an O-Ring.
3. Insert the spool in the casing
bore, and move it while turning
it.
1. If a defect detectable with your fingernail
is found on the sliding part of the outer
circumference, replace the spool.
2. If the sliding part is damaged, replace
the spool.
3. If the spool damages the O-Ring or
does not move smoothly, repair or
replace the spool.

Poppet 1. Look for damage on the poppet 1. If sealing is incomplete, correct or

and the spring. replace the seal.
2. Insert the poppet in the casing, 2. If the poppet moves lightly without
and move it. catching, it is normal.

Spring and related 1. Look for rust, corrosion, 1. If damaged heavily, replace.
parts deformation, and breakage of
the spring, spring seat, plug
and cover.

Spool seal and related 1. Look for external oil leak. 1. Repair or replace.
parts 2. Look for rust, corrosion and 2. Repair or replace.
deformation of sealing plate.

Main relief valve 1. Look for rust and damage on 1. Replace.

Port relief valve outer surface.
2. Inspect the contact face of the 2. If damaged, replace.
valve seat.
3. Inspect the contact face of the 3. If damaged, replace.
poppet.
4. Look for spring abnormality. 4. Replace.
5. Inspect the O-Ring, backup 5. As a general rule, replace all parts with
ring, and seal. new ones.

Lock valve (selector 1. Spool, bushing and spring are 1. If damaged, replace.
portion) not damaged.
2. Spool seat shows even contact 2. If damaged, replace.
marks.
E215-E235 W2-7-1

SWING DEVICE

REMOVAL AND INSTALLATION OF

SWING DEVICE

WARNING
Possible leakages of fluids under pressure could
penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure
before disconnecting hydraulic pipes or other
pipes.
Hydraulic oil, at the end of a work shift, can be very
hot and can cause, when spilling, potentially seri-
ous burns.
Prior to beginning any intervention, make sure that
the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the
pressure is not released from the tank. Press the
valve located on the hydraulic oil tank to release
any residual pressure present in the tank itself.

Preparation

1. Park the machine on a firm, level surface.

2. Cut-off the engine. Actuate the manual and pedal

pilot valves to release any residual pressure from
inside the hydraulic system. Press the valve locat-
ed on the hydraulic oil tank to release any residual
pressure present inside the tank itself.

3. Remove hydraulic oil tank cap. Connect a vacuum

pump to maintain negative pressure in the hydrau-
lic oil tank.

NOTE - Be sure to run the vacuum pump continuously

while working.
W2-7-2 E215-E235

SWING DEVICE

Removal

1. Remove hose (3) from the Tee in the makeup port 1 2

M.
: 36 mm

2. Remove the hoses (1 and 2) from the Tee in the

drain port Dr.
: 27 mm
3
3. Remove the hose (7) from the elbow of the PG port.
: 19 mm

4. Remove the hoses (4 and 5) from the elbows of the

A, B port.
: 36 mm

5. Put in plugs into the opened ports on the swing 4

motor unit.

6. Remove the swing motor unit by loosing the screws

(8) (Q.ty 8). 5
: 30 mm R0281

7. Remove the plastic cap (6) M12 at the top of the

swing motor and install the lifting eye bolt.
: 36 mm
6

8. Sling and remove the swing unit.

WARNING 7
Swing unit weight: 205 kg 8

R0282
E215-E235 W2-7-3

SWING DEVICE

Installation

1. Clean mating surfaces of swing motor unit and

upper frame. Loctite 8
FAG3
2. Apply Loctite FAG3 on entire mounting surface of
swing motor unit.

3. Place the swing unit on the upper frame.

WARNING
Swing unit weight: 205 Kg.

4. Remove the lifting eye bolts and inserts on the

holes, the plastic caps (6) M12, previsiously re-
moved.

5. Fix the swing unit to the frame by tightening the

screws (8) (Q.ty12).
: 30 mm
: 539 ± 54 Nm
R0283

6. Install the hoses (4 and 5) on the elbows of port A

and B.

7. Install the hose (7) on the elbow of port PG.

: 19 mm
: 29.4 ± 2.9 Nm

8. Install the hoses (1 and 2) on the tee in the drain

port Dr.
: 27 mm
: 93.1 ± 9.3 Nm

9. Install the hose (3) on the make up port M.

: 36 mm
: 176.5 ± 17.6 Nm
W2-7-4 E215-E235

SWING DEVICE

DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

44

19

35 38

20

21
1
31
2
33
27
3
19 15 17 13-14
43
16 43 42 29 12 30
38
A A
32
22 23
35

37

36
4

41
40

39
25
6
26 3
8
24
10 45
Section A-A

9
7 18
11
28 34 5 R0284
E215-E235 W2-7-5

SWING DEVICE

1 - Relief valve (Q.ty 2) 24 - Swing shockless valve (Q.ty 2)

2 - O-Ring (Q.ty 2) 25 - O-Ring (Q.ty 2)
3 - Swing shockless valve 26 - Backup ring (Q.ty 2)
4 - Shockless valve casing 27 - Socket bolt (Q.ty 4)
5 - Drive shaft 28 - Roller bearing
6 - Cylinder 29 - Roller bearing
7 - Spring 30 - Pin (Q.ty 2)
8 - Piston (Q.ty 9) 31 - Plug (Q.ty 2)
9 - Shoe 32 - O-Ring
10 - Set plate 33 - O-Ring (Q.ty 2)
11 - Shoe plate 34 - Oil seal
12 - Valve plate 35 - Brake piston
13 - Plug (Q.ty 2) 36 - O-Ring
14 - O-Ring (Q.ty 2) 37 - O-Ring
15 - O-Ring (Q.ty 2) 38 - Brake spring (Q.ty 24)
16 - O-Ring (Q.ty 2) 39 - Friction plate (Q.ty 3)
17 - Socket bolt (Q.ty 4) 40 - Separation plate (Q.ty 4)
18 - Swing motor casing 41 - Plug (PF 1/4)
19 - Valve casing 42 - Plug (PF 3/8)
20 - Plunger (Q.ty 2) 43 - Plug (PF 3/4) (Q.ty 3)
21 - Spring (Q.ty 2) 44 - Plug (PT 1/2)
22 - Name plate 45 - Plug (PT 3/4)
23 - Rivet (Q.ty 2)
W2-7-6 E215-E235

SWING DEVICE

Preliminary operations

1. Hydraulic components are precision products and

have small clearance. Therefore, assemble and
disassemble in a less dusty clean place. Use clean
tools and cleaning oil and handle components with
full care.

2. If a component is removed from the main body,

clean the area around the ports thoroughly and
plug them up so no dust and water do not enter.
When fitting them back to the body, do not remove
the plugs till piping is completed.

3. Study the structural drawing before the work be-

gins and prepare necessary parts according to
your purpose and the scope of work. Seals and O-
Rings once removed can not be used again.

4. The piston and the cylinder block are shop fitted

when new. If you intend to reuse them, put a
matching mark on the piston and the cylinder block.

Disassembly

1. Remove the drain plug and drain hydraulic oil from 3

casing (18).
19 1
2. Fix the motor on a work bench so the drive shaft (5)
end comes down. On that occasion, put a matching 38
mark on the mating parts of casing (18) and valve
casing (19). 35

NOTE - Choose a clean place, and lay with a rubber

sheet or a cloth on a work bench. Handle the valve
casing with care so parts do not have dents.

5 18
R0285
E215-E235 W2-7-7

SWING DEVICE

3. Loosen relief valve (1) and separate it from valve 20

casing (19).
: 41 mm
21
4. Loosen swing shockless valve sub assy (3) and 19
valve casing (19).
: 6 mm

5. Separate plug (31) from valve casing (19) and draw 31

out spring (21) and plunger (20).
: 14 mm

6. Loosen socket bolt (27) and separate valve casing 1

27 R0391
(19) from casing (18). If the socket bolt (27) are
loosened, the valve casing floats off casing (18) by
the force of brake spring (38). Then separate valve
plate (12) from valve casing (19). 380001056
: 17 mm 12
35
7. Draw out brake spring (38) from brake piston (35).

8. Put the claw of the brake piston removing jig

(380001056) in the concaved part of brake piston
(35).
Tighten at the same time the screws of the jigs and
draw out the spring from motor casing. 18

9. Lay the motor on its side again and draw out R0392
cylinder block (6) from drive shaft (5). Then draw
out piston (8), retainer plate (10), the spring (7) and
shoe plate (11).
10 8 6
9
IMPORTANT - Handle the parts with care so as not to
score the sliding surfaces of cylinder block (6) and
shoe (9). 11

18 39 40
R0393
W2-7-8 E215-E235

SWING DEVICE

10. Draw out friction plate (39) and separator plate

18
(40) from casing (18).

11. Draw out drive shaft (5) from casing (18), while
lightly tapping on the shaft (5), using a plastic
mallet.

28

R0394

12. Drawing the inner race of roller bearing (28) from Press
drive shaft (5), using a press.
5
NOTE - Do not reuse the removed bearing.

13. Drawing out the outer race of roller bearing (28)

from casing (18), by lightly tapping the steel rod
28
from the oil seal (34) housing side.

14. Separate the outer race of roller bearing (29) from

valve casing (19), using a slide hammer bearing
puller.
R0395
E215-E235 W2-7-9

SWING DEVICE

Assembly

1. Place casing (18) on a proper bench so its valve Output shaft side
casing (19) faces upward.
5
NOTE - This operation is necessary only when the
roller bearing is removed.
28
2. Shrinkage fit the inner race of roller bearing (28)
into drive shaft (5).

3. Shrinkage fit the inner race of roller bearing (29) to

drive shaft (5).

4. Install the oil seal (34) to casing (18).

NOTE - Coat the lip of the oil seal with grease and
check the direction of it, before fixing it.
29 R0396
5. Assemble the outer race of roller bearing (28) into
casing (18), by lightly tapping the steel rod.

6. Attach drive shaft (5) to casing (18).

28 34 5 18
R0397
W2-7-10 E215-E235

SWING DEVICE

7. Place casing (18) as shown in Figure and insert

shoe plate (11).

NOTE - Remove the grease from surface of shoe

plate.
11

28 18

5
R0398

8. Set the retainer plate (10) and spring (7), then 10

install the piston sub assy (8-9).

9. Assemble piston sub assy (8, 9) fixed in retainer

plate (10) into cylinder (6). Match it to the spline of 9
drive shaft (5) and insert it in place.
8

5
R0399

10. Replace casing (18) with seal cover facing down-

ward and assemble separator plate (40) (Q.ty 4)
and friction plate (39) (Q.ty 3) into casing (18), in
that order. 40

39
IMPORTANT - Assemble the same phases of four
slits in the gears of friction plate (39). Assemble four
slits in the four claws of separator plate (40) in the
position of the figure shown on side.
34 18

Separation
plate position

"PG" Port
R0400
E215-E235 W2-7-11

SWING DEVICE

11. Fit O-Rings (36 and 37) to casing (18). 35

12. Assemble brake piston (35) into casing (18).

13. Assemble brake spring (38) into brake piston

(35). Make sure that the spring is placed positively
in the spot faced part of the brake piston.

NOTE - This operation is necessary only where roller

bearing (29) is removed.

"PG" Port
R0401
14. Insert the outer race of roller bearing (29) into
valve casing (19), while lightly tapping the steel
rod placed on the outer race, using a hammer.

15. Assemble valve plate (12) into valve casing (19)

and fit O-Ring (32) in it.

16. Install valve casing (19) to casing (18) and fasten

them with socket bolts (27).
: 17 mm
: 431 Nm

17. Fit plunger (20) and spring (21) to valve casing

(19). Then tighten the plug (31) fitted with O-Ring
(33) against valve casing (19).

: 14 mm
: 334 Nm

18. Fit relief valve (1) to valve casing (19).

: 41 mm
:177 Nm

19. Fit the swing shockless valve (3) to valve casing

(19).
: 6 mm
: 29 Nm
W2-7-12 E215-E235

SWING DEVICE

DISASSEMBLY AND ASSEMBLY OF SWING REDUCER

33 29 28 27 26 25
19
18 22
17 23
16 24
14 22
20
15
21
13 10
12

11
34

31

30
32 9
8
7 5

6
2 1
R0402

1 - Pinion shaft 19 - #1 Sun gear

2 - Sleeve 20 - Spring pin (Q.ty 4)
4 - Plug 21 - Shaft (Q.ty 4)
5 - O-Ring 22 - Thrust washer (Q.ty 8)
6 - Oil seal 23 - #2 Pinion (Q.ty 4)
7 - Retainer 24 - Needle bearing (Q.ty 4)
8 - Socket bolt M8 (Q.ty 12) 25 - Thrust washer (Q.ty 3)
9 - Bearing 26 - #1 Pinion (Q.ty 3)
10 - Housing 27 - Roller (Q.ty 102)
11 - Spacer 28 - Thrust washer (Q.ty 3)
12 - Bearing 29 - Snap ring (Q.ty 3)
13 - Snap ring 30 - Pipe
14 - #2 Spider 31 - Elbow
15 - #2 Sun gear 32 - Plug (Q.ty 2)
16 - Ring gear 33 - Snap ring
17 - #1 Spider assy 34 - Set screw (Q.ty 2)
18 - Socket bolt M14x130 (Q.ty 10)
E215-E235 W2-7-13

SWING DEVICE

Preliminary operations

1. Before disassembly, clean thoroughly the swing

reduction unit outer, checking for no damage or
scratches. 18
2. Drain out the gear oil from reduction unit.
X
3. Remove the draining pipe.

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

32
bly put a matching mark (X) on the parts to be
connected on the reduction casing.

160
Disassembly 290 R0403

1. Place the reduction unit assy on a stable work

bench as shown in figure, remove plug (32), drain 17
19
out oil put a matching mark on the matching surface
of the figure on the right side.

2. Loosen all socket bolt (18) (M14). Attach eye bolts 16

(M12×1.75) in the lifting bolt holes in the top surface
of the swing motor and lift the assy by crane.
If it is hard to remove the swing motor assy from the
reduction unit, float it by inserting a flat-blade
screwdriver in the groove of the flange.
10
: 12 mm
R0404

3. Remove #1 sun gear (19).

4. The spider assy (17) [consisting of thrust washer

(28), #1 pinion (26), needle bearing (27) and snap
ring (29)] can be removed from the spline easily if
it is lifted up in that condition. 16

5. Attach eye bolts (M14) to the top surface of ring

gear (16) and lift the ring gear lightly by a wire sling.
Put a flat-blade screwdriver into the matching sur-
10
face of ring gear (16) and housing (10) and remove
ring gear (16) by lightly tapping the outer circumfer-
ence of the ring gear with a plastic mallet.
R0405

15
6. Draw out #2 sun gear (15) and remove the #2
spider assy.

R0406
W2-7-14 E215-E235

SWING DEVICE

7. Turn over the housing so gear side of pinion shaft

faces up, as shown in figure on side. 1

180
350±10
R0407

8. Remove all socket bolts (8) (Q.ty 12).

8 R0408

9. Remove retainer (7) with oil seal (6).

R0409
E215-E235 W2-7-15

SWING DEVICE

10. Attach an M10 eye bolt to the end of the pinion and M10
lift it upright.

1
5
2
9

11

12

13
R0410

11. Disassembly #1 spider assy in its components,

carring out the following operations: 17 26 29 27 28

a. Remove snap ring (29) with a plier.

b. Remove thrust washers (25 and 28), pinion
(26) and roller (27).

25
NOTE - The shaft attached to spider assy (17) is R0411
caulked. When replacing parts, replace the spider
assy as a whole. The pinion can not be replaced as a
piece. For replacement, do it in a set of three.

12. Disassembly #2 spider assy in its components,

carring out the following operations:
a. Draw out spring pin (20). 21 22
b. Draw out shaft (21) from spider (14) and re-
move thrust washer (22), pinion (23) and nee-
dle bearing (24). 24

23
NOTE - Pinions (23) can not be replaced singly.
Replace them in a set of four.
22
14 20
R0412
W2-7-16 E215-E235

SWING DEVICE

13. Remove snap ring (13), using pliers.

13

R0413

14. Erect three supporting metal bars (380001060) at

equal intervals in the grooves in the teeth of pinion
shaft (1), place sleeve (2) on them and draw down
the pinion shaft by press.

WARNING 2
Bind the supporting metal bars (380001060) around
1
their outside with a steel wire when performing
press operation.
380001060
R0414

15. Draw out the pinion shaft (1) and remove O-Ring
(5) from sleeve (2).
7

12 5

2
11

9 1

R0415
E215-E235 W2-7-17

SWING DEVICE

Assembly

1. Clean parts thoroughly in cleaning oil and dry them

with jet air.

2. Check that parts are not faulty.

3. Apply a thin film of grease over O-Ring (5) and the

O-Ring seat of pinion shaft (1).

4. Heat sleeve (2) to 100-120 °C, fit O-Ring (5) and fix 5
it into pinion shaft (1).

5. Coat the outer surface of the sleeve with a thin film 2

of grease.
1
6. Coat the outer circumference of pinion shaft (1)
with a thin film of gear oil to prevent seizure.
R0416

7. Heat bearings (9,12) to 100-120 °C, fit the bearings

with spacer (11) into pinion shaft (1). Push them in,
using jig (380001058) and fix snap ring (13).
380001058

13

12

19
9

R0417
W2-7-18 E215-E235

SWING DEVICE

8. Assembly #1 Spider Assy carring out the following

operations: 17 26 29 27 28
a. Coat the bore surface of pinion (26) with grease.
Put pinion (26) on thrust washer (25) and as-
semble roller (27) into the bore surface.
b. Fit thrust washers (25 and 28) and pinion (26) and
fit snap ring (29) by means of pliers. 25
R0411

Motor Side

29

R0418

25
28

17

29 26
R0419

9. Assembly #2 Spider Assy, carring out the follwing Gear side

operations:
a. Coat the bore surface of pinion (23) with grease.
Put pinion (23) on thrust washer (22) and fit
needle bearing (24) to the bore surface.
b. Fit thrust washer (22) and pinion (23), then insert
shaft (21) into spider (14) and fix spring pin (20).

NOTE - Make sure that the oil hole (A) in shaft (21)
6 ~ 7 mm 6 ~ 7 mm
faces the outside as shown in the figure. Insert shaft
(21) into spider (14) so spring pin hole (20) is aligned.
View from I

A 21 22

24

23
▼

I
22
14 20
R0420
E215-E235 W2-7-19

SWING DEVICE

10. Place housing (10) on a work bench. Lift the

pinion assy and lower it slowly into the housing till
it is set in place. 1

NOTE - Take care on this step so that outer race of

bearing (9) is installed straight along the inner face of
housing (10). 9

IMPORTANT - Outer races of bearings (9 and12) can

normally be installed in the housing (10) easily as
enough clearance is provided between the two parts.
If they cannot be inserted easily, check to see whether
or not the outer race of bearings (9 and 12) are
positioned correctly and if there is any damage to 12
housing (10). Pressing them in with undue force may
damage these parts. 10

R0421

11. Fill grease in the groove of the oil seal lip in contact
with the oil seal till about 1/3 of the groove is filled
with grease.

12. Fit the oil seal to retainer (7), making sure of its
direction and set it in place by using oil seal fixing
jig (380001059).

13. Apply sealing compound (Loctite #515) to the

retainer (7) with oil seal and the matching surface
of housing (10). Then fit it to sleeve (2).
8
10 7 R0422

IMPORTANT - Use care when assembling so as not

to score the oil seal by the gear teeth of pinion.
#2 Spider
14. Tighten socket bolt (8) (Q.ty 12).
: 6 mm
:33 Nm

15. Place pinion shaft (1) on a stable workbench, with

its spline facing up.

R0423
16. Insert the #2 spider assy into the spline shaft of
pinion shaft (1).

15
17. Install #2 sun gear (15) with its spline facing up.

R0406
W2-7-20 E215-E235

SWING DEVICE

18. Apply a thin film of sealing compound (Loctite

#515) to the matching surface of housing (10) and
ring gear (16) and assemble them, aligning the
gear teeth and according to the matching marks
given. 16

MATCHING
MARKS

10

R0424

19. Mesh the #1 spider assy with ring gear (16) and
set them in place. 19

20. Mesh #1 sun gear (19) with #1 pinion (26) and set 16
them in place.
26
21. Fit drain hose (36) and plug (37).
: 12 mm
22. Fill in 7.5 L of Extreme pressure gear oil in the
reduction casing. 10

R0425
23. Attach eye bolts (M12×1.75) in the tapped holes
of the swing motor and put a wire sling in them.
Coat the matching surface of ring gear (16) with
sealing compound (Loctite #515).
Insert the spline joint of the swing motor and
match the matching marks.
18
Coat socket bolts (18) (Q.ty 10) with Three-Bond
1360K and fasten them.
: 12 mm MATCHING
: 181 Nm MARKS

24. Fill in the swing motor with oil till the maximum
level.
160 290

R0426
E215-E235 W2-7-21

SWING DEVICE

MAINTENANCE STANDARD

Swing motor maintenance

Standard Recommended
Item Dimension Value for Remedy
(mm) Replacement (mm)
Clearance between piston and cylinder bore
(D-d)

Replace piston or cylinder

0.027 0.052
d D

R0427

Gap between piston and caulked part of shoe

(σ)

Replace piston and shoe

0 0.3
assy

R0428

Thickness of shoe (t)

Replace piston and shoe

5.5 5.3
assy
t

R0429

Assembled height of retainer plate and retainer

(H-h)

Replace a spherical
H 5.5 5.0 bushing and a retainer
h plate as a pair.

R0430

Thickness of friction plate

1.8 1.6 Replace

t

R0431
W2-7-22 E215-E235

SWING DEVICE

Swing reduction maintenance

OIL
LEVEL
D

C
LOCTITE 515

LOCTITE 515

R0432

Code Item Standard Value (mm) Serviceability Limit (mm) Remedy

Replace
-0,021
A Wear in #1 planetary Ø 39.45 -0,032 entire
shaft spider assy
No flaking
Replace four
0
B Wear in #2 planetary shaft Ø 29 -0,009 shafts as a
set

Replace
Condition of There should be no pitching exceeding 1.6mm dia,
(Planetary
tooth face abnormal wear or seizure
pinion
C Gears should be
replaced in a
Condition of set of four)
There should be no cracks
tooth flank

D Thickness of thrust washer 2.0 ± 0.1 1.8 Replace

Wear in sleeve (Diameter of

E part coming in contact with Ø 160 -0
-0,063
Ø 159.5 Replace
oil seal )
E215-E235 W2-8-1

PILOT VALVE

REMOVAL AND INSTALLATION OF RIGHT AND LEFT PILOT VALVE

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.

Preparation 2. Cut-off the engine. Actuate the manual and pedal

pilot valves to release any residual pressure from
1. Park the machine on a firm, level surface. inside the hydraulic system. Press the valve lo-
cated on the hydraulic oil tank to release any
residual pressure present inside the tank itself.

Removal
5 1
1. Free and lift rubber cap (5) complete with plate (4) 6
unlocking its hooks using a screwdriver. 7
3
8

2. Remove side panels (2 and 3) removing securing 4

screws (1). 9
2
14 10
13 11
3. Remove the handgrip removing lock-nut (6) dis- 12
connecting the relevant electric connection.
: 22 mm
1
1
R.H. R0116

IMPORTANT - Attach an identification tag on each

hose to aid in reassembly.
6 1
5 7
4
8
4. Disconnect pipes (from 9 through 14) of body (8). 3
: 19, 22 mm
9
2 10
14
13 11
NOTE - Attach a cap on each of disconnectd hose 12
ends.

5. Remove body (8) removing securing screws (7)

1
complete with washers.
1
: 10 mm
L.H. R0117
W2-8-2 E215-E235

PILOT VALVE

Installation
5 1
1. Install body (8) on the frame tightening securing 6
screws (7) complete with washers. 7

: 10 mm 3
8
: 11 Nm
4
2. Connect pipes (from 9 through 14) to body (8). 9
2
: 19 mm 14 10
: 29.4 Nm 13 11
: 22 mm 12
: 39.2 Nm

3. Tighten the handgrip on the pilot valve, tighten lock- 1

nut (6) and reconnect the electric connector. 1

: 22 mm R.H. R0116

4. Install side panels (2 and 3) tightening securing

screws (1).

6 1
5 7
5. Arrange rubber cap (5) complete with plate (4) 4
locking the hooks on side panels (2 and 3). 8
3

9
2 10
14
13 11
12

1
1

L.H. R0117
E215-E235 W2-8-3

PILOT VALVE

REMOVAL AND INSTALLATION OF TRAVEL PILOT VALVE

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.

Preparation 2. Cut-off the engine. Actuate the manual and pedal

pilot valves to release any residual pressure from
1. Park the machine on a firm, level surface. inside the hydraulic system. Press the valve lo-
cated on the hydraulic oil tank to release any
residual pressure present inside the tank itself.

Removal

1. Remove the floor mats in the cab.

2. Remove the pedal removing securing screws (1)

(Q.ty 4) then remove the levers, removing securing
screws (2) (Q.ty 4).
: 13, 17 mm

3. Disconnect electric joints (7) from body (8).

IMPORTANT - Attach an identification tag on each

hose to aid in reassembly. 1
2

4. Disconnect pipes (from 3 through 6) of body (8).

9
: 19, 22 mm

8 3
NOTE - Attach a cap on each of disconnected hose
ends. 4
7

5. Remove body (8) removing securing screws (7) 6 5

complete with washers. R0118

: 17 mm
W2-8-4 E215-E235

PILOT VALVE

Installation

1. Install body (8) on the frame tightening securing

screws (9) complete with washers.
: 17 mm
: 64 Nm

2. Connect pipes (from 3 through 6) to body (8).

: 19 mm
: 29.4 Nm
: 22 mm
: 39.2 Nm
1
2
3. Connect joints (7) to body (8).

9
4. Install the levers tightening securing screws (2)
and the pedals tightening securing screws (1).
: 17 mm 3
: 34.8 ± 3.4 Nm 8
: 13 mm
7 4
: 29.5 Nm

6 5
R0118
E215-E235 W2-8-5

PILOT VALVE

NOTES:
W2-8-6 E215-E235

PILOT VALVE

DISASSEMBLY RIGHT AND LEFT PILOT VALVE

15
1 16

17
18
19
2
19

20
3 21

4
22

6 7 23
24
7
8
25
8
9
9
10 26
10 11
13
12 27
14 27
28
28

R0119

1 - Adjusting nut; M14 11 - Spring seat 2 (Q.ty 2) 21 - Spool (Q.ty 2)

2 - Boots 12 - Spring seat 1 (Q.ty 2) 22 - Casing
3 - Circular plate 13 - Spring seat 2 (Q.ty 2) 23 - O-Ring
4 - Joint; M14 14 - Spring seat 1 (Q.ty 2) 24 - Bushing
5 - Plate 15 - Spring (Q.ty 2) 25 - Spring pin
6 - Seal (Q.ty 4) 16 - Spring (Q.ty 2) 26 - Port plate
7 - Plug (Q.ty 4) 17 - Spring (Q.ty 2) 27 - Seal washer (Q.ty 2)
8 - O-Ring (Q.ty 4) 18 - Spring (Q.ty 2) 28 - Socket bolt; M8x35 (Q.ty 2)
9 - Push rod (Q.ty 4) 19 - Washer 2 (shim) (Q.ty 4)
10 - Spring (Q.ty 4) 20 - Spool (Q.ty 2)
E215-E235 W2-8-7

PILOT VALVE

Disassembly right and left pilot valve

Be sure to thoroughly read "Precautions for Disas-

sembly and Assembly" on page W1-1-1 before start-
ing the disassembly work.

NOTE - Replace O-Ring every disassembly opera-

tions, as a rule.

1. Plug each port of pilot valve, and clean it.

2. Fix pilot valve with vise, and remove boots (2).

3. Remove adjusting nut (1) applying spanners to

circular plate (3).
: 22 mm, 32 mm
1

4. Remove circular plate (3).

: 32 mm 3

R0120

5. Turn joint (4) in counterclockwise with (380001055)

380001055
to remove.
: 24mm
4

WARNING
When the force of return springs (15 and 16) is high,
never loosen joint (4). If loosened, it might result in
jumping out of plate (5) plug (7) and push rod (9).
Remove joint (4) pressing plate (5) downward with
two fingers.
R0121
W2-8-8 E215-E235

PILOT VALVE

6. Remove plate (5). 5

NOTE - When the force of return spring (15 and 16) is

high, press plate to let it come up slowly.
When the force of return springs (15 and 16) is low,
plug is left in casing (22) due to sliding resistance of
O-Ring (8).

R0122

22

R0123

7. Pull plug (7) out with a driver.

7 R0124

8. Remove push rod (9), plug (7), pressure reducing

valve assy (spool) and the return springs (15 and
16) from casing (22). 9

7
NOTE - Record combination of port holes on casing
and the pulled out parts. The stroke differs according
to direction. 15-16

22

R0125
E215-E235 W2-8-9

PILOT VALVE

9. Turn upside down the assembly in order to posi-

tion upward the port plate (26), then fix it in a vise.

10. Remove the socket bolt (28).

: 6 mm 26

28

R0126

11. Remove port plate (26), O-Ring (23) from casing

(22). 25
26
12. Remove bushing (24) from casing (22).
24

23

22

R0127

13. Press springs (17 e 18) so that the movement of

the spring seats (12 and 14) is 7 mm (max), then
remove spools (20 and 21) through the larger hole
of the seat. 12-14

IMPORTANT - Under no circumstances press spring

seat (12) 7 mm or more, through passages 1 and 3. 20-21
Under no circumstances press spring seat (14)
9,4 mm or more, through passages 2 and 4. R0128

14. Remove spool (20 and 21), spring seats (12 and
12-14
14), springs (17 and 18) and washer (19).

10
11-13 17-18

R0129
W2-8-10 E215-E235

PILOT VALVE

15. Remove spring (10), spring seat (11 and 13) from
push rod (9). 11-13 8

16. Pull out push rod (9) from plug (7).

10
17. Remove O-Ring (8) from plug (7).

7 9
R0130

18. Remove inside seal (6) from plug (7) with small
driver.

6 R0261

Cleaning parts

1. Clean parts with wash oil roughly and the parts of

pilot valve completely.

2. Dry parts by swabbing clean waste cloth.

3. Apply rust preventives on parts.

E215-E235 W2-8-11

PILOT VALVE

NOTES:
W2-8-12 E215-E235

PILOT VALVE

ASSEMBLY RIGHT AND LEFT PILOT VALVE

1
2
3

6 4

5 9

10
13
7

8
11

14 12

17
18

21 20

16 15

24
19 23

22
27
25
PORTS 2, 4 PORTS 1, 3 28
26
R0262

1 - Adjusting nut; M14 11 - Spring seat 2 (Q.ty 2) 21 - Spool (Q.ty 2)

2 - Boots 12 - Spring seat 1 (Q.ty 2) 22 - Casing
3 - Circular plate 13 - Spring seat 2 (Q.ty 2) 23 - O-Ring
4 - Joint; M14 14 - Spring seat 1 (Q.ty 2) 24 - Bushing
5 - Plate 15 - Spring (Q.ty 2) 25 - Spring pin
6 - Seal (Q.ty 4) 16 - Spring (Q.ty 2) 26 - Port plate
7 - Plug (Q.ty 4) 17 - Spring (Q.ty 2) 27 - Seal washer (Q.ty 2)
8 - O-Ring (Q.ty 4) 18 - Spring (Q.ty 2) 28 - Socket bolt; M8x35 (Q.ty 2)
9 - Push rod (Q.ty 4) 19 - Washer 2 (shim) (Q.ty 4)
10 - Spring (Q.ty 4) 20 - Spool (Q.ty 2)
E215-E235 W2-8-13

PILOT VALVE

Assembly right and left pilot valve

1. Fit bushing (24) and O-Ring (23) to casing (22).

NOTE - Meet the position of spring pin (25).

2. Install port plate (26) on casing with socket bolt (28)

and seal washer (27). 26
28
: 6 mm
: 20.6 ± 1.5 Nm
27

NOTE - Replace seal washer (27) with new one.

R0263

3. Fit washer 2 (19), springs (17 and 18), spring seats

20-21
(12 and 14) to spool (20 and 21).
17-18 12-14
4. Push spring seat 1 (12) in the range of that the
movement is 7 mm or less, and install spool (20)
through the large hole of spring seat 1.
For spring seat 1 (14), push spring seat (14) in 9.4
mm or less and install spool (21)

19
R0264

5. Place spring (15) into ports 1,3 of casing (22), and

then install pressure reducing valve assy (29) in it.
Place spring (16) into ports 2,4 and install it. 29

NOTE - Install the removed respective assy into 15

respective holes.
22

R0265
W2-8-14 E215-E235

PILOT VALVE

6. Fit O-Ring (8) and seal (6) into plug (7).

Apply hydraulic oil on surface of push rod. 8 7 6

7
6

9
HYDRAULIC OIL

R0266 R0267

7. Insert push rod (9) in plug (7) and install spring

seat 2 (11) to push rod (9) on port 1,3 side.
And install spring seat 2 (13) to push rod on port
2,4 side.

9 7 10 11
R0268

8. Fit plug (7) assy to casing (22).

9. When the force of spring (15 and 16) is low, it

stops at the position where it is pushed in by the
sliding resistance of O-Ring (8).

22 7 R0269

10. When the force of spring (15 and 16) is high,

attach plate (5) and press 4 push rods by hand at
the same time, and tighten joint (4) temporarily.
4

R0270
E215-E235 W2-8-15

PILOT VALVE

11. Install joint (4) on casing (22) with special tool

(380001055) securely.
: 22 mm
: 47.1 ± 2.9 Nm

22 380001055

R0271

12. Install circular plate (3) to joint (4).

IMPORTANT - Screw it in until it comes in contact with

4 push rods (9) equally.
The exceeding of screw in may cause malfunction of
machine. 1

13. Screw adjusting nut (1), applying Loctite #277 to 3

the thread of joint, until it touches circular plate (3),
and tighten it applying spanner to stop circular
plate returning.
: 22 mm
R0272
: 68.6 ± 4.9 Nm
: 32 mm

14. Apply heat-resisting grease to joint (4) rotating

section and the top of push rod (9).
GREASE
15. Cover it with boots (2).

16. Spray rust preventives through each port and

attach plug respectively.

9
R0273
W2-8-16 E215-E235

PILOT VALVE

DISASSEMBLY TRAVEL PILOT VALVE

▲ Z 33 2 36 33
13 12 28
36 B 14 42
19
37 25
26
1,3 30
20
34 25
15
22 21 42
20 20
39
32 17
33 36 33
44, 16 40
6 7 SECTION A-A
18 8
24 25, 42
A A
41
27
B
4 10, 11 35
9 31 5 29

4
38

24, 41
SECTION B-B
VIEW Z
R0274

1 - Orifice 24 - Plug; PF1/8

2 - Seat 25 - Plug; PF1/4
3 - Orifice 26 - Socket bolt; M10x60
4 - Spool 27 - Flange bolt
5 - Body 28 - Set screw; M8
6 - Stopper 29 - Washer
7 - Spring 30 - Washer
8 - Spring 31 - Rivet
9 - Name plate 32 - Pin
10 - Shim (0.2 mm) 33 - Ball
11 - Shim (0.1 mm) 34 - Ball
12 - Cam 35 - Ball
13 - Boots 36 - Ball
14 - Pin 37 - U packing
15 - Cover 38 - O-Ring
16 - Piston 39 - O-Ring
17 - Guide 40 - O-Ring
18 - Sleeve 41 - O-Ring
19 - Holder 42 - O-Ring
20 - Ring 44 - Piston assy
21 - Orifice
22 - Spring
E215-E235 W2-8-17

PILOT VALVE

Disassembly travel pilot valve 9. Disassembling the damper.

a. Draw out piston assy (44) and guide (17) from
Be sure to thoroughly read "Precautions for Diseas-
cover (15).
sembly and Assembly" on page W1-1-1 before starting
the disassembly work.
It is usual that disassembly and assembly are execut- NOTE - The damper is drawn out easily if it is pushed
ed at the maker's factory, but in unusual cases, do the from the ball (36) side.
work at a service shop where skilled technicians are
available.
b. Draw out four balls (36), holders (19) and orifices
Hydraulic parts are precision products of small clear-
(1), (3) from piston assy (44).
ance. Therefore, disassembly and assembly work
shall be performed in a clean place where there is little
dust in the following manner: NOTE - On that occasion, align the hole in the cover,
the piston assy and the guide as a set as each part is
- Never knock on precision parts in case they do not
shop fitted. Therefore, if parts for different locations
operate smoothly.
are assembled, functional faults may occur in some
- Replace seal parts such as O-Rings and U packings cases.
with new ones. Ring (20), orifice (21), spring (22) and ball (34) can not
be separated from the piston assy as they are assem-
1. Put a plug into each port (P,T,1,2,3,4,5,6) of the bled with ring (20) press fitted.
valve and clean the outside.
c. Separate four O-Rings (39) (Q.ty 4) from guide
2. Fix the valve after cleaning it in a vise.
(17).
3. Remove two boots (13). d. Remove four U packings (37) (Q.ty 4) from cover
(15), using a scriber.
4. Loosen 2×2 places of socket head set screws (28)
(Q.ty 4) and remove them from cam (12).
37
: 4 mm
15

5. Draw out two pins (14) from cover (15). On that

occasion, the pins may be drawn out with ease if the
pins are pushed out of the inside by the use of an
allen wrench.
: 4 mm 36
19
6. Remove two cams (12). 1, 3

7. Loosen socket bolts (26) and remove two of them 44, 16

with washers (30). 20
21
: 8 mm 34
22
8. Remove two dampers from the reducing valve.
20 20
39
17
R0275
W2-8-18 E215-E235

PILOT VALVE

10. Disassembling the reducing valve section.

6

Reducing valve assy

a. Separate three socket plugs (24) from body
(5).
: 5 mm
b. Separate O-Ring (41) from socket plug (24).
c. Remove four reducing valve spool assemblies
from body (5).
7
d. Remove stopper (6) from the reducing valve
40
spool assy.
e. Remove four springs (7), parallel pins (32), 32
O-Rings (38), (40) from body (5).
38

24

5
41

R0276

11. Disassembling the reducing valve spool assy

(See Fig.4-5.)
27
a. Fix spool (4) in a vise (Put a copper plate
against the mouthpiece.) and loosen four 18
socket flange bolts (27).
: 3 mm 8
b. Draw out socket flange bolt (27), sleeve (18), 10, 11, 29
spring (8), shims (10), (11) and washer (29)
from spool (4), in that order.

NOTE - On that occasion, mate the disassembled 4

R0277
parts with mating parts as sets.

12. Disassembling the shuttle.

IMPORTANT - The shuttle is inseparable basically as 33 33

seat (2) is fixed with adhesive agent (Loctite #262). 36 36
2 2
a. Remove two socket plugs (25) from body (5).
: 6 mm 33 33

b. Remove two seats (2) from body (5).

: 5 mm

NOTE - On that occasion, the Loctite comes off. 42 42

Remove it including that adhered to the neighbouring 25 25 R0278

area of the screw.

c. Draw out two balls (36) from body (5) by

attracting the balls to a magnet.

NOTE - Balls (33), (35) are for circuit plugs and press
fitted to body (5). Therefore, they are not separable.
E215-E235 W2-8-19

PILOT VALVE

ASSEMBLY TRAVEL PILOT VALVE

Assembly Travel Pilot Valve

IMPORTANT - Clean and degrease parts before

assembly. In particular, clean the body with a nylon
brush. Foreign matter intruded into the valve causes 33 33
functional faults to occur.
36 36
Before assembling prepare new seals (O-Rings and
U packings) and coat the surface with hydraulic oil or 2 2
a thin film of grease.
33 33
1. Assembling the shuttle.
a. Put two balls (36) into body (5).
b. Coat the screwed part of seat (2) with
Loctite#262 and fit two of them to body (5). 42 42
25 25
: 5 mm R0278

: 14.7 ± 0.98 Nm
c. Set O-Rings (42) to socket plugs (25) and fasten
two plugs to body (5).
: 6 mm 27
: 24.5 ± 1.9 Nm
18
2. Assembling the reducing valve spool assy.
a. Fix spool (4) in a vice. (Put copper plates against 8
the mouth.) Set washer (29), shims (10), (11),
spring (8) and sleeve (18), in that order, and 10, 11, 29
tighten them with four socket flange bolts (27).
: 3 mm
: 4.9 ± 0.98 Nm 4
R0277

IMPORTANT - On that occasion, pair parts with the

disassembled parts as sets, before performing as-
sembly work. Incorrect pairing may change the sec-
ondary pressure.
Reducing valve assy

6
3. Assembling the reducing valve.
a. Fit four O-Rings (38), (40), parallel pins (32) and
springs (7) to body (5).
b. Fit four reducing valve spool assemblies and
stoppers (6).
7
IMPORTANT - On that occasion, use care as stopper 40
(6) has a direction in which it should be installed. Place
it so the concave surface of it faces down (reducing 32
valve spool side).
38

24
c. Set O-Rings (41) to socket plugs (24). Fasten
three plugs to body (5).
5
41
: 5 mm
: 9.8 ± 0.98 Nm
R0276
W2-8-20 E215-E235

PILOT VALVE

4. Assembling the damper.

37
a. Fit four U packings (37) to cover (15).
15

NOTE - On that occasion, place the cover so the lip of

the U packing faces down (damper chamber side).

b. Insert four piston assemblies (44) into cover (15).

36
NOTE - In that case, make sure that each piston is set 19
in the same hole where it was before disassembly. 1, 3
The performances of the piston are not affected at all
44, 16
if it is placed in any direction on the circumference.
20
21
c. Fit O-Ring (39) to guide (17). Install four guides 34
to cover (15). 22
20 20
NOTE - Fix the guide in the same hole where it was set 39
before disassembly. 17
R0275

d. Set orifices (1), (3) to piston assy (44) that is set

in the cover.

NOTE - The orifices absorbs rattles that are made

when cam (12) is in neutral: either orifice may be at the
top or at the bottom.
In case the cam rattles very much because the cam
and the pin are worn out after long hours of use, 13
increase the number of orifices.
However, if many orifices are set when there is no gap,
the reducing valve spool is actuated at neutral and
pressure is built up in the secondary pressure port. 28
When there is no gap on the cam at neutral, do not
increase the orifices. 12
26
30
e. Set four holders (19) and balls (36) to piston
assembly (44).
f. Install two dampers on the reducing valve and
14
fasten them with socket bolts (26) with washers
(30).
In that case, parallel pin (32) set in body (5) is
placed in the hole of cover (15) to position the
Damper

reducing valve and the damper in place.

: 8 mm
Reducing valve

: 58.8 ± 4.9 Nm

R0279
E215-E235 W2-8-21

PILOT VALVE

g. Set cam (12) to cover (15) and insert pin (14). On

that occasion, check the gap of the cam and if
the gap is large, increase orifices (1), (3) accord-
ing to step 4.d above.

NOTE - Ball (36) and holder (19) can be drawn out

easily by magnet bar. If a magnet bar is not available,
place the valve on its side and give vibration to it.

h. When the gap adjustment of the cam has been

finished, apply grease to the moving parts of
cam (12), pin (14), cover (15) and ball (36).
i. Attach 2×2 pcs. set screws to cam (12) and
tighten them.
: 4 mm
: 14.7 ± 0.98 Nm

l. Fit two boots (13).

W2-8-22 E215-E235

PILOT VALVE

MAINTENANCE STANDARD RIGHT AND LEFT PILOT VALVE

Check items Standard Remarks

Push rod When the wear of top is 1 mm or-

more, replace it with new one.

Looseness of control section When looseness of 2 mm or more on In case of the looseness due to
circular plate (3) on control section and the loosening on tightening sec-
joint section (4) due to wear is pro- tion, adjust it.
duced, replace them with new ones.

Stability of operation When trouble such as noise, hunt-

ing, drop of primary pressure, etc.
has occurred in operation, and it
does not restore after taking correc-
tive action according to below Trou-
bleshooting, replace pilot valve assy
with new one.
E215-E235 W2-9-1

SOLENOID VALVE UNIT

REMOVAL AND INSTALLATION OF SOLENOID VALVE UNIT

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.

Preparation

1. Park the machine on a firm, level surface.
2. Cut-off the engine. Actuate the manual and pedal
pilot valves to release any residual pressure from
inside the hydraulic system. Press the valve lo-
cated on the hydraulic oil tank to release any
residual pressure present inside the tank itself.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
lic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal 13 14 15 16 17 18 19
12
1. Remove all wiring harnesses from solenoid valves
connectors. 11
1
2. Disconnect pilot lines (1 to 10).
: 19, 22 mm

3. Remove bolts (11) to remove solenoid valve unit.

2 3 4 5 6 7 8 9 10
: 17 mm
R0108

1 - Hose (delivery from pilot system filter)

2 - Hose (to swing motor)
3 - Hose (to centre joint)
Installation 4 - Hose (arm variable re-circulation valve piloting)
5 - Hose (by-pass cut-off valve P1 piloting)
6 - Hose (travel straight valve piloting)
1. Install solenoid valve unit with bolts (11).
7 - Hose (by-pass cut-off valve P2 piloting)
2. Connect pilot lines (1 to 10). 8 - Hose (main pressure relief valve piloting)
3. Connect all wiring harnesses for solenoid valves to 9 - Hose (to pilot system valves)
connectors. 10 - Hose (to hydraulic oil tank)
11 - Securing screws
12 - Swing parking brake solenoid valve
13 - Transmission 1st and 2nd speed solenoid valve
14 - Arm variable re-circulation proportional solenoid valve
Wrench Size Tightening Torque Remark 15 - By-pass cut proportional solenoid valve P1
(mm) (Nm) 16 - Travel straight proportional solenoid valve
17 - By-pass cut proportional solenoid valve P2
: 17 64 Bolt 18 - POWER BOOST solenoid valve
19 - Pilot system cut-off solenoid valve
: 19 29.4 Hose

: 22 39.2 Hose
W2-9-2 E215-E235

SOLENOID VALVE UNIT

DISASSEMBLY AND ASSEMBLY

OF SOLENOID VALVE

Disassembly Assembly

1. Remove solenoid valve (2) from main body (1) 1. Install O-Rings (from 3 to 6) on solenoid valve (2).
removing securing screws (7).
2. Install solenoid valve (2) on main body (1) tighten-
: 4 mm ing securing screws (7).

2. Remove from solenoid valve (2) the relevant : 4 mm

O-Rings (from 3 to 6).
: 7 Nm

SECTION A-A
2

3
1
4

A A

A8 A7 A6 A5 A4 A3 A2 A1

R0109

1- Central body 5 - O-Ring

2- Solenoid valve 6 - O-Ring
3- O-Ring 7 - Securing screws
4- O-Ring
SECTION 3 E215-E235

UNDERCARRIAGE

CONTENTS

Group 1 - Swing Bearing Group 6 - Upper and Lower Roller

Removal and Installation of Removal and Installation of

Swing Bearing ...................................... W3-1-1
Group 2 - Travel Device
Removal and Installation of
Travel Device (E215) ............................ W3-2-1
Disassembly Travel Device (E215) ....... W3-2-2
Assembly Travel Device (E215) .......... W3-2-25
Maintenance Standard (E215) ............ W3-2-51
Group 3 - Swivel Joint
Removal and Installation
of Swivel Joint ..................................... W3-3-1
Swivel Joint
Disassembly and Assembly ................. W3-3-4
Maintenance Standard ......................... W3-3-9
Upper Roller (E215) .............................. W3-6-1
Removal and Installation of
Upper Roller (E235) .............................. W3-6-5
Removal and Installation of
Lower Roller ......................................... W3-6-8
Upper Roller Disassembly
(E215) ................................................ W3-6-11
Upper Roller Assembly (E215) ........... W3-6-13
Upper Roller Disassembly
(E235) ................................................ W3-6-15
Lower Roller Disassembly
(E215) ................................................ W3-6-16
Lower Roller Assembly (E215) ........... W3-6-18
Lower Roller Disassembly
(E235) ................................................ W3-6-20
Lower Roller Assembly (E235) ........... W3-6-22
Maintenance Standard (E215) ............ W3-6-24
Maintenance Standard (E235) ............ W3-6-26

Group 4 - Track Adjuster Group 7 - Tracks

Removal and Installation of Removal and Installation of Tracks ....... W3-7-1
Track Adjuster (with Front Idler) ............ W3-4-1 Maintenance Standard ......................... W3-7-5
Disassembly and Assembly
Track Adjuster (E215) ........................... W3-4-2
Disassembly and Assembly
Track Adjuster (E235) ........................... W3-4-8

Group 5 - Front Idler

Disassembly and Assembly
Front Idler Assy (E215) ........................ W3-5-1
Maintenance Standard (E215) .............. W3-5-4
Disassembly and Assembly
Front Idler Assy (E235) ........................ W3-5-5
Maintenance Standard (E235) .............. W3-5-8
E215-E235 W3-1-1

SWING BEARING

REMOVAL AND INSTALLATION OF

SWING BEARING

Before removing the swing bearing, the upperstructure

must be removed first. For removal and installation of
the upperstructure, refer to “Remove and Install Main
Frame” section. In this section, the procedure starts
on the premise that the upperstructure has already
been removed.

Removal
Mark
1. Put alignment marks on swing bearing (1) and track
frame (2).

1 2
SM1307

2. Remove screws (3) (Q.ty 36) and the relevant

washers (Q.ty 36).

: 30 mm

3 R0062

WARNING
Swing bearing weight: 245 kg

3. Attach lifting tools (380001026), hoist swing bearing

(4) and remove it.

4 SM1309
W3-1-2 E215-E235

SWING BEARING

Installation

Clean the matching surfaces of swing bearing and the

frame.

1. Apply THREEBOND 1102 to the matching sur-

faces of swing bearing and track frame.

WARNING
Swing bearing weight: 245 kg
SM1309

IMPORTANT - Inner race soft zone (S) and the ball Front Side
filler port should be placed on the same position (right "S" Soft Zone
side of the frame). Marking
Position

2. Hoist the swing bearing. 0°

Align the swing bearing with the alignment mark on
the track frame and install the swing bearing.
Position of Plug

SM1310

3. Install screws (3) (Q.ty 36) with the relevant wash-

ers (Q.ty 36) and tighten them to the prescribed
torque.
: 30 mm
: 563 ± 56 Nm

3
R0062
E215 W3-2-1

TRAVEL DEVICE

REMOVAL AND INSTALLATION OF TRAVEL DEVICE (E215)

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank.
Press the valve located on the hydraulic oil tank to release any residual pressure present in the tank itself.

Preparation
1. Park the machine on a firm, level surface. 3. Remove hydraulic oil tank cap. Connect a vacuum
2. Cut-off the engine. Actuate the manual and pedal pump to maintain negative pressure in the hydrau-
pilot valves to release any residual pressure from lic oil tank.
inside the hydraulic system. Press the valve lo-
cated on the hydraulic oil tank to release any
NOTE - Be sure to run the vacuum pump continuously
residual pressure present inside the tank itself.
while working.

Removal Installation
The procedure starts on the premise that the track link 1. Install the travel device using bolts (1).
has already been removed. 2. Connect hoses (2) to (5).
3. Install cover (6) using bolts (7).
1. Loosen bolts (7) to remove cover (6). Disconnect
hoses (2) to (5).
IMPORTANT - After completing travel motor installa-
: 19 mm tion, be sure to fill the travel motor with hydraulic oil.
: 29.4 Nm After completing installation of the travel motor or the
travel device, be sure to perform test driving to pre-
: 27 mm vent motor seizure. Test drive as follows:
1. Run the engine with the engine control dial in the
: 93 Nm slow idle position.
: 36 mm 2. Turn the travel speed mode switch to the slow
speed position.
: 176.5 Nm 3. Test drive the machine back-and-forth for 0.5 m to
1 m in each direction five times or more.

NOTE - Install caps on all disconnected hose and line

ends.

2. Attach the travel device to a crane using a wire

rope. Remove any slack from the wire rope so as 5 1
to secure the travel device when the mounting
bolts are removed. 4

WARNING 2
Travel device weight:
Approx. 300 kg

3. Remove bolts (1). Remove the travel device using

the crane.
7
: 30 mm
6
R0519
: 415 Nm
W3-2-2 E215

TRAVEL DEVICE

DISASSEMBLY TRAVEL DEVICE (E215)

Preliminary operations

In the case that it was necessary to undergo a (partial

or total) revision, it will be necessary to dismount the
gearmotor from the machine. As this is known as an
out of the ordinary maintenance procedure, it is im-
portant that only personnel with specific skills and
experience undertake it.
It is also important that this procedure is undertaken
in a workshop that is adequately tooled. As well as
normal workshop tools it will be necessary to use
special tools.
In the following pages all the procedures for disas-
sembling and reassembling the gearmotor are given,
it is important to strictly adhere to them.
Proceed with these operations using all the neces-
sary safety measures, like for example:

1. Cutting off all the hydraulic system connections on

the gearmotor to avoid the introduction of any
foreign parts in the circuit and the gearmotor.

2. Making sure that the coupling surfaces are not

damaged.

3. Following the handling so as to be sure that there

are no risks for human safety and to guarantee the
reliability of the gearmotor.

4. Making available a work area that is in line with

work and health safety in the workplace guidelines.

NOTE - Initial inspection of hydraulic motor and

gears, can be made without disassembling the track
drive from the machine.
E215 W3-2-3

TRAVEL DEVICE

Gearbox disassembly

1. Make sure that the oil is discharged.

2. Unscrew the socket bolts (1) (Q.ty 10) which fix the
end cover (2) to the gearbox housing (3). 2

: 8 mm

R0520

3. Remove the end cover (2) by using screws (4) 4

screwed into the oil plugs holes.
: 32 mm

R0521
W3-2-4 E215

TRAVEL DEVICE

4. Remove the O-Ring seal (1) from the end cover (2).
1

R0522

5. Take out 1st stage sun gear (3).

R0523

st
6. Remove the 1 reduction assembly (4). 4

R0524

nd
7. Remove the 2 reduction assembly (5). 5

R0525
E215 W3-2-5

TRAVEL DEVICE

18. By using pliers remove the circlips (1) from the 3rd
reduction planet assemblies (2).
1

R0526

19. By using a puller remove the planet assemblies

(2).
2

R0527

10. Take out the spacers (3) from the pin of the
hydraulic motor (4). 3

R0528
W3-2-6 E215

TRAVEL DEVICE

11. By using an electric drill remove the stakings on

the ring nut (1).

R0529

12. By using the torque multiplier loosen the nut (1).

R0530

13. Take out the nut (1).

1

R0531

14. Remove the centering ring (2) from the hydraulic

motor.
2

NOTE - The above operation must be execute only in

case of replacement of the hydraulic motor.

R0532
E215 W3-2-7

TRAVEL DEVICE

IMPORTANT - Assemble in the threaded hole of the

gearbox housing a safety retainer to avoid the hous- 60
20
ing comes out from the hydraulic motor during the

15
movement of the unit. Remove the safety retainer A
when the unit is positioned (scketch below).

10
40
A-A

R0534

R0533

15. Position the gearbox housing (1) on two supports.

By using a press remove the hydraulic motor (2)
from the gearbox housing (1).

R0535

16. Take out the spacer from the hydraulic motor (2).

R0536
W3-2-8 E215

TRAVEL DEVICE

17. By using screwdriver remove the lifetime seal (1)

from the hydraulic motor (2).

2 1

R0537

18. Place the puller in the hydraulic motor and turn the
screw until the bearing inner ring comes out.

R0538

19. Take out the bearing inner ring (3) from the
gearbox housing (4). 3

R0539
E215 W3-2-9

TRAVEL DEVICE

20. Remove the bearing balls from the gearbox hous- 1

ing (1).

R0540

Disassembly hydraulic motor

DISASSEMBLY OF THE TWO SPEED CONTROL

ASSY 3

1. Unscrew the plug (2) from the base plate (3).

R0541

2. Remove the O-Ring seal (4) from its seat in the plug
(2). 2

R0542

3. Remove the O-Ring seal (5) from its seat in the plug
(3).

R0543
W3-2-10 E215

TRAVEL DEVICE

4. Take out the spring (1).

R0544

5. Unscrew the plug (2) from the base plate.

2
R0545

6. Remove the O-Ring seal (3) from its seat in the plug
(2). 3
2

R0546

7. Take out the two speed spool (4).

R0547
E215 W3-2-11

TRAVEL DEVICE

DISASSEMBLY OF THE RELIEF VALVE

1. Unscrew the relief valve (1) from the base plate (2).
2
: 27 mm

R0548

2. Take out the free piston (3) from the relief valve (1).

R0549

3. Remove the O-Ring seal (4) and the backup rings

(5) from their seats in the free piston (3).

R0550

4. Remove the O-Ring seal (6) from relief valve (1).

Repeate the same steps for the 2nd relief valve
6
disassembly (1).

R0551
W3-2-12 E215

TRAVEL DEVICE

DISASSEMBLY OF THE COUNTERBALANCE

VALVE
1. Unscrew the socket bolts (1) (Q.ty 4), of the 1st 1
flanged plug assy (2).
: 10 mm

2
R0552

st
2. Take out the 1 flanged plug assy (2).
2

R0553

st
3. Take out the 1 spring seat (3).

R0554

st
4. Remove the 1 spring (4).

R0555
E215 W3-2-13

TRAVEL DEVICE

5. Take out the 1st spring seat (1) from the counterbal-
ance valve spool (2).

R0556

st
6. Remove the 1 spring (3).

R0557

7. Remove the O-Ring seal (4).

R0558

8. Remove the check valve (5).

Repeate the same steps for the 2nd check valve
disassembly.

R0559
W3-2-14 E215

TRAVEL DEVICE

9. Unscrew the socket bolts (1) (Q.ty 4), of the 2nd

flanged plug assy (2).
: 10 mm 1

R0560

nd
10. Take out the 2 flanged plug (2).

R0561

11. Take out the 2nd spring seat (3).

3

R0562

12. Remove the 2nd spring (4).

R0563
E215 W3-2-15

TRAVEL DEVICE

13. Take out the 2nd spring seat (1) from the counter-
balance valve spool (2).
2

R0564

14. Take out the counterbalance valve spool (3).

DISASSEMBLY OF FLANGED PLUG R0565

1. Remove the O-Ring seal (2) from the flanged plug

(4). 4
2

R0566

2. Unscrew the plug (5) from the flanged plug (6).

6
5

R0567
W3-2-16 E215

TRAVEL DEVICE

3. Remove the O-Ring seal (1) from the plug (2).

2

DISASSEMBLY OF THE BASE PLATE R0568

1. Unscrew the plugs (3) from the base plate (4).

4

R0569

2. Remove the O-Ring seal (5) from the plug (6).

6

5
R0570

3. Unscrew the conical plugs (7) from the base plate

(4).

R0571
E215 W3-2-17

TRAVEL DEVICE

4. Unscrew the orifices (1) from the base plate.

R0572

5. Remove the caulking with a M5 tap before un-

screwing the orifices (2).

R0573

6. Unscrew the orifices (2) from the base plate.

R0574

7. Unscrew the socket bolts (3) (Q.ty 9), of the base

plate.
: 12 mm

R0575
W3-2-18 E215

TRAVEL DEVICE

8. Remove carefully the base plate (1) until pins (2)

are completely out.
1

R0576

9. Take out the pins (2).

R0577

10. Remove the valve plate (3).

R0578

11. By using a puller, remove the bearing (4) from the

base plate (1). 1
4

R0579
E215 W3-2-19

TRAVEL DEVICE

DISASSEMBLY OF MOTOR SHAFT AND

CYLINDER BLOCK 1
2
1. Remove the O-Ring seal (1) from its seat in the
flanged hub (2).

R0580

2. Remove the O-Ring seal (3) from its seat of the

brake pilot hole in the flanged hub (2).

R0581

3. Remove the O-Ring seals (3) from their seat of the

two speed control holes in the flanged hub (2). 3

R0582

4. Remove the springs (4) from the brake piston. 4

R0583
W3-2-20 E215

TRAVEL DEVICE

5. Mark the position of the brake piston (1) as a

reference for the reassembling step.

1
R0584

6. Remove the brake piston (1).

1

R0585

7. Remove the O-Ring seals (2) from their seats in the

brake piston (1).

R0586

8. Take out the brake discs (3).

3

R0587
E215 W3-2-21

TRAVEL DEVICE

9. Take out the steel discs (1).

1

R0588

10. Remove the cylinder block (2).

R0589

11. Take out the spherical retainer plate holder (3).

R0590

12. Take out the pins (4) (Q.ty 3) from their seats in the
cylinder block (2).

R0591
W3-2-22 E215

TRAVEL DEVICE

13. Disassemble the pistons and the retainer plate (1).

R0592
14. Take out the pistons (2) from the retainer plate (3).

R0593
15. Remove the swash plate (4) from the flanged hub
(5).
4
5

R0594
16. Take out the steel balls (6) (Q.ty 2).

R0595
E215 W3-2-23

TRAVEL DEVICE

17. Take out the two speed control pistons (1) (Q.ty 2).

R0596

18. Take out the two speed control springs (2) (Q.ty 2).

R0597

19. By using a punch, take out the motor shaft and the
bearing from the the flanged hub.

R0598

20. By using a puller, take out the bearing (3) from the
motor shaft (4).

R0599
W3-2-24 E215

TRAVEL DEVICE

21. By using a screwdriver remove the seal ring (2)

from its seat in the flanged hub (1). 2 1

NOTE - Disassemble the seal ring only in case of

replacement, because this will damage it.

R0600
E215 W3-2-25

TRAVEL DEVICE

ASSEMBLY TRAVEL DEVICE (E215)

Preliminary operations

When proceeding with the gearbox reassembly, it is

necessary to follow the rules listed below:

1. In case of damaged gears, for example a planet, do

not replace the single gear, but the whole reduction
stage.

2. Replace always the O-Rings and seal rings of the

part to be reassembled after having carefully
cleaned the seats and having buttered some
grease on the seats themselves and on the
O-Rings to make easier the reassembly.

3. Always replace all the components that seems to

be damaged or with excessive wear, with original
spare parts.

Hydraulic motor assembly

ASSEMBLY OF MOTOR SHAFT AND CYLINDER

BLOCK
1. Place the seal ring (1) into its seat in the flanged hub
1 2
(2).

R0601

2. By using the tool (380001061) and a rubber hammer

push the seal ring against the seat shoulder. 380001061

R0602
W3-2-26 E215

TRAVEL DEVICE

3. Place the bearing (1) on the motor shaft (2).

1

R0603

4. By using a tool (380001062) and a rubber hammer

380001062
push the bearing (1) against the motor shaft shoul-
der (2).

R0604

5. Place the bearing-motor shaft unit (4) in the seat 5

inside the flanged hub (5).

NOTE - Be careful when inserting the shaft inside the

motor seal, that must be greased. 4

R0605

6. By using a tool (380001063) hammer push the

bearing-motor shaft unit (4) against the flanged hub 380001063
shoulder (5).

R0606
E215 W3-2-27

TRAVEL DEVICE

7. Assemble the steel balls (1) (Q.ty 2) into their

seats in the flanged hub.

R0607

8. Assemble the two speed springs (2) into their

seats in the two speed pistons (3).

R0608

9. Assemble the two speed pistons (3) (Q.ty 2) into

their seats inside the flanged hub.

NOTE - Be sure that the pistons can move freely into

the seats.

R0609

10. Insert the swash plate (4) inside the flanged hub
being careful that spherical housings matches 4
with the steel balls (1).

R0610
W3-2-28 E215

TRAVEL DEVICE

11. Assemble the pins (1) (Q.ty 3) in their seats in the 2

cylinder block (2).

R0611

12. Assemble the spherical retainer holder (3) on the

cylinder block (2).

NOTE - The two splines must be aligned together. 3

2
R0612

13. Piston orifice (4) must be open and free of dust or

dirt.

R0613

14. Assemble correctly the pistons (4) (Q.ty 9) in the

retainer plate (5).
5
4

R0614

R0615
E215 W3-2-29

TRAVEL DEVICE

15. Assemble the pistons-retainer plate unit (1) in the

cylinder block (2).
1

R0616

16. Assemble the cylinder block unit (2) into the

3
flanged hub (3) on the motor shaft spline (4).

R0617

17. Assemble the brake discs package according to

the following order: firstly, insert one brake disc 5
with internal toothing (5).

R0618

18. Then insert a steel disc (6). Repeat the operation

untill all 3 brake discs and 2 steel discs have been 6
assembled.

R0619
W3-2-30 E215

TRAVEL DEVICE

19. Assemble the O-Ring seals (1) into their seats in

1
the brake piston (2).

2
R0620

20. Assemble the brake piston (3) respecting the 3

markings set out previously and being careful not
to damage the seals already fitted.

R0621

21. Assemble the O-Ring seal (4) into its seat in the 4 5
flanged hub (5).

R0622

22. Assemble the O-Ring seal (6) into the brake pilot
hole of the flanged hub (5).

R0623
E215 W3-2-31

TRAVEL DEVICE

23. Assemble the O-Ring seals (1) into their seats in

the two speed control holes in the flanged hub.
1

R0624

24. Insert the springs (2) in their seats in the brake 2

piston (3). 3

ASSEMBLY OF THE BASE PLATE R0625

1. Assemble the bearing (4) into its seat in the base

plate.
4

R0626

2. By using a tool (380001064) and a rubber hammer

push the bearing (4) against the base plate seat
shoulder (5).
380001064

4
5
R0627
W3-2-32 E215

TRAVEL DEVICE

3. Place the valve plate (1) on the base plate. 1

NOTE - Bronze layer surface must be upwards.

R0628

4. Insert the pins (2).

R0629

5. Place the base plate (3) on the flanged hub (4).

NOTE - The base plate is centered by two pins and the

second speed oil passages must match together.

R0630

6. Fix the base plate (3) to flanged hub (4) by using

socket head bolts (5) (Q.ty 9).
: 12 mm
: 205 ± 10 Nm

R0631
E215 W3-2-33

TRAVEL DEVICE

7. By using the tool (380001065) assemble the

O-Ring seals (1) in their seats in the plugs (2). 1

380001065

R0632

8. Tighten the plugs (2) by a torque wrench at

36.8 ± 2.5 Nm torque.

R0633

9. Tighten the orifices (3) in the base plate by a

torque wrench at 2.5 ± 0.5 Nm torque.

R0634

10. Seal the thread of the plugs (4) by Teflon tape.

Tighten the plugs in the base plate by a torque
wrench at 10 ± 1 Nm torque.

R0635
W3-2-34 E215

TRAVEL DEVICE

11. Tighten the orifices (1) in the base plate by a

torque wrench at 2.5 ± 0.5 Nm torque.

R0636

12. By using a punch and an hammer deform the

thread hole.

ASSEMBLY OF THE FLANGED PLUG R0637

1. By using the tool (380001066) assemble the

O-Ring (2) in its seat in the plug (3).
2
380001066

R0638

2. Tighten the plug (3) by a torque wrench at 3

20.6 ± 1.0 Nm torque.

R0639
E215 W3-2-35

TRAVEL DEVICE

3. Assemble the O-Ring (1) in its seat in the flanged

1
plug (2).

ASSEMBLY OF THE COUNTERBALANCE VALVE R0640

1. Insert the counterbalance valve spool (3).

R0641

2. Assemble the check valve (4) into its seat.

R0642

3. Assemble the O-Ring seal (5).

R0643
W3-2-36 E215

TRAVEL DEVICE

4. Insert the 1st spring (1).

Repeate the same steps for the 2nd check valve
reassembly.

R0644

st
5. Insert the 1 spring seat (2) on the counterbalance
valve spool (3).
3

R0645

st
6. Insert the 1 spring (4) on the counterbalance valve
spool (3).

R0646

st
7. Assemble the 1 spring seat (5) into the flanged
plug assy (6).

R0647
E215 W3-2-37

TRAVEL DEVICE

8. Assemble the 1st flanged plug assy (1) on the base

plate (2). 2

R0648

9. Tighten the socket bolts (3) (Q.ty 4), of the 1st

flanged plug (1) using a torque wrench at 108 ± 10
Nm torque.

R0649

nd
10. Insert the 2 spring seat (4) on the counterbal-
ance valve spool.

R0650

nd
11. Insert the 2 spring (5) on the counterbalance
valve spool.

R0651
W3-2-38 E215

TRAVEL DEVICE

12. Assemble the 2nd spring seat (1) into the flanged 1
plug assy (2).
2

R0652

nd
13. Assemble the 2 flanged plug assy (2) on the
base plate (3). 3

2
R0653

st
14. Tighten the socket bolts (4) (Q.ty 4), of the 1
flanged plug (2) using a torque wrench at
108 ± 10 Nm torque.
2

ASSEMBLY OF THE RELIEF VALVE R0654

1. By using the tool (380001067) assemble the 380001067

O-Ring seal (5) in its seat in the relief valve (6).

R0655
E215 W3-2-39

TRAVEL DEVICE

2. Assemble the 1st backup-ring (1) into its seat in the

free piston (2).

R0656

3. Assemble the O-Ring seal (3) into its seat in the

free piston. After this step assembly the 2nd backup
ring as shown on the sketch below. 3

Backup ring

R0658

O-Ring

R0657

4. Insert the free piston (2) in the relief valve (4)

checking that the groove side is toward inside of the
motor.

2
4

R0659
W3-2-40 E215

TRAVEL DEVICE

5. Insert the relief valve (1) inside the base plate (2).
2

R0660

6. Tighten the relief valve (1) by a torque wrench at

373 ± 20 Nm torque.

ASSEMBLY OF THE TWO SPEED CONTROL R0661

1. By using the tool (380001068) assemble the O-Ring

(3) in its seat in the plug (4).
3

380001068

R0662

2. Tighten the plug (4) by a torque wrench at

118 ± 5 Nm torque.

R0663
E215 W3-2-41

TRAVEL DEVICE

3. Insert the two speed spool (1) in the base plate (2). 2

NOTE - Two speed spool have to move smoothly

inside its seat in the base plate.

1
R0664

4. Insert the spring (3) in the two speed spool (1).

R0665

5. Insert the spring seat (4) and the washer.

R0666
W3-2-42 E215

TRAVEL DEVICE

6. By using the tool (380001068) assemble the O-Ring

seal (1) in its seat in the plug (2).
1

380001068

2
R0667

7. Tighten the plug (3) by a torque wrench at

118 ± 5 Nm torque.

R0668
E215 W3-2-43

TRAVEL DEVICE

Gearbox assembly

1. Fit the lower ball row (d), into the gearbox housing
(1) holding the inner raceway (c) with spacers
(a-b).

2. Remove the spacer (a). d

c
1

135
a
b

20
Ø 244.5
20 Ø 260.5

R0669

3. Insert the spacer (e).

4. Drop the upper ball row (f).

g
5. Assemble the inner raceway (g).

a b

R0670
W3-2-44 E215

TRAVEL DEVICE

6. Makeready of the lifetime seal

Instructions to properly assemble the lifetime seal:
a. Carefully clean the seats (1 and 2) using, if
1 2
necessary, metal brushes or solvent (surfaces
in contact with or (3) must be perfectly clean and
dry).
6 6
b. Make sure that sealing surfaces (4) of metal
rings (5) are free from scratches, dinges or
foreign substances; metal ring surfaces must be
perfectly clean and dry. 3 3
c. Carefully clean the lapped surface (4) of metal
5 5
rings (5) and remove dust or fingerprints. Then
lubrificate them with a thin oil film, taking care not
to oil the other components. 4 4

R0671

7. Assemble an half seal (7) on the tool (380001069).

380001069
R0672
E215 W3-2-45

TRAVEL DEVICE

8. Assemble the half seal (1) on the gearbox hous-

ing (2). 1

2
R0673

9. Assemble, by using the tool (380001069), the half

seal (1) on hydraulic motor (3).

3
R0674

10. Clean carefully the metallic faces of the lifetime

seal (1), and lube them with a thin oil film.

R0675

11. By using a tackle position the hydraulic motor (3)

inside the gearbox housing (2).
3

R0676
W3-2-46 E215

TRAVEL DEVICE

12. By using a press and the tool (380001070), push

the hydraulic motor (1) against the shoulder of the
gearbox housing (2) until assembly of the unit is
complete.

R0677

IMPORTANT - Assemble in the threaded hole of the

gearbox housing a safety retainer to avoid the hous- 60
20
ing comes out from the hydraulic motor during the
movement of the unit. Remove the safety retainer 15 A
when the unit is positioned (scketch below).

A
10

40
A-A

R0534

R0533

13. Turn the gearbox usdide down. By using a press

and a metal tool (380001071) assemble the
centering ring in its seat in the hydraulic motor.

R0678
E215 W3-2-47

TRAVEL DEVICE

14. Place the nut (1).

1

R0679

15. By using the mutiplier tighten the ring nut (1), by

a torque wrench with torque of 6250 to 6750 Nm.

R0680

16. Stake the ring nut near 2 seats of the hydraulic

motor.

Stake
Ø 4 to 5 mm
(depth 1 to 1.5 mm)

R0681

R0682

17. Assemble correctly the spacers (2) on the pins of

2
the hydraulic motor (3).

R0683 R0684
W3-2-48 E215

TRAVEL DEVICE

18. Place correctly the reduction planet assemblies 1

(1) on the pins of the hydraulic motor (2) checking 2
that the groove is towards the end cover.

R0685
R0686

19. By using a rubber hammer and the tool 380001072

(380001072) push the reduction planet assem-
blies (1) against the pins of the hydraulic motor
(2).

R0687

20. By using pliers assemble the circlips (3) in the

hydraulic motor pin seats (2). 3

R0688

nd
21. Assemble the 2 reduction assembly (4).

4
R0689
E215 W3-2-49

TRAVEL DEVICE

22. Assemble the 1st reduction assembly (1).

R0690

st
23. Insert the 1 stage sun gear (2).

R0691

24. Assemble the O-Ring seal (3) into its seat in the
end cover (4).

3
4

R0692

25. Assemble the end cover (4) on the gearbox hous-

ing (5).

R0693
W3-2-50 E215

TRAVEL DEVICE

26. Fix the cover (1) to the gearbox housing (2) by

using socket bolts (3) (Q.ty 10).
: 8 mm
: 75 Nm

R0694

27. Fill the gearbox with the lubricant oil. Tighten the
plugs (4) into the oil draining-filling holes of the
end cover (1).
: 17 mm
: 30 to 40 Nm

R0695
E215 W3-2-51

TRAVEL DEVICE

MAINTENANCE STANDARD (E215)

Sprocket

E
A
SM1103

IMPORTANT - Consult FIAT KOBELCO S.p.A. for any inqueries concerning welding procedures.

Standard Allowable Limit

(mm) (mm) Remedy

A 68 60

B 584.7 575
Build up and
C PCD644.6 - finishing

D 659 648

E 190.0 -
W3-2-52 E215

TRAVEL DEVICE

NOTES:
E215-E235 W3-3-1

SWIVEL JOINT
REMOVAL AND INSTALLATION OF SWIVEL JOINT

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.

Preparation
1. Park the machine on a firm, level surface.
2. Cut-off the engine. Actuate the manual and pedal
pilot valves to release any residual pressure from
inside the hydraulic system. Press the valve
located on the hydraulic oil tank to release any
residual pressure present inside the tank itself.
3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the
hydraulic oil tank.
NOTE - Be sure to run the vacuum pump continuously
while working.

Removal

3. Remove tubes (2 and 8). (PF1)

NOTE - Attach labels or tags to hoses and adapters,
to aid in assembly. : 36 mm
: 177 Nm

1. Remove tube (5 and 6). (PF1/2) 4. Remove the hoses (3 and 4). (PF1/4)

: 27 mm : 19 mm
: 79 Nm : 177 Nm

2. Remove tubes (1 and 7) (PF1).

: 36 mm
: 177 Nm

1
2

4
8

7
5

6
R0038
W3-3-2 E215-E235

SWIVEL JOINT

5. Remove drain hose (2). (PF1/2) 1

: 27 mm
: 78.5 Nm
2
6. Remove hoses (4 and 6).
: 36 mm 3
: 177 Nm

7. Remove hoses (1 and 3).

: 36 mm
: 177 Nm

8. Remove hose (5).

6
: 19 mm 4
: 29 Nm

R0039

9. Loosen the stop nut (7) M20 of swivel joint and

remove the screw (8) M20×120. 7 8
: 30 mm
: 157 Nm

R0040

10. Remove two adapters (9 and 10).

10
: 19 mm
: 36 Nm

9
R0041
E215-E235 W3-3-3

SWIVEL JOINT

11. Remove six screws (2) M10×25. 1

: 19 mm
: 14.7 Nm 2

12. Remove clip (1).

: 6.8 Nm 3

13. Remove seal (4).

4
R0042

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

remove three screws (2) M12×25.
: 19 mm
: 108 Nm
5

WARNING
Swivel joint weight: 31 kg

Installation
R0043

NOTE - Refer to “Removal” section above for wrench

sizes and tightening torque.

1. Proceed with the re-installation of the centre joint

following the operation in reversed order with re-
spect to the removal.

WARNING
Swivel joint weight: 31 kg
W3-3-4 E215-E235

SWIVEL JOINT

SWIVEL JOINT DISASSEMBLY AND ASSEMBLY

X
View from X
E

G
A
2

6
G
1 E
C
B
D D

Section G-G
A

F
5
7
3
9
8 E E 12
4

R0044

1 - Body 6 - Seal assy

2 - Stem 7 - O-Ring
3 - Thrust plate 8 - Socket Bolt (M8×20)
4 - Cover 9 - Socket Bolt (M8×30)
5 - Seal assy 12 - Plug
E215-E235 W3-3-5

SWIVEL JOINT

Disassembly
2
1
The part numbers used in this disassembly procedure 4
correspond to those of a construction drawing in the 9
figure on page W-3-3-4.

1. Mark cover (4) and body (1) with matching marks for
convenient reassembly.

2. Place a ' V' (A) block on a work bench, place a swivel

joint set on the side, fix it and loosen socket bolt (9)
by means of a pipe and wrench. Alternately, the A
swivel joint may be fixed by holding stem (2) in a
vise.
R0045
: 6 mm

3. Remove cover (4) from body (1) and draw out O-Ring
(7) from cover (4).

R0046

4. Loosen socket bolt (8) fastening thrust plate (3), in

1
the same manner as the removing of the above-
3
mentioned cover.
8
- When removing thrust plate (3) by fixing body (1),
support stem (2) so it may not fall down.
: 6 mm

R0047
W3-3-6 E215-E235

SWIVEL JOINT

5. Place body (1) on a 'V' (A)-block. Put a wooden B

block against stem (2) via the body so about half of 1
the stem is covered by the wooden block (B) and 2
knock it out using a mallet.
By hitting out the stem over about 1/2 from the body,
it can be easily pulled out by hand.

A
R0048

6. Take off the slip ring (B) of the seals assemblies C

(5 and 6) by means of pin of screwdriver (A) and
remove them from the O-Ring grooves (D). The
figure on side shows the use of only one pin of
screwdriver, but by using two screwdriver pins,
these can be extracted with more sureness.
B
NOTE - Make sure the body (1) is not scored from the
screwdriver (A). Detail
5 and 6
1
A
6

R0049

7. Remove the back-up ring of the seals assemblies

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

NOTE - Make sure the body (1) is not scored from the
tip of the spatula (E).

R0050
E215-E235 W3-3-7

SWIVEL JOINT

Assembly B

Prior to assembly, clean each parts (excluding the

O- Ring and slipper ring), and arrange in the sequence
of assembly.

1. Make sure that oil and grease remains have been

completely removed.

2. Apply grease on the groove where are seated the

O- Ring (6).

3. Slipper ring (B) is assembled, after first inserting the

backup ring, by slightly-distorting the shape as
shown in figure. Also after inserting all of the seals, R0051
be certain that these are installed in the seal groove
by use of the spatula.

4. Lightly coat the outer circumference of stem (2) and

Press with
the inner surface of body (1) with grease or vaseline boths hands
and slowly insert stem (2) into body (1).

2
NOTE - If stem (2) is pressed in too fast, the seal may
be damaged. Do it slowly. The clearance between
body (1) and stem (2) is about 0.1mm. Push stem
straight along the shaft center.
6

R0052
W3-3-8 E215-E235

SWIVEL JOINT

5. While holding stem (2) and body (1), match the hole
of thrust plate (3) and the stem (2) hole. 8 3 2

6. Next, after removing any oil from the thread of

socket bolt (8), coat it with Loctite 242 and tighten
to stem (2).

: 6 mm
: 30.4 Nm

R0053

7. After installing O-Ring (7) to cover (4) and aligning

the matching marks of the cover (4) and body (1), 1
A
coat socket bolt (9) with Loctite 242 and tighten it
which will then complete assembly.
9
: 6 mm
4
: 30.4 Nm

R0054
E215-E235 W3-3-9

SWIVEL JOINT

MAINTENANCE STANDARD

Item Allowable Limit (basis of judgment) Remedy

Sliding surface
Scored or something hurt it. Replace
and sealed parts

1. Scored more than 0.1 mm. Replace

Sliding surface
exception sealed parts 2. Scored less than 0.1 mm. Repair
with oil stone
Body, Stem
1. Wear more than 0.5 mm deep. Normal wear

Sliding surface ring 2. Wear less than 0.5 mm deep.

Repair
a 0.5 mm.

3. Scored less than 0.5 mm and able

Repair
to repair.

1. Wear more than 0.5 mm. Replace

Cover Sliding surface ring 2. Wear less than 0.5 mm. Repair

3. Scored less than 0.5 mm and able

Repair
to repair.

1. Protruded excessively from seal

groove.

Replace (with
back-up ring)

R0055

2. Slipper ring narrower than 1.5 mm

of seal groove, or narrower than
back-up ring.

Slipper ring Replace (with

back-up ring)

1.5 mm (max)

R0056

3. Worn unevenly more than 0.5 mm.

0.5 mm (max) Replace (with

back-up ring)

R0057
W3-3-10 E215-E235

SWIVEL JOINT

Inspection after assembly

After completion of assembly, inspection for oil leak-

age, pressure resistance, etc., using a device as 1
shown in the figure on right.

1. High pressure port (A,B,C,D port)

9
Install a directional valve (8) and pressure gauge (1)
to the stem side port and body side port respective-
ly, and while watching the pressure gauge (for high
pressure) installed on the body side and also by 2
regulating high pressure relief valve (7), gradually
increase the pressure. When the pressure has
reached 1.5 times the maximum working pressure,
close stop valve (3) and lock in the hydraulic oil in
3
the swivel.
At this time, keep stop valve (6) on the low pressure 8
relief valve side closed for, at least, 3 minutes and
check for any distortions, breakages or loosening.
During the first minute, check for oil leakages and,
in case of pressure drop, this shoul be the 10% of 7
the pressure trapped. This check should be per-
formed on each circuit.

2. Low pressure port

(Drain port, return port : E,F port.)
Similar to the high pressure port, install a directional
valve and pressure gauge on each port of the stem
side and body side. 4 6 5
Open stop valve (6) on the side of low pressure relief R0058

valve (5) and while watching the pressure gauge (for

low pressure) connected to the body side and also
1 - Pressure Gauge
by regulating low pressure relief valve (5), gradually 2 - Swivel Joint
increase the pressure and check for outside leak- 3 - Stop Valve
age with a color check at a pressure of 0.49 MPa. 4 - Hydraulic source
5 - Relief Valve for low pressure
6 - Stop Valve
7 - Relief Valve for high pressure
8 - Directional Valve
9 - Piping, etc.
E215-E235 W3-4-1

TRACK ADJUSTER

REMOVAL AND INSTALLATION OF

TRACK ADJUSTER (WITH FRONT IDLER)

Before removing the track adjuster, the tracks and the

front idler must be removed first. For removal and
installation of the tracks and the front idler, refer to
applicable removal/installation sections. In this sec-
tion, the procedure starts on the premise that the
tracks and the front idler have already been removed.

Removal

WARNING
Track adjuster assembly weight:
210 kg (E215)
300 kg (E235)

WARNING
Be sure cables are anchored and the anchor point
is strong enough to handle the expected load. Keep
exposed personnel clear of anchor point and ca- SM1801

bles or chain.

1. After swinging superstructure to 90° related to

machine longitudinal centerline for easier access
to track components, remove the front idler and
track adjuster assembly from track frame by prying
it out, using a pry bar shown in figure.

Installation

WARNING
Be sure cables are anchored and the anchor point
is strong enough to handle the expected load. Keep
exposed personnel clear of anchor point and ca-
bles or chain.

1. As shown in figure, install the front idler and track

adjuster into spring guide on track frame.

SM1802
W3-4-2 E215

TRACK ADJUSTER

DISASSEMBLY AND ASSEMBLY TRACK

ADJUSTER (E215)

Disassembly Track Adjuster

Be sure to thoroughly read "Precautions for Disas-

sembly and Assembly" on page W1-1-1 before start-
380001029
ing the disassembly work.

Be sure to use special tool (380001029) for

assembly / disassembly of the track adjuster.

WARNING
Prevent personal injury. The spring force of the
SM1160
track adjuster is extremely large. Thoroughly in-
spect the special tool for any damage. Carefully
perform assembly work referring to the procedure
below.

WARNING
Approximate weight of the track spring holder
assembly: 225 kg Plate

1. Place a jack on the bottom of the track spring holder

assembly (380001029).

2. Loosen four nuts to remove the plate.

: 46 mm

SM1161
WARNING
Track adjuster weight: 103 kg

3. Connect the track adjuster to a hoist using a lifting

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

R0098
E215 W3-4-3

TRACK ADJUSTER

4. Draw out piston (6) from grease cylinder (1) of the

idler adjuster assy. 2 4 3 7 1 5 9 8 6

5. Removing oil seal (9), O-Ring (8) from grease

cylinder (1).

6. Set the idler adjuster assy on the stand of the jig,

with its bracket side facing up.

11 10
R0099

7. Fit retainer plate (1) to bracket (2), tighten holding-

down nuts alternately, and secure idler adjuster 4
assy.
: 46 mm

1
3 R0100

8. Remove spring pin (4), press spring (5) lifting it with 5

jack so that nut (3) can be turned freely, and remove
nut.
: 46 mm

: 75 mm

R0101
W3-4-4 E215

TRACK ADJUSTER

19. Allow the hydraulic jack to retract slowly till the

spring is extended to its free length. Remove the
retainer plate and take off bracket (2) and cover
(11).

The free length of the spring: 531.1 mm

: 46 mm
2

11

R0102

10. Hook lifting eye nut (W) to screw M48 on grease

cylinder (1) top end and hoist it. Then, remove the
set of grease cylinder (1) and spring (5) using W
1
crane from the jig.
Remove spring (5), collar (7), grease cylinder (1),
in that order.
5

R0103
E215 W3-4-5

TRACK ADJUSTER

Assembly
2 4 3 7 1 5 9 8 6
1. Insert grease cylinder (1) and collar (7) into spring
(5) and attach lifting eye nut (W) to screw M48 at the
tip of the grease cylinder. Lift the grease cylinder by
crane and erect it in the center of the jig stand
upright (380001029).

11 10
R0099

R0104

2. Install bracket (2) and cover (11) on top of spring (5). 12

Center the rod of grease cylinder (1) and the holes
in bracket (2). Attach the retainer plate (12) and four 13
holding-down nuts (13). Fasten the nuts evenly all
round and fix the idler adjuster assy to the jig body
(75301508).
: 46 mm
2
4
3. Extend the hydraulic jack, compress spring (5) to a 3
set length and screw in nut (3) to the screwed part 7
at the tip of grease cylinder (1). 11
1
Set length of the spring: 429 mm
5

4. Tighten nut (3) till the holes for locking spring pins R0105
(4) are aligned. Then fit spring pin (4).
: 46 mm

: 75 mm
W3-4-6 E215

TRACK ADJUSTER

5. Remove idler adjuster assy from jig (380001029).

WARNING
Track adjuster weight: 103 kg

R0106

6. Apply grase on the oil seal (9) and O-Ring (8) then
fit them to grease cylinder (1). 1 9 8
6
7. Fill up grease in cylinder (1), remove the grease
nipple from piston (6) in order to discharge the inside
air, and press in the piston by hand.
Direct grease nipple hole downward to make air
discharge easier.

8. Tighten grease nipple (X) to piston (6). X

R0107
: 19 mm
: 59 Nm
E215 W3-4-7

TRACK ADJUSTER

NOTES:
W3-4-8 E235

TRACK ADJUSTER

DISASSEMBLY AND ASSEMBLY TRACK ADJUSTER (E235)

6 7 8

4
3

SM1803

1 - Valve 4 - Seal 7 - Spring pin

2 - Piston 5 - Cylinder 8 - Retaining nut
3 - Seal 6 - Spring 9 - Plate
E235 W3-4-9

TRACK ADJUSTER

Disassembly and assembly Track Adjuster

Be sure to thoroughly read "Precautions for Disassem-

bly and Assembly" on page W1-1-1, before starting the
disassembly work.
Release mechanism disassembly calls for the use of
portable hydraulic press 380001019 complete with its
tool kit. Loosen screw (13) and separate the idler wheel 15 12 12 13
14
assy with supports from the yoke. Remove the screws
(15) securing the yoke to spring support and take out
the yoke.

WARNING 12
13
Do not attempt to eject the piston from cylinder
using compressed air. SM1804

1. To remove piston from release control cylinder,

simply inject some grease through the hydraulic
adjuster valve until the piston is ejected.

2. To remove piston from release control cylinder,

simply inject some grease through the hydraulic
adjuster valve until the piston is ejected.

3. Locate service kit components in the arrangement

as shown at the bottom page.

WARNING
Track release spring is assembled into machine with
high compressive load. Follow procedures recom-
mended in Service Manual when assembling or
disassembling this parts.

4. Activate the press to relieve nut of the spring load.

5. Remove the nut and gradually reduce press action

until spring load is fully relieved.

2 1 3 4
R0021

1 - Track release spring 4 - Hydraulic cylinder 380001019

2 - Frame 380001014 5 - Adapter 380001017
3 - Pusher 380001023
W3-4-10 E235

TRACK ADJUSTER

6. For spring reassembly use the same service kit;

activate the press until the spring reaches an assem-
bled leght of 585 mm under a load of 13000 kg.

TRACK ADJUSTER SECTION

X = 585 mm under a load of 13000 kg

8 Vs

13 Vr

SM1806

8 - Retaining nut Vr - Hydraulic adjuster valve

13 - Screw securing yoke Vs - Pressure relief valve

7. Lock the spring retaining nut (8) and neutralize the

press.
Install release mechanism back on machine.
E215 W3-5-1

FRONT IDLER

DISASSEMBLY AND ASSEMBLY

FRONT IDLER ASSY (E215)

Disassembly

1. Remove plug (8) on the side of collar (3) to drain oil.

: 5 mm
1
2
3
7

8
6
5
4

R0089

2. To remove pin (5) apply pin push bar (380001051) to

the top of pin, and push out striking bar lightly by 5
380001051
hammer.

R0090

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

(380001052), push out shaft (6) with collar (3), then Push with press
remove collar (3).

380001052
6
3
1

R0091
W3-5-2 E215

FRONT IDLER

4. If removal of collar (3) on the opposite side is Push with press

required, turn over front idler and proceed with the
procedure described in the previous step.

380001052
6 3

R0092

5. With idler (1) mounted on the stand, tap bushing

380001053 2
(380001053) lightly by hammer, while placing the 1
bushing drawing rod against the end face of bushing
(2) evenly all round, till it comes out.

6. Take out floating seals (4) from idler (1), collar (3).
If you intend to re-use floating seals (4), confirm that
there is no scoring and rusting on the contact
surface and store the floating seals in pairs by
placing card board between the sealing faces.

R0093
7. Separate O-Ring from shaft.
E215 W3-5-3

FRONT IDLER

Assembly
Push with press
1. Align inner hole of idler (1) and bushing (2) and press 2 380001054
fit it vertically with press so that jig (380001054) for 1
bushing press-fitting is inserted into bushing.

R0094

2. Fit O-Ring (7) to O-Ring groove on shaft (6). Press

3. Press fit the O-Ring installed side of shaft (6) into 6

collar (3), and drive pin (5).

3
4. Fit the half of floating seal (4) on each side of collar 5
(3) and idler (1).

R0095

5. Install idler (1) on the shaft (6) with the floating seal 6
(4) fitted into shaft (6) with the toward collar (3). 44

1
6. Fit floating seal (4) on the other side of idler (1).

R0096

7. Fit the half of floating seal (4) on the other collar (3),
8 3
press fit it in shaft (6), and drive pin (5) in with
hammer. 5

8. Fill in 265 cm³ of engine oil API grade CD 30 through 1

the plug hole of collar (3), wind seal tape and tighten
plug (8).
: 5 mm
R0097

NOTE - After installing the idler assy to the idler

adjuster assy, make certain that no oil leaks from
floating seal and plug (8) and that idler (1) rotates
smoothly.
W3-5-4 E215

FRONT IDLER

MAINTENANCE STANDARD (E215)

Front Idler

C D

A
B
SM1189

Unit: mm

Standard Allowable Remedy

A 84 66

B 159 -

C 500 482 Buildup weld and finishing

D 540 -

E 20 -

IMPORTANT - Consult FIAT KOBELCO for any inqueries concerning welding procedures.

Axle and Bushing

Unit: mm

Standard Allowable Limit Remedy

Axle Outside Dia 75 74.2

Bushing Inside Dia 75 76 Replace

Bushing Flange thickness 2 1.2

E235 W3-5-5

FRONT IDLER

DISASSEMBLY AND ASSEMBLY FRONT

IDLER ASSY (E235)

Before removing the front idler, the tracks must be

removed first. For removal and installation of the
tracks, refer to "Remove and Install Tracks" section.
In this section, the procedure starts on the premise
that the tracks have already been removed.

Disassembly and install

WARNING
Front idler weight: 130 kg

1. Drain out oil through plug (9).

9
SM1807

2. Remove spring pin (4) and, using a bridge type

1
puller, take wheel supports off the shaft (3).

2
6

4 5
7 3
5 8

3. Pickup the floating seals (6) keep their halves

paired to prevent mixups at reassembly. Using a SM1808
suitable drift, remove the bushings.

Draw out the bushings by means of a proper

puscher.
W3-5-6 E235

FRONT IDLER

4
7
5
3
5
6

1 2

2
6
4
7

SM1809

1 - Idler 5 - O-ring (Q.ty 2)

2 - Bushing (Q.ty 2) 6 - Floating seal (Q.ty 2)
3 - Shaft 7 - Support (Q.ty 2)
4 - Spring pin (Q.ty 2) 8 - Plug (Q.ty 2)
E235 W3-5-7

FRONT IDLER

WARNING
Wear safety glasses with side shields or goggles, to
reduce the danger of personal injury from flying
particles.

4. For reassembly, reverse the disassembly opera-

tion sequence. Fit back the idler wheel (1), taking
the necessary precautions for the assembly of
floating seals (6) and O-Rings (5).
Oil quantity : 0.3 kg
Oil grade : SAE 30
W3-5-8 E235

FRONT IDLER

MAINTENANCE STANDARD (E235)

Front Idler

C D

A
B
SM1810

Unit: mm

Standard Allowable Limit Remedy

A 85 67

B 175 -

C 550 532 Buildup weld and finishing

D 590 -

E 20 -

IMPORTANT - Consult FIAT KOBELCO for any inqueries concerning welding procedures.
E215 W3-6-1

UPPER AND LOWER ROLLER

REMOVAL AND INSTALLATION OF

UPPER ROLLER (E215)

Removal

WARNING
Do not loosen valve (1) quickly or loosen it too
much as high-pressure grease in the adjusting
cylinder may spout out. Loosen carefully, keeping
body parts and face away from valve (1).
Never loosen grease fitting (2).
SM1228

IMPORTANT - When gravel or mud is packed be-

tween sprockets and tracks, remove it before loosen-
ing.

1. Loosen valve (1) to drain grease.

: 19 mm

1
2
R0022

WARNING 3
Insert a piece of non-sliding rag between track
frame (5) and hydraulic jack to prevent that the
latter slides.

2. Lift track chains (3) with the hydraulic jack to a

height sufficient to remove upper roller (4).

4
SM1828

3. Insert a wooden block between tracks (3) and track

3
frame (5).

SM1827
W3-6-2 E215

UPPER AND LOWER ROLLER

4. Remove nuts (3) securing the support as well as

screw (2) M20 x 120. 3
4
: 30 mm
4
2
5. Remove the upper roller complete with support (1)
extracting the shaft from the collar of the lower 1
frame.

R0024

Installation

1. Prior to the installation, check that the roller turns

freely by hand and there are no leaks.
S
2. Insert fully securing screws (2) fully in the collar
toward the centre of the machine.

3. Insert the roller until the collar contacts the support.

4. Position the support roller directing the mark of

bevel (S) on the shaft end, upward.

5. Apply on the screw M20 x 120 (2) and tighten it to

the specified torque listed here below.
: 30 mm
: 539 Nm MACHINE
CENTRE

2-4 1 3-4
R0025

6. Remove the wooden blocks and the hydraulic jack.

SM1230
E215 W3-6-3

UPPER AND LOWER ROLLER

7. Supply grease to valve (1) to adjust tracks tension.

Track sag specifications (A): 320 to 350 mm

: 19 mm
: 59 Nm

NOTE - Check track sag after thoroughly removing soil

stuck on the track area by washing.
1
2
R0022

SM1234

8. Add engine oil via plug (3) hole on cover (4). Apply
sealant (Loctite 503 or equivalent) to plug (3).
Tighten plug (3).

Engine oil quantity: 50 cm3

: 6 mm
: 23 Nm
3

4
R0026
W3-6-4 E215

UPPER AND LOWER ROLLER

NOTES:
E235 W3-6-5

UPPER AND LOWER ROLLER

REMOVAL AND INSTALLATION OF

UPPER ROLLER (E235)

Removal

WARNING
Do not loosen valve (1) quickly or loosen it too
much as high-pressure grease in the adjusting
cylinder may spout out. Loosen carefully, keeping
body parts and face away from valve (1).
Never loosen grease fitting (2).
SM1228

IMPORTANT - When gravel or mud is packed be-

tween sprockets and tracks, remove it before loosen-
ing.

1. Loosen valve (1) to drain grease.

: 50 mm

SM1811

WARNING 3

Insert a piece of non-sliding rag between track

frame (5) and hydraulic jack to prevent that the
latter slides.

2. Lift track chains (3) with the hydraulic jack to a

height sufficient to remove support roller (4).

4
SM1828

3. Insert a wooden block between tracks (3) and track

frame (5). 3

SM1827
W3-6-6 E235

UPPER AND LOWER ROLLER

4. Remove bolts (2) from upper roller (1).

: 24 mm

SM1232

WARNING
Upper roller weight: 21 kg

5. Remove upper roller (1) from track frame (3). 1

3
SM1233

Installation

WARNING
Upper roller weight: 21 kg

1. Install upper roller (1) and bolts (2).

1
: 24 mm
: 265 Nm 2

SM1232

2. Remove the wooden blocks and the hydraulic jack.

SM1230
E235 W3-6-7

UPPER AND LOWER ROLLER

3. Supply grease to valve (1) to adjust tracks tension.

Track sag specifications (A): 250 to 320 mm

NOTE - Check track sag after thoroughly removing

soil stuck on the track area by washing.

SM1811

SM1234

4. Add engine oil via plug (6) hole on cover (7). Apply
sealant (Loctite 503 or equivalent) to plug (6). 7
Tighten plug (6).

Engine oil quantity: 0.26 kg

: 5 mm
: 9.8 to 19.6 Nm

SM1812
W3-6-8 E215-E235

UPPER AND LOWER ROLLER

REMOVAL AND INSTALLATION OF

LOWER ROLLER

Removal
5
1. Remove the roller guard and loosen bolts (5).
: 30 mm

SM1236

2. Lift the one side of the track frame high enough to

remove the lower roller.
Insert wooden blocks under track frame (2).

2
SM1237

WARNING
Do not loosen valve (3) quickly or loosen it too
much as high-pressure grease in the adjusting
cylinder may spout out. Loosen carefully, keeping
body parts and face away from valve (3).
Never loosen grease fitting (4).

SM1228

3. Loosen valve (3) to drain grease enough to permit

the roller removal. E215
: 19, 24 mm

E235
3

3
4
R0019

Grease Outlet R0020

E215-E235 W3-6-9

UPPER AND LOWER ROLLER

WARNING
Lower roller weight:
35 kg (E215)
48 kg (E235)

4. Securely hold the lower roller using a fork lift.

Remove lower roller (1).
1
SM1238

Installation
2 1
1. Securely hold the lower roller using a fork lift.
Put lower rollers (1) on the tracks as illustration.

SM1239

2. Lower track frame (2) enough to allow bolts (4) to

2 4
be installed into track frame (2).

SM1240

3. Align tapped holes in track frame (2).

Tighten bolts (4).

: 27 mm
: 400 Nm
4

SM1236
W3-6-10 E215-E235

UPPER AND LOWER ROLLER

4. Supply grease to valve (3) throught nipple (4) to E215

adjust tracks tension.

Track sag specifications (A): 320 to 350 mm (E215)

: 19 mm
: 59 Nm

3
4
R0019

Track sag specifications (A): 250 to 320 mm (E235)

E235
: 24 mm 3
: 147 Nm

NOTE - Check track sag after thoroughly removing soil

stuck on the track area by washing.

Grease Outlet
R0020

SM1234
E215 W3-6-11

UPPER AND LOWER ROLLER

UPPER ROLLER DISASSEMBLY (E215)

1. Remove plug (10) and drain out oil. 9 11

4
: 6 mm 10
8
5
2. Mount the end face inside upper roller (1) on stand
jig (380001045) and separate snap ring (11), using
snap ring pliers. 1

3. Take off cover (5) upwards, utilizing the screwed

hole for the plug.
380001045

4. Separate O-Ring (8) from cover (5).

5. Loosen two socket bolts (9) and draw out plate (4)
from roller (1).
R0027
: 8 mm

6. Put the extrusion jig (380001047) against the end

face of shaft (2) and push shaft with collar (3) for PUSH
WITH PRESS
floating seal (7), using a press or hammer.

380001047

380001045

R0028
W3-6-12 E215

UPPER AND LOWER ROLLER

7. Take out floating seal (7) from roller (1).

7

R0029

8. Remove from collar (3), floating seal (7) that is

located on the side from which shaft (2) was
disparted. 2

7
IMPORTANT - Collar (3) is press fitted into shaft (2) by
means of press.Therefore do not disassemble it. 3

R0030

9. Since the bushing is thin, machine it on a lathe or

scrape it off, exercise care so as not to damage the
380001046
bore of roller (1). If the bushing is not worn much,
mount upper roller (1) on jig (380001045), insert jig
6
(380001046) into the end face of bushing (6) and
push it out with a press.
1

380001045

R0031
E215 W3-6-13

UPPER AND LOWER ROLLER

UPPER ROLLER ASSEMBLY (E215)

1. Assembly of the upper roller is done in the reverse PUSH

WITH PRESS
order of disassembly.
380001048
2. Place upper roller (1) on the top end face of jig
6
(380001045), with its floating seal setting side
facing down.
1

3. Confirm that the outer surface of bushing (6) is not

seized and coat the outer surface of the inserting
side of the bushing, with molybdenum disulfide 380001045
grease.

4. Put jig (380001048) into bushing (6) and press it in,

using the bore of the bushing and the bore of the R0032
roller as guides.

IMPORTANT - If you fail in this operation by pressing

the bushing unevenly, the bushing is distorted and
gets unserviceable. In that case, do not re-use the
bushing as it may develop malfunctioning after as-
sembly.

5. Two floating seals (7) make a pair. Attach one

floating seal to retainer fixed in shaft (2), and
2
another to the inside of upper roller (1).

- Prior to placing floating seal (7) in, apply engine

oil lightly to seal surface. 7

R0033

R0034
W3-6-14 E215

UPPER AND LOWER ROLLER

6. Coat shaft (2) with a thin film of oil and insert it into PUSH
upper roller (1). WITH PRESS

R0035

7. Mount upper roller (1) on the stand jig (380001045) 11

and attach plate (4) to the end face of the shaft 9
with bolt (9). 8
5
: 8 mm
4
: 114.7 Nm 1

8. Fit O-Ring (8) to the groove of cover (5).

- Apply grease to O-Ring.

9. Attach cover (5) to upper roller (1). Use a press in

this operation as a press fit is used. 380001045

10. Fix snap ring (11) into upper roller (1), using snap
ring pliers.

R0036

11. Fill in 50 cm3 of engine oil through the plug hole in

cover (4).
5

12. Wind seal tape around plug (10) and screw it into
the plug hole of cover (5).
: 6 mm 1
: 23 Nm

- After assembling the upper roller, confirm that

oil is not leaking from it and that it rotates
smoothly by.
380001045

R0037
E235 W3-6-15

UPPER AND LOWER ROLLER

UPPER ROLLER DISASSEMBLY (E235)

NOTE - Replace the upper roller as an assembly.

SM1241
W3-6-16 E215

UPPER AND LOWER ROLLER

LOWER ROLLER DISASSEMBLY (E215)

3
2
4
5
8

6
7
6
5
4
3
2
1

SM1242

1 - Plug (Q.ty 2) 4 - O-Ring (Q.ty 2) 7 - Roller

2 - Collar (Q.ty 2) 5 - Floating Seal (Q.ty 2) 8 - Axle
3 - Elastic pin (Q.ty 2) 6 - Bushing (Q.ty 2)
E215 W3-6-17

UPPER AND LOWER ROLLER

Disassembly Lower Roller

Be sure to thoroughly read “Precautions for Disas- 2 5 7 5

sembly and Assembly” on page W1-1-1 before start-
ing the disassembly work.

1. Remove plug (1) and elastic pins (3) from collars

(2), and drain oil. 5 2

: 6 mm
: 14 mm
SM1243

2. Press down axle (8) until O-Ring (4) comes out of

collar (2). 4 2
Remove collar (2) from axle (8).

3. Remove O-Ring (4) from axle (8).

Remove axle (8) from roller (7).
8
4. Remove floating seal (5) from roller (7) and collar
(2).

5. Press out axle (8), and remove collar (2) and O-

Ring (4) from axle (8). SM1244

6. In case of replacing bushings (6), remove the

bushings using a press and the special tool.
Special Tool: (380001030).
380001030

SM1245
W3-6-18 E215

UPPER AND LOWER ROLLER

LOWER ROLLER ASSEMBLY (E215)

2 7 6 5 4 3 1

8
SM1246

1 - Plug (Q.ty 2) 4 - O-Ring (Q.ty 2) 7 - Roller

2 - Collar (Q.ty 2) 5 - Floating Seal (Q.ty 2) 8 - Axle
3 - Elastic pin (Q.ty 2) 6 - Bushing (Q.ty 2)
E215 W3-6-19

UPPER AND LOWER ROLLER

Assembly Lower Roller

8 3
1. Install bushings (6) (Q.ty 2) onto roller (7) using a
press. Take care not to dent the flange surface of
bushings. Apply a coat of grease to O-Ring (4) and
install onto axle (8).

2. Install collar (2) onto axle (8), aligning the pin holes.
Secure them using elastic pin (3). Take care not to 2 4
damage O-Ring (4). SM1247

7 5
IMPORTANT - The elastic pin has to be fitted with the
slit oriented to the internal side of the roller.

5 2

IMPORTANT - For handling of floating seal (4), refer

to the section “Precautions for floating seal handling”
on page W1-1-3. SM1248

3. Install floating seal (5) to roller (7) and to collar (2).

2 5 8 7
4. Insert axle (8) into roller (7). Install the other floating
seal (5) to roller (7) and to collar (2). Install O-Ring
(4) the other collar (2). Secure them using elastic
pin (3).

IMPORTANT - The elastic pin (3) has to be fitted with 9

the slit oriented to the internal side of the roller. SM1249

5. Add engine oil via plug (1) hole on collar (2). Apply 3 7
sealant (Loctite 503 or equivalent) to plug (1).
Tighten plug (1).
1
Engine oil quantity: 278 cm3
: 6 mm
: 9.8 to 19.6 Nm

2 SM1250
W3-6-20 E235

UPPER AND LOWER ROLLER

LOWER ROLLER DISASSEMBLY (E235)

7
1

4 3

A 2

6 1

7
A

SM1813

1 - Floating seal (Q.ty 2) 4 - O-Ring (Q.ty 2) 6A - Bushing (Q.ty 2)

2 - Shaft 5 - Spring pin (Q.ty 2) 7 - Support (Q.ty 2)
3 - Plug 6 - Lower roller assembly
E235 W3-6-21

UPPER AND LOWER ROLLER

Lower roller disassembly 3

Be sure to thoroughly read "Precautions for Disas-

5 5
sembly and Assembly" on page W-1-1-1 before start-
ing the disassembly work.

1. Remove plug (3) and drain the oil.

Draw out the pins (5).
: 5 mm SM1814

: 14 mm
7
4
2. Press shaft (2) to end of support (7) than remove 4
the support and O-Ring (4).

SM1815

3. Remove the floating seal (1) from the roller (6) and
7 1 1 6 1
support (7).
The floating seal can be reused if they are not worn.
Floating seals are to be kept in matched sets and
to put cardbord to protect the sealing face.

1 SM1816

4 7

SM1817

4. Press shaft (4) and remove support (7) and O-Ring

(4) from the axle.
Press
380001027

5. In case of changing bushings (6A), remove the

6A
bushings using press and special tools 380001027.

SM1818
W3-6-22 E235

UPPER AND LOWER ROLLER

LOWER ROLLER ASSEMBLY (E235)

2 7 3 6 1 4 5

SM1819

1 - Floating seal (Q.ty 2) 4 - O-Ring (Q.ty 2) 6A - Bushing (Q.ty 2)

2 - Shaft 5 - Spring pin (Q.ty 2) 7 - Support (Q.ty 2)
3 - Plug 6 - Lower roller assembly
E235 W3-6-23

UPPER AND LOWER ROLLER

Lower roller assembly

Before assembling:
- Clean all parts . 380001027
- Polish up scratches and roughness of the parts by 7
using oil stone
- Replace O-Ring and floating seals with new as a
rule. 6

1. Press bushing (7) into roller (6) by using press and SM1820
special tool 380001027.

2. Apply grease to O-Ring (4) and install it to shaft (2). 5

Install support (7) to shaft (2) and fix it by pin (5). 2

3. Install floating seal (1) into roller (6) and support (7).

7 4 SM1821

NOTE - Apply engine oil to matching surface of

floating seals (1).
1 1 6 1

1 7

SM1822

4. Install shaft (2) into roller (6).

5 6
5. Fix the other support (7) to roller (5).

7
SM1823

6. Supply engine oil to roller through the plug (3) hole.

3
Install pug (3).

Recommended oil:

SAE 40
Quantity: 0.4 kg

SM1824
W3-6-24 E215

UPPER AND LOWER ROLLER

MAINTENANCE STANDARD (E215)

Upper Roller

A
B SM1251

Unit: mm

Standard Allowable Limit Remedy

A 84 -

B 150 - Replace

C 140 130

Lower Roller

C A C
B
SM1252

Unit: mm

Standard Allowable Limit Remedy

A 172 181.5

B 218 - Buildup
weld and
C 23 11.5 finishing
D 150 132

IMPORTANT - Consulting FIAT KOBELCO for any inquiries concerning welding procedure.
E215 W3-6-25

UPPER AND LOWER ROLLER

Upper roller axle and Bushing

Unit: mm

Standard Allowable Limit Remedy

Axle Outside Dia. 50 49.3

Replace
Bushing Inside Dia. 50 51

Lower roller axle and Bushing

Unit: mm

Standard Allowable Limit Remedy

Axle Outside Dia. 65 64.2

Bushing Inside Dia. 65 66 Replace

Bushing Flange Thickness 2 1.2

W3-6-26 E235

UPPER AND LOWER ROLLER

MAINTENANCE STANDARD (E235)

Upper Roller

A
B
SM1825

Unit: mm

Standard Allowable Limit Remedy

A 84 -

B 153 - Replace

C 150 140

Lower Roller

C A C
B
SM1826

Unit: mm

Standard Allowable Limit Remedy

A 184 192

B 228 - Buildup
weld and
C 22 4.5 finishing
D 172 160

IMPORTANT - Consulting FIAT KOBELCO for any inquiries concerning welding procedure.
E235 W3-6-27

UPPER AND LOWER ROLLER

Axle and bushing

Unit: mm

Standard Allowable Limit Remedy

Axle Outside Dia. 75 74

Bushing Inside Dia. 75.36 76.36 Replace

Bushing Flange Thickness 4 3.2

W3-6-28 E215-E235

UPPER AND LOWER ROLLER

NOTES:
E215-E235 W3-7-1

TRACKS

REMOVAL AND INSTALLATION OF TRACKS

Removal

WARNING
Do not loosen valve (1) quickly on loosen too much
since high-pressure grease in the adjusting cylin-
der may spout out.
Loosen carefully, keeping body parts and face
away from valve (1).
Never loosen grease fitting (2).

SM1253

1. Move the tracks so that master pin (3) is positioned

over front idler (4). 5
Put a wooden block under track shoes (5), as
shown.

SM1254

2. To loosen the track tension, slowly turn valve (1) E215

counterclockwise one turn; grease will escape
from grease outlet.
: 19, 24 mm

1
2
R0022

E235

R0023
W3-7-2 E215-E235

TRACKS

WARNING
The front idler may jump out of position due to
strong spring force when the tracks is discon-
nected. Especially, the strong spring force is al-
ways applied to the bolt part of the rod. If the rod
and/or the bolt are damaged, metal fragments may
fly off when the tracks is disconnected.

SM1256

3. Remove master pin (3) by using a special tool. 3

R0076

A: 380001008
D C 3 E
B: 380001009
C: 380001013 (E215); 380001010 (E235)
D: 380001012 (E215); 380001011 (E235)
E: 380001015 (E215); 380001016 (E235)
G: 380001019
3: MASTER PIN
G B A
SM1258

4. Slowly drive the machine in reverse until the whole

length of the removing track comes on the ground.

SM1259

5. Rotate the upperstructure 90 degrees toward the

removing track side, perpendicular to the tracks.
Operate the boom and arm so that the angle
between them is 90 to 110 degrees. Lower the
90° to 110°
boom with the bucket rolled-in to jack up the ma-
chine as illustrated.

SM1260
E215-E235 W3-7-3

TRACKS

Installation

1. Jack up the machine and put the track under the

lower roller. Idler side Sprocket
Be sure to position the track in correct direction, as side
illustrated.

SM1261

2. Lift the track, and place it on sprocket (1).

SM1262

3. Slowly turn the sprocket in forward direction.

SM1263

4. Turn sprocket (1) until end of track (4) comes on

front idler (3). 3
Lower the machine and put a wooden block as
illustrated.

SM1264
W3-7-4 E215-E235

TRACKS

IMPORTANT - Hole surfaces, link holes and 5

counterbore surfaces, bushing ends, shall be free
from dust and rust.

5. Install master pin (5), using a hammer and special

tool.

R0076
A: 380001008
B: 380001009
C: 380001013 (E215); 380001010 (E235)
D: 380001012 (E215); 380001011 (E235)
E: 380001015 (E215); 380001016 (E235)
G: 380001019 D C 5 E
5: MASTER PIN

IMPORTANT - Inject rust preventive protective (ex.

TECTYL165 G) between pin and bushing clearance.
G B A
SM1258

IMPORTANT - If any links have been removed from

the track, be sure to charge the grease into the
clearance between the pin and bushing when recon-
necting the links. Also, apply a coat of grease tothe
ends of the bushing.
Grease Charging Method:
- Stand the bushing on a flat plate.
- Fill the bushing bore with the grease.
- Insert the pin into the bushing while pushing the
bushing onto the plate (so that the bushing end
stays on the plate).
- Wipe off excess grease.

6. Supply grease to the cylinder through the grease

fitting to adjust the track tension.
: 19, 24 mm
SM1265

Track sag specifications (A):

320 to 350 mm (E215)
250 to 320 mm (E235)

: 19 mm
: 59 Nm
: 24 mm
: 147 Nm

IMPORTANT - Check track sag after thoroughly

removing soil stuck on the track area by washing.
SM1234
E215-E235 W3-7-5

TRACKS

MAINTENANCE STANDARD

Link Pin and Track Bushing

• Measure the length of four links, as illustrated, with

the tension on the track.
• Do not measure the master-pin included part of the
trtack.

A
SM1266

Unit: mm
Standard Allowable Limit Remedy
E 215 E 235 E 215 E 235

A 761 760 774 778 Replace

Master Pin

E215 E235
B

A
A
R0087 SM1269

Unit: mm

Standard Allowable Limit Remedy

E 215 E 235 E 215 E 235

A 207 220 200 - Replace

B 38 39.7 36.5 37 Replace

W3-7-6 E215-E235

TRACKS

Master Bushing

B C

A
SM1267

Unit: mm

Standard Allowable Limit

Remedy
E215 E235 E215 E235

A 129.2 135 - -

+0,87
B 38 40 +0 39.5 42.8 Replace

C 58.7 60 54.1 57

Grouser Shoe

C
B

SM1268

Unit: mm

Standard Allowable Limit

Remedy
E215 E235 E215 E235

A 220 222.5 - -

B 9.5 12.5 - - Replace

C 25.5 28 15 14
SECTION 4 E215-E235

FRONT ATTACHMENT

CONTENTS

Group 1 - Front attachment Group 2 - Cylinders

Removal and Installation of
Front Attachment ................................. W4-1-1
Maintenance Standard ......................... W4-1-6
Bucket Teeth ........................................ W4-1-8
Standard Dimensions for Arm and
Bucket Connection ............................... W4-1-9
Removal and Installation of
Front Attachment
(triple articulation version) .................. W4-1-11
Maintenance Standard
(triple articulation version) .................. W4-1-16
Removal and Installation of Cylinders .. W4-2-1
Hydraulic Circuit Pressure
Release Procedure ............................. W4-2-12
Disassembly Cylinders ...................... W4-2-14
Assembly Cylinders ........................... W4-2-20
Maintenance Standard ....................... W4-2-26
Special Tools ...................................... W4-2-27
E215-E235 W4-1-1

FRONT ATTACHMENT

REMOVAL AND INSTALLATION OF FRONT ATTACHMENT

WARNING
Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries.
Prevent this dangers by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes.
Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns.
Before starting any intervention, make sure that oil and components have cooled off.
the hydraulic oil tank cap can be ejected if the residual pressure in the system is not released first.
Press the valve located on the hydraulic oil tank to bleed the residual pressure trapped inside the tank.

Preparation

1. Park the machine on firm, level ground.

Position the front attachment as illustated and
lower the bucket to the ground.

SM1317

Removal

1. Disconnect lubrication pipes (12) from both boom

12
cylinder rod ends.
: 19 mm

2. Loosen lock nuts (1), remove bolt (2) and stoppers

(3) from both boom cylinder rod ends.
Carry out the same procedure for the other boom
cylinder.
: 24 mm
SM1318

WARNING
Boom cylinder weight: 177 kg

WARNING 4
Prevent personal injury. Metal fragments may fly 2
off when a hammer is used to remove pins. Be sure
to wear necessary protection, such as goggles, 3 5
hardhat, etc.

1
3. Attach each boom cylinder to a crane.
Remove cylinder rod end pin (5) and thrust plate (4)
using a hammer and bar.
SM3502
W4-1-2 E215-E235

FRONT ATTACHMENT

IMPORTANT - Avoid boom cylinder damage. A

grease fitting is located on the boom cylinder. Be sure
to position a wooden block so that the grease fitting
does not come in contact with the wooden block when
the boom cylinder is lowered.

4. Position a wooden block between the main frame

and the boom cylinder bottom, as illustrated.
Slowly lower the boom cylinder using the crane
onto the wooden block.

5. Cut-off the engine. Press the valve located on the

hydraulic oil tank to bleed the residual pressure
inside the tank itself.
Complete the bleeding of the residual pressure
from the hydraulic system, making reference to
"Procedure for the bleeding of the pressure from
the hydraulic system" at page W4-2-12.

Wooden Block
SM1320

6. Disconnect hoses (7) and (8) of arm cylinder and

bucket cylinder.
Close all openings with plugs to keep clean.

: 36, 41 mm 7 8

SM3504

7. Remove side panel (3) and cover (1) of the tool

compartment by removing securing screws (2) 1
(Q.ty 12) with the relevant washers.

: 19 mm

R0072
E215-E235 W4-1-3

FRONT ATTACHMENT

8. Remove screws (10) and plate (9) securing pin (11)

of the boom foot of the main frame.
: 22 mm

11

10

9
R0059

WARNING
Approximate mass of the front equipment:
3450 kg

9. Sling the boom to a hoist. Lift slightly the boom

making sure that none of the slings is loose.

SM1323

10. Pull out the boom lower pivot pin (1) to the frame
using the appropriate puller (380001031).

380001031

R0060

11. Lift the front equipment. Move the machine away

from the front equipment and the hoist.

SM1325
W4-1-4 E215-E235

FRONT ATTACHMENT

Installation

WARNING
Approximate mass of the front equipment:
3450 kg

1. Install the front attachment

Install dust seals to boom foot.
Align the boom foot boss with the main frame boss. 11
Insert a thrust plate to both right and left sides of the
boom foot boss to take out clearance between the 10
boom foot boss and the main frame boss the
remaining clearance should be less than 1 mm. 9
R0059

2. Install boom foot pin (11) using a hammer and bar. 1

Install bolt (10) (Q.ty 2) and lock plate (9).
: 22 mm
: 175 Nm

3. Install side panel (3) and cover (1) of the tool 3

compartment tightening securing screws (2)
(Q.ty 12) with the relevant washers.
2
: 19 mm
: 108 Nm
R0072

4. Remove the plugs of the hoses and pipes. Connect

hoses (7) and (8) of the arm and bucket cylinders
to the pipes.
: 36 mm
: 176 Nm 7 8
: 41 mm
: 205 Nm

SM3504

WARNING
Boom cylinder weight: 177 kg

5. Attach the boom cylinder to a crane. Lift the boom

cylinder and align the boom cylinder rod with the
pin hole on the boom.

NOTE - For easy alignment, start the engine and use

the boom control lever.

SM1326
E215-E235 W4-1-5

FRONT ATTACHMENT

NOTE - Fill the hydraulic oil tank with hydraulic oil to

the specified level.
Run the engine at idle. Check hose connections for
any oil leakage.

IMPORTANT - Bleed air from hydraulic circuit.

WARNING
Prevent personal injury. Metal fragments may fly 4
off when a hammer is used to insert pins. Be sure 4
to wear necessary protection, such as goggles,
hardhat, etc. 2

3 5

6. Install thrust plate (4). Drive pin (5) into the pin
hole. 1

7. Install thrust plate (4), stopper (3), tighten bolt (2)

and lock nuts (1). SM3502

: 24 mm
: 270 Nm

8. Connect lubrication pipes (12) to each boom cyl-

12
inder rod. Tighten the connection to specification.
: 19 mm
: 29 Nm

9. Remove the pipes, with pipe fittings located in the

holes (14), from the boom foot boss.

10. Remove plug (13) and install an adeguate grease SM1318

fitting into plug (13) removed hole.

Plug tapered thread: 3/8 GAS - UNI339

11. Fill grease via grease fitting.

Remove grease fitting and re-install the plug (13)
in the original position.

12. Connect the pipes, with pipe fittings, on the boom

foot boss.

SM5521
W4-1-6 E215-E235

FRONT ATTACHMENT

MAINTENANCE STANDARD

F E
G
C
H
D J
A
I
K
B

SM1328

Unit: mm

Parts Name Standard Allowable Limit Remedy

A Pin 90 89.0
Bushing 90 91.5

B Pin 90 89.0
Boss (Main Frame) 90 91.5
Bushing (Boom Cylinder) 90 91.5

C Pin 85 84.0
Bushing (Boom Cylinder) 85 86.5
Boss (Boom) 85 86.5 Replace

D Pin 90 89.0
Bushing 90 91.5

E Pin 85 84.0
Boss (Arm) 85 86.5
Bushing (Arm Cylinder) 85 86.5

F Pin 85 84.0
Boss (Boom) 85 86.5
Bushing (Arm Cylinder) 85 86.5
E215-E235 W4-1-7

FRONT ATTACHMENT

Unit: mm

Parts Name Standard Allowable Limit Remedy

G Pin 80 79.0
Boss (Arm) 80 81.5
Bushing (Bucket Cylinder) 80 81.5

H Pin 80 79.0
Bushing 80 81.5
Bushing (Bucket Cylinder) 80 81.5 Replace

I Pin 70 69.0
Bushing 70 71.5

J Pin 80 79.0
Bushing 80 81.5

K Pin 80 79.0
Bushing 80 81.5

IMPORTANT - Be sure to install front attachment bushings using a press.

W4-1-8 E215-E235

FRONT ATTACHMENT

BUCKET TEETH

REPLACEMENT

WARNING
Keep people not involved in the maintenance work
outside the working area.
Wear adequate personal clothes and glasses with
side shields as a protection against flying debris.

• Ensure the machine is parked on a level surface.

5 1 2 3
• Rest the bucket to the ground.

• Switch off the auto-idle, fully turn the engine speed

manual control anticlockwise, stop the engine,
remove the ignition key and move the safety lever
in the locked position (LOCK).

• Using a hammer (3) and a drift (2), as shown, drive

the lock pin (1) from its seat and remove the tooth.

NOTE - Hit the lock pin (1) with the drift (2) on the pin
tapered portion to drive it out of its seat. 4
SM1329

• Clean shank (5) surface and install a new tooth (4)

onto the shank.

• Install the lock pin (1) into its seat and drive it in
using a drift (2) and a hammer (3) until it is fully
seated.
E215-E235 W4-1-9

FRONT ATTACHMENT

STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION

d
e
f c
b

j
o p
k
i n

h m
g l
q
Section A Section B

SM1330

Unit: mm

E215-E235 EX215-EX235

a (*) 419 450

b (*) 23 0

c 630 604

d 610 580

e 430 472

f 1464 ←

g 433 ←

h 326 ←

i 80 ←

j 428.7 470

k 33 43

l 433 ←

m 307 304

n 80 ←

o 20° 90°

p 3.73° 20°

q 449 ←
(*) Arm: 2940 mm
W4-1-10 E215-E235

FRONT ATTACHMENT

NOTES:
E215-E235 W4-1-11

FRONT ATTACHMENT

REMOVAL AND INSTALLATION OF FRONT ATTACHMENT

(triple articulation version)

WARNING
Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries.
Prevent this dangers by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes.
Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns.
Before starting any intervention, make sure that oil and components have cooled off.
the hydraulic oil tank cap can be ejected if the residual pressure in the system is not released first.
Press the valve located on the hydraulic oil tank to bleed the residual pressure trapped inside the tank.

Preparation

1. Park the machine on firm, level ground.

Position the front attachment as illustated and
lower the bucket to the ground.

SM1357

Removal

1. Disconnect lubrication pipes (12) from both boom

cylinder rod ends. 12
: 19 mm

2. Loosen lock nuts (1), remove bolt (2) and stoppers

(3) from both boom cylinder rod ends.
Carry out the same procedure for the other boom
cylinder.
: 24 mm
SM1318

WARNING
Boom cylinder weight: 177 kg 4
4
2
WARNING
Prevent personal injury. Metal fragments may fly 3 5
off when a hammer is used to remove pins. Be sure
to wear necessary protection, such as goggles,
hardhat, etc. 1

3. Attach each boom cylinder to a crane.

Remove cylinder rod end pin (5) and thrust plate (4)
using a hammer and bar. SM3502
W4-1-12 E215-E235

FRONT ATTACHMENT

IMPORTANT - Avoid boom cylinder damage. A

grease fitting is located on the boom cylinder. Be sure
to position a wooden block so that the grease fitting
does not come in contact with the wooden block when
the boom cylinder is lowered.

4. Position a wooden block between the main frame

and the boom cylinder bottom, as illustrated.
Slowly lower the boom cylinder using the crane
onto the wooden block.

Wooden block
SM1320

5. Cut-off the engine. Press the valve located on the

hydraulic oil tank to bleed the residual pressure
inside the tank itself.
Complete the bleeding of the residual pressure
from the hydraulic system, making reference to
"Procedure for the bleeding of the pressure from
the hydraulic system" at page W4-2-12. 7

6. Disconnect pipes (7), (8), (31) and (32) from the

bucket cylinder, the arm cylinder and the postioner
arm cylinder.
Plug all the tips of the pipes to prevent the entry of
dirt into the system.
: 22, 30, 36, 41 mm

32 8 31
R0061

7. Remove side panel (3) and cover (1) of the tool

1
compartment by removing securing screws (2)
(Q.ty 12) with the relevant washers.
: 19 mm

R0072
E215-E235 W4-1-13

FRONT ATTACHMENT

8. Remove screws (10) and plate (9) securing pin (11)

of the boom foot of the main frame.
: 22 mm

11

WARNING 10
Front assembly weight: 4200 kg
9
R0059

WARNING
Avoid wire rope damage. Be sure to position a
necessary protection between the wire rope and
boom pin hole surfaces.

9. Attach the boom to a crane.

Using the boom pin hole for front attachment sling.

WARNING
To secure the top arm with an other crane, when
remove the front attachment.
380001031

10. Slighty hoist the boom to take out any wire rope 1
slack.

R0060

11. Pull out the boom lower pivot pin (1) to the frame
using the appropriate puller (380001031).

12. Lift the front attachment. Drive the base machine

away from the front attachment and the crane.

SM1325
W4-1-14 E215-E235

FRONT ATTACHMENT

Installation

WARNING
Approximate mass of the front equipment
assembly: 4200 kg

WARNING
11
To secure the top arm with an other crane, when
remove the front attachment.
10
9
R0059

1. Install the front attachment.

Install dust seals to boom foot.
Align the boom foot boss with the main frame boss. 1
Insert a thrust plate to both right and left sides of the
boom foot boss to take out clearance between the
boom foot boss and the main frame boss the
remaining clearance should be less than 1 mm.

3
2. Install boom foot pin (11) using a hammer and bar.
Install bolt (9) (2 used) and lock plate (10).
2
: 22 mm
: 175 Nm

R0072

3. Install side panel (3) and cover (1) of the tool

compartment tightening securing screws (2) (Q.ty
12) with the relevant washers.
: 19 mm
: 108 Nm

7
4. Remove the plugs of the hoses and pipes. Connect
hoses (7), (8), (31) and (32) of the arm, positioner
arm and bucket cylinders.
: 22 mm : 36 mm
: 39 Nm : 176 Nm
: 30 mm : 41 mm
: 137 Nm : 205 Nm

WARNING
Mass of the boom cylinder: 177 kg

32 8 31
R0061
E215-E235 W4-1-15

FRONT ATTACHMENT

5. Tie the boom cylinder to a lifting hoist. Raise the

boom cylinder and align the rod hole on the pin hole
on the boom.

NOTE - To easy the alignement, start engine and

operate on the boom pilot valve.

NOTE - Fill the hydraulic oil tank with hydraulic oil to

the specified level.
Run the engine at idle. Check hose connections for
any oil leakage. SM1326

IMPORTANT - Bleed air from hydraulic circuit.

4
WARNING 4
Prevent personal injury. Metal fragments may fly 2
off when a hammer is used to insert pins. Be sure
to wear necessary protection, such as goggles, 5
3
hardhat, etc.

1
6. Install thrust plate (4). Drive pin (5) into the pin hole.

7. Install thrust plate (4), stopper (3), tighten bolt (2)

and lock nuts (1).
SM3502
: 24 mm
: 270 Nm

8. Connect lubrication pipes (12) to each boom cyl- 12

inder rod. Tighten the connection to specification.
: 19 mm
: 29 Nm

9. Remove the pipes, with pipe fittings located in the

holes (14), from the boom foot boss.

10. Remove plug (13) and install an adeguate grease SM1318

fitting into plug (13) removed hole.
Plug tapered thread: 3/8 GAS - UNI339

11. Fill grease via grease fitting.

Remove grease fitting and re-install the plug (13)
in the original position.

12. Connect the pipes, with pipe fittings, on the boom

foot boss.

SM5521
W4-1-16 E215-E235

FRONT ATTACHMENT

MAINTENANCE STANDARD
(triple articulation version)

L
E
M
D G
F C

A
N

H
B

I J

SM1357

Unit: mm

Parts Name Standard Allowable Limit Remedy

A Pin 90 89.0
Bushing 90 91.5

B Pin 90 89.0
Boss (Main Frame) 90 91.5
Bushing (Boom Cylinder) 90 91.5

C Pin 85 84.0
Bushing (Boom Cylinder) 85 86.5
Boss (Boom) 85 86.5 Replace

D Pin 90 89.0
Bushing 90 91.5

E Pin 90 89.0
Boss (Positioning arm) 90 91.5
Bushing (Positioning Cylinder) 90 91.5

F Pin 90 89.0
Boss (Boom) 90 91.5
Bushing (Positioning Cylinder) 90 91.5
E215-E235 W4-1-17

FRONT ATTACHMENT

Unit: mm

Parts Name Standard Allowable Limit Remedy

G Pin 80 79.0
Boss (Arm) 80 81.5
Bushing (Bucket Cylinder) 80 81.5

H Pin 80 79.0
Bushing 80 81.5
Bushing (Bucket Cylinder) 80 81.5

I Pin 70 69.0
Bushing 70 71.5

J Pin 80 79.0
Bushing 80 81.5
Replace
K Pin 80 79.0
Bushing 80 81.5

L Pin 85 84.0
Boss (Positioning Arm) 85 86.5
Bushing (Arm Cylinder) 85 86.5

M Pin 85 84.0
Boss (Arm) 85 86.5
Bushing (Arm Cylinder) 85 86.5

N Pin 90 89.0
Bushing 90 91.5

IMPORTANT - Be sure to Install front attachment bushings using a press.

W4-1-18 E215-E235

FRONT ATTACHMENT

NOTES:
E215-E235 W4-2-1

CYLINDERS

REMOVAL AND INSTALLATION OF CYLINDERS

WARNING
Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries.
Prevent this dangers by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes.
Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns.
Before starting any intervention, make sure that oil and components have cooled off.
the hydraulic oil tank cap can be ejected if the residual pressure in the system is not released first.
Press the valve located on the hydraulic oil tank to bleed the residual pressure trapped inside the tank.

Preparation

1. Park the machine on firm, level ground.

Position the front attachment as illustrated and
lower the bucket to the ground.

2. Press the valve located on the hydraulic oil tank to

bleed the residual pressure inside the tank itself.
SM1317

Removal of Bucket Cylinder

1. Insert wooden block (15) between bucket cylinder

(1) and arm (8).
1

2. Completely release the residual pressure from the

hydraulic circuit by performing the “Hydraulic Cir-
cuit Pressure Release Procedure”. Refer to page
W4-2-12.
15

IMPORTANT - Pin (6) end of the link will drop when 8

pin is removed, possibly resulting in personal injury. 15
Be sure to secure the link using a piece of wire before
removing pin (6). SM1331

3. Loosen nuts (4) and bolt (5), in that order.

16
Pull out pin (6). Then, remove thrust plates (16).
5

: 24 mm

6 SM3506
W4-2-2 E215-E235

CYLINDERS

4. Use wire (14) to secure cylinder rod (13) as illus-

trated. 13 1

5. Disconnected hoses (9) (Q.ty 2) from bucket

cylinder (1).
Put plugs on cylinder pipes and hoses.
: 8 mm
: 36 mm

14
SM1333

WARNING
Bucket cylinder weight: 17
153 kg
10
12

6. Use a hoist to lift slightly bucket cylinder (1).

Loosen locking nuts (11) remove screw (12) and
pull-out pin (10) with the help of a mallet and a bar
so that the end of the cylinder is free. Recover 11
adjusting shims (17).
: 24 mm
1

7. Remove bucket cylinder (1). 9

9
R0063
E215-E235 W4-2-3

CYLINDERS

Installation of Bucket Cylinder

WARNING
Bucket cylinder weight: 17
153 kg
10
12
1. Connect bucket cylinder (1) to a crane using a sling
belt.
Align the hole on the bucket cylinder tube with the
pin hole on the arm-tip bracket.
11
2. Install adjusting shims (17) and insert pin (10),
install screw (12) and tighten lock-nuts (11).
1
: 24 mm
: 270 Nm
9
3. Connect two hoses (9) to bucket cylinder (1). 9
R0063
: 8 mm
: 64 Nm
: 36 mm
: 175 Nm

NOTE - Fill the hydraulic oil tank with hydraulic oil to

the specified level.
Run the engine at idle. Check hose connections for
any oil leakage.

4. Align the bucket cylinder rod with bucket links (2),

(3). 2 5 18 16
Install thrust plates (16) and pin (6).

NOTE - For easy alignment, start the engine and use

the arm control lever.

5. Install bolt (5), onto pin (6) and stopper (18); tighten
lock nuts (4).
: 24 mm
6 3 4
: 270 Nm
SM3506

IMPORTANT - If link (3) has been disconnected from

the arm, be sure to insert thrust plate (16) when
connecting it. Bleed air from hydraulic circuit.
W4-2-4 E215-E235

CYLINDERS

Removal of Arm Cylinder

1
1. Insert a wooden block between arm cylinder (1)
and boom (12).

2. Cut-off the engine. Press the valve located on the

hydraulic oil tank to bleed the residual pressure
inside the tank itself.
Complete the bleeding of the residual pressure
from the hydraulic system, making reference to
"Procedure for the bleeding of the pressure from
the hydraulic system" at page W4-2-12. 12 SM1347

3. Loosen lock-nuts (10) and remove screw (11).

13
: 24 mm
11
9

2 1
4. Remove pin (9) and thrust plate (13).

10
R0064

5. Use wire to secure cylinder rod (2) as illustrated.

SM1337

6. Disconnect arm cylinder hoses (7), (16).

Put plugs on the pipe on arm cylinder (1) and
1
hoses.
: 36 mm 8
7

7. Disconnect Iubricant supply pipe (8).

: 19 mm

16
R0065
E215-E235 W4-2-5

CYLINDERS

WARNING 1
Arm cylinder weight:
251 kg

8. Use a crane to slightly hoist arm cylinder (1).

SM1335

9. Loosen lock nuts (4). Remove bolt (5) and pin (3).
Then remove thrust plate (15) from arm cylinder 1 5 15
(1). 3
: 30 mm

R0066
W4-2-6 E215-E235

CYLINDERS

Installation of Arm Cylinder

WARNING
Arm cylinder weight:
251 kg

1. Use a crane to install arm cylinder (1) to the boom

bracket.

2. Install adjusting shims (15), pin (3), install screw (5)

into pin (3) and tighten lock-nuts (4). 1 5 15 3
: 24 mm
: 270 Nm 8

7
3. Attach lubricant supply pipe (8) and arm cylinder
hoses (7) and (16).
: 19 mm 4
: 29 Nm
: 36 mm
16
: 175 Nm
R0067

NOTE - Fill hydraulic oil tank with hydraulic oil to the

specified level.
Run the engine at idle. Check hose connections for
any oil leakage. 6

4. Remove wire (6) from arm cylinder (1). 2

Slightly hoist arm cylinder (1) and align the arm
cylinder rod with arm.

NOTE - For easy alignment, start the engine and use SM1337
the arm control lever.

5. Install adjusting shims (13), pin (9), install screw 13

(11) into pin (9) and tighten lock-nuts (10).
11
9

: 24 mm
2
: 270 Nm 1

IMPORTANT - Bleed air from hydraulic circuit.

10 R0064
E215-E235 W4-2-7

CYLINDERS

Removal of Boom Cylinder

1. Park the machine on firm, level surface and lower

the bucket teeth and arm top to the ground with the
arm and bucket cylinders fully retracted as illu-
strated.

2. Disconnect lubricant supply pipes (1).

SM1317

: 19 mm

1
WARNING
Boom cylinder weight:
177 kg

3. Use a crane to hoist the boom cylinder. 3

4. Loosen lock nuts (2), remove bolt (3) and stopper

(4).
Using bar and hammer, tap pin (5) until the boom
cylinder is free. Remove thrust plate (6).
: 24 mm 4

5. Use a wire to secure the boom cylinder rod as 2

illustrated. 6 5
SM3511
Lower cylinder on proper stand.

6. Cut-off the engine. Press the valve located on the

hydraulic oil tank to bleed the residual pressure
inside the tank itself.
Complete the bleeding of the residual pressure
from the hydraulic system, making reference to
"Procedure for the bleeding of the pressure from
the hydraulic system" at page W4-2-12.

7. Disconnect boom cylinder hoses (11) (Q.ty 4). Put

plugs on cylinder pipes.
: 30, 36 mm
SM1342
8. Remove securing screws (8) complete with wash-
ers, then remove pin (9) and recover adjusting
shims (10).
: 30 mm

WARNING
Boom cylinder weight: 11 11
177 kg
9 9

9. Hoist the boom cylinder with a crane.

Remove the other boom cylinder following the
same procedures.

10 10
8 8
R0068
W4-2-8 E215-E235

CYLINDERS

Installation of Boom Cylinder

WARNING
Boom cylinder weight:
177 kg

1. Use a crane to install the boom cylinders to the

main frame.

2. Install adjusting shims (10) and pin (9), then tighten SM1342

securing screws (8) complete with washers.

: 30 mm
: 540 Nm

3. Install the other side boom cylinder.

4. Connect the boom cylinder hoses (11) (Q.ty 4).

: 30 mm : 36 mm 11 11
: 137 Nm : 176 Nm 9 9

NOTE - Fill the hydraulic oil tank with hydraulic oil to

the specified level.
Run the engine at idle. Check hose connections for
any oil leakage. 10 10
8 8
R0068
5. Hoist the boom cylinder, and align the rod side with
the boom.

NOTE - For easy alignment, start the engine and use

the boom control lever. 3

WARNING
Prevent personal injury. Metal fragments may fly
off when a hammer is used to insert pins. Be sure
to wear necessary protection, such as goggles,
hardhat, etc. 4
2
6 5 6
6. Install pin (5) using a bar and hammer, then install SM3511
thrust plates (6).

7. Install bolt (4), stopper (3), and lock nuts (2).

Tighten lock nuts (2).
1
: 24 mm
: 270 Nm

8. Install lubricant supply pipes (1).

: 19 mm
: 29 Nm

9. Install other boom cylinder following the same

procedure.

IMPORTANT - Bleed air from hydraulic circuit. SM1346

E215-E235 W4-2-9

CYLINDERS

Removal - installation of positioning cylinder

(triple articulation version)

PREPARATION

1. Park the machine on firm, level ground.

Position the front attachment as illustrated and
lower the bucket to the ground.

2. Press the valve located on the hydraulic oil tank to

bleed the residual pressure inside the tank itself. SM1357

REMOVAL 5 6

1. Insert a wooden block between positioning cylinder

and boom.

2. Completely release the residual pressure from the

hydraulic circuit by performing the “Hydraulic Cir-
cuit Pressure Release Procedure”. Refer to page
W4-2-12.

4
R0069
3. Disconnect the lubrication pipe of the positioner
arm cylinder (rod side) from pin (6).
: 19 mm

14
4. Loosen lock-nut (4) and the relevant nut, then pull-
out screw (5) from the spacer.
13
Push-out pin (6) using a mallet and a punch, then
remove any adjusting shim.
: 30 mm
SM1337

5. Use wire (14) to secure cylinder rod (13) as illus-

trated.

6. Disconnect hoses (9) from the positioner arm cyl- 9

inder.
Install plugs to the steel pipes of the cylinder.
: 30 mm
A
7. Disconnect lubrication pipe (A) from positioning
cylinder (bottom side).
: 19 mm

R0070
W4-2-10 E215-E235

CYLINDERS

WARNING 1
Positioning arm cylinder weight:
251 kg

8. Use a hoist to lift slightly positioning arm cylinder (1).

Loosen lock-nut (11) and the relevant nut, then
remove screw (12) and pin (10).
Remove any adjusting shim.
SM1361

9. Remove positioning arm cylinder (1).

12
1 10

11
R0071
E215-E235 W4-2-11

CYLINDERS

INSTALLATION 12
1 10
WARNING
Positioning arm cylinder weight:
251 kg

1. Connect positioning arm cylinder (1) to a crane

using a sling belt.
Align the hole on the positioning cylinder tube with
the pin hole on the boom-tip bracket. 11
R0071
2. Install any adjusting shim, (if removed previously)
and insert pin (10), then install screw (12) into pin
(10). Secure pin (10) using a nut and lock-nut (11).
: 30 mm
: 540 Nm 9

3. Connect lubrication pipe (A) to positioning cylinder

(bottom side).
: 19 mm A
: 29 Nm

4. Connect two hoses (9) to positioning cylinder (1).

: 30 mm
: 137 Nm

NOTE - Fill the hydraulic oil tank with hydraulic oil to

the specified level. Run the engine at idle. Check hose
connections for any oil leakage.
R0070

5. Remove wire (14) from positioning cylinder (13).

6. Align the hole of the positioner arm cylinder with the 14

holes on the positioner arm. Install any adjusting
shim, (if removed previously) and insert pin (6). 13

NOTE - For easy alignment, start the engine and use

SM1337
the positioner control lever.
5 6
7. Install screw (5), nut and lock-nut (4) on pin (6).
: 30 mm
: 540 Nm

8. Connect the lubrication pipe of the positioner arm

(rod side) on pin (6).
: 19 mm
: 29 Nm

NOTE - Bleed air from hydraulic circuit.

4 R0280
W4-2-12 E215-E235

CYLINDERS

HYDRAULIC CIRCUIT PRESSURE

RELEASE PROCEDURE

The procedure for the bleeding of the pressure inside

the hydraulic system can be performed in two man-
ners: 2

- pressure bleeding with engine in operation;

- pressure bleeding with engine inoperative.
1
In the version of the machine with triple articulation,
anti-drop valve (1) is installed, trapping residual pres-
sure between the latter and the positioner cylinder. R0073

Thus, it is necessary to bleed such a pressure loosen-

ing slowly screw (2).
: 19 mm

Bleeding the pressure with engine in operation

1. The switch, located behind the operator's seat, PR

provides the bleeding of the pressure inside the
hydraulic system of the machine.

Note - The pressure bleeding operation must be

performed with engine in operation.

2. To bleed the pressure in the hydraulic system,

press the switch and actuate the pilot valves so that
any residual pressure is discharged.
R0074

Bleeding the pressure with engine inoperative

WARNING
Be sure to slowly loosen the overload relief valves.
Quick loosening of the overload relief valves may
cause pressurized oil to spout, possibly resulting in
severe burns and/or oil penetration of skin.

Release the residual circuit pressure by slowly loos-

ening the overload relief valve(s) for the line(s) or
hose(s) to be disconnected.
: 22 mm

IMPORTANT - Be sure to loosen the valve body, not

the adjusting screw. Also, be sure to re-tighten the
overload relief valve after releasing the residual circuit
pressure.
E215-E235 W4-2-13

CYLINDERS

6 1

5 2

8
4
R0075

1- Boom cylinder (bottom side) 5- Bucket cylinder (bottom side)

2- Boom cylinder (rod side) 6- Bucket cylinder (rod side)
3- Arm cylinder (bottom side) 7- Positioning arm cylinder (rod side)
4- Arm cylinder (rod side) 8- Positioning arm cylinder (bottom side)
W4-2-14 E215-E235

CYLINDERS

DISASSEMBLY CYLINDERS

Boom Cylinder

11 1 2 3 4 7 5 6 9 10

8
20 15 16 21 23 22
12

14 13 19 16 17 18 20 19 24
R0079

Bucket Cylinder

11 1 2 3 4 7 5 6 9 10

8
20 15 16 20 21 22
12

13 19 16 17 18 19 24 23
R0080

1 - Wiper Ring 10 - O-Ring 19 - Slide Ring (Q.ty 2)

2 - Backup Ring 11 - Cylinder Rod 20 - Slide Ring (Q.ty 2)
3 - Seal 12 - Cylinder Tube 21 - Shim
4 - Seal 13 - Cushion Bearing 22 - Set Screw
5 - Bushing 14 - Cushion Seal 23 - Steel Ball
6 - Snap Ring 15 - Piston 24 - Nut
7 - Cylinder Head 16 - Backup Ring (Q.ty 2)
8 - Socket Bolt (Q.ty 12) 17 - Seal Ring
9 - Backup Ring 18 - O-Ring
E215-E235 W4-2-15

CYLINDERS

Disassembly of Boom and Bucket Cylinders 5. Remove set screw (22) and steel ball (23).

Be sure to thoroughly read all the precautions for

NOTE - Cut away its mushroomed portion using a drill
disassembly/assembly work on page W1-1-1 before
first, as set screw was mushroomed with a punch and
starting the disassembly procedure.
hammer at two places after it had been screwed in.
The disassembly procedure below starts on the
premise that the hydraulic lines and the line securing : 10 mm
bands have been removed.

6. Loosen nut (24) using special tool (380001025).

Remove piston (15), shim (21) cushion bearing
WARNING (13).
Boom cylinder: 177 kg For the boom cylinder, also remove and cushion
Bucket cylinder: 153 kg seal (14).

Socket to loosen nut (24):

1. Lift and securely place the cylinder on a workbench - Boom cylinder. 95 mm (380001007)
using a crane. Be sure that the cylinder is placed - Bucket cylinder. 90 mm (380001024)
horizontally. Drain hydraulic oil from the cylinder.

SM1366

SM1364 7. Remove seal ring (17), slide rings (19), (20), O-ring
(18) and backup rings (16) from piston (15).

2. Fully extend cylinder rod (11). Secure the rod end

using a crane. Remove socket bolts (8) from cylin-
der head (7).
: 14 mm
IMPORTANT - Be sure to pull cylinder rod (11)
straight so as not to damage the sliding surfaces.
8. Remove cylinder head (7) from cylinder rod (11).
9. Remove O-Rings (10), backup rings (9) and (2)
from cylinder head (7). Then remove wiper ring (1),
U-ring (3), buffer ring (4), snap ring (6), and bushing
(5).

3. Pull out cylinder head (7) from cylinder tube (12) by

tapping with a plastic hammer.

4. Secure cylinder rod (11) on special tool

(380001025). Put matching marks between cylinder
rod (11) and nut (24).

380001025

SM1365
W4-2-16 E215-E235

CYLINDERS

Arm Cylinder

11 1 2 3 4 7 5 6 9 10

20 15 16 25 26 28 24 22 12

14 13 19 16 17 18 20 19 27 21 23 R0081

1 - Wiper Ring 11 - Cylinder Rod 21 - Shim

2 - Backup Ring 12 - Cylinder Tube 22 - Set Screw
3 - Seal 13 - Cushion Bearing 23 - Steel Ball
4 - Seal 14 - Cushion Seal 24 - Nut
5 - Bushing 15 - Piston 25 - Snap Ring
6 - Snap Ring 16 - Backup Ring (Q.ty 2) 26 - Cushion Seal
7 - Cylinder Head 17 - Seal Ring 27 - Cushion Bearing
8 - Socket Bolt (Q.ty 12) 18 - O -Ring 28 - Stopper (Q.ty 2)
9 - Backup Ring 19 - Slide Ring (Q.ty 2)
10 - O-Ring 20 - Slide Ring (Q.ty 2)
E215-E235 W4-2-17

CYLINDERS

Disassembly of Arm Cylinder 5. Remove set screw (22) and steel ball (23).

Be sure to thoroughly read all the precautions for

disassembly/assembly work on page W1-1-1 before
NOTE - Cut away its mushroomed portion using a drill
starting the disassembly procedure.
first, as set screw was mushroomed with a punch and
hammer at two places after it had been screwed in.
The disassembly procedure below starts on the
premise that the hydraulic lines and the line securing
bands have been removed.
: 10 mm

WARNING
Arm cylinder weight: 251 kg
6. Loosen nut (24) using special tool (380001025).
Remove piston (15), shim (21) cushion bearing
(13) and cushion seal (14).
1. Place the cylinder horizontally on a workbench
using a crane and secure it. Nut (24) Turning Special Tool:
Drain hydraulic oil from the cylinder. - (Arm): 100 mm (380001022)

SM1366
SM1364

7. Remove seal ring (17) and slide ring (19), (20), O-

2. Fully extend cylinder rod (11). Secure the rod end ring (18) and backup ring (16) from piston (15).
using a crane. Remove socket bolts (8) from cylin-
der head (7).
8. Remove cylinder head (7) from cylinder rod (11).
: 14 mm

9. Remove O-Rings (10), backup rings (9) and (2)

IMPORTANT - Be sure to pull cylinder rod (11) from cylinder head (7). Then remove wiper ring (1),
straight so as not to damage the sliding surfaces. U-ring (3), buffer ring (4), snap ring (6), and bushing
(5).

10. Remove stopper (28) from cylinder rod (11) using

3. Pull out cylinder head (7) from cylinder tube (12) by
a screw driver. Remove cushion bearing (27),
tapping with a plastic hammer.
cushion seal (26), and snap ring (25).

4. Secure cylinder rod (11) on special tool

(380001025). Put matching marks between cylinder
rod (11) and nut (24).

380001025

SM1365
W4-2-18 E215-E235

CYLINDERS

Positioning Cylinder (triple articulation version)

11 1 2 3 4 7 5 6 9 10

8
20 15 16 21 23 22
12

19 16 17 18 20 19 24
R0082

1 - Wiper Ring 9 - Backup Ring 19 - Slide Ring (Q.ty 2)

2 - Backup Ring 10 - O-Ring 20 - Slide Ring (Q.ty 2)
3 - Seal 11 - Cylinder Rod 21 - Shim
4 - Seal 12 - Cylinder Tube 22 - Set Screw
5 - Bushing 15 - Piston 23 - Steel Ball
6 - Snap Ring 16 - Backup Ring (Q.ty 2) 24 - Nut
7 - Cylinder Head 17 - Seal Ring
8 - Socket Bolt (Q.ty 12) 18 - O-Ring
E215-E235 W4-2-19

CYLINDERS

Disassembly of Positioning Cylinder 5. Remove set screw (22) and steel ball (23).

Be sure to thoroughly read all the precautions for

disassembly/assembly work on page W1-1-1 before
NOTE - Cut away its mushroomed portion using a drill
starting the disassembly procedure.
first, as set screw was mushroomed with a punch and
hammer at two places after it had been screwed in.
The disassembly procedure below starts on the
premise that the hydraulic lines and the line securing
bands have been removed.
: 12 mm

WARNING
Positioning cylinder weight: 251 kg
6. Loosen nut (24) using special tool (380001025).
Remove piston (15), shim (21) cushion bearing
(13) and cushion seal (14).
1. Place the cylinder horizontally on a workbench
using a crane and secure it. Nut (24) Turning Special Tool:
Drain hydraulic oil from the cylinder. - (Positioning): 110 mm (380001018)

SM1366
SM1364

2. Fully extend cylinder rod (11). Secure the rod end 7. Remove seal ring (17) and slide ring (19), (20), O-
using a crane. Remove socket bolts (8) from cylin- ring (18) and backup ring (16) from piston (15).
der head (7).
: 17 mm 8. Remove cylinder head (7) from cylinder rod (11).

IMPORTANT - Be sure to pull cylinder rod (11) 9. Remove O-Rings (10), backup rings (9) and (2)
straight so as not to damage the sliding surfaces. from cylinder head (7). Then remove wiper ring (1),
U-Ring (3), buffer ring (4), snap ring (6), and
bushing (5).

3. Pull out cylinder head (7) from cylinder tube (12) by

tapping with a plastic hammer.

4. Secure cylinder rod (11) on special tool

(380001025). Put matching marks between cylinder
rod (11) and nut (24).

380001025

SM1365
W4-2-20 E215-E235

CYLINDERS

ASSEMBLY CYLINDERS

Boom Cylinder

Notch side toward

the piston

18 23
1 2 3 4 56 7 8 9-10 11 12 13 14 1516 17 19 20 21 22 24

Be sure that oil groove faces

the correct direction when
assembling
R0083

Bucket Cylinder

Notch side toward

the piston

18 23
1 2 3 4 5 6 7 8 9-10 11 12 13 14 15 16 17 19 20 21 22 24

Be sure that oil groove faces

the correct direction when
assembling
R0084

1 - Wiper Ring 10 - O-Ring 19 - Slide Ring (Q.ty 2)

2 - Backup Ring 11 - Cylinder Rod 20 - Slide Ring (Q.ty 2)
3 - Seal 12 - Cylinder Tube 21 - Shim
4 - Seal 13 - Cushion Bearing 22 - Set Screw
5 - Bushing 14 - Cushion Seal 23 - Steel Ball
6 - Snap Ring 15 - Piston 24 - Nut
7 - Cylinder Head 16 - Backup Ring (Q.ty 2)
8 - Socket Bolt (Q.ty 12) 17 - Seal Ring
9 - Backup Ring 18 - O-Ring
E215-E235 W4-2-21

CYLINDERS
7. Install cushion bearing (13) to cylinder rod (11).
Assembly of Bucket and Boom Cylinder Install piston (15) to cylinder rod (11).
(For boom cylinder only, install cushion seal (14).
1. Install bushing (5) to cylinder head (7) using a
press.
Special tools for bushing installation (5): 8. Install shim (21) to cylinder rod (11). Tighten nut
- (Boom): Ø 85 mm (380001036) (24) using special tool (380001025).
- (Bucket): Ø 80 mm (380001094)

IMPORTANT - Be sure that the rings are installed 380001025

correctly.

2. Install seal (3), back-up ring (2), elastic ring (6) and
seal (4) on the cylinder front sleeve (7).
SM1365

3. Install wiper ring (1) to cylinder head (7) using a

plastic hammer.
Be sure to align the machine mark on the rod with
Special tools:
that on the nut.
- (Boom): (380001033)
Nut (24) Turning Special Tools:
- (Bucket): (380001039)
- (Boom): 95 mm (380001007)
- (Bucket): 90 mm (380001024)
4. Install O-Rings (10) and backup ring (9) to cylinder : 5470 Nm (Boom)
head (7). : 7280 Nm (Bucket)

5. Install O-Ring (18), backup ring (16) (Q.ty 2), seal 9. Align the holes on cylinder rod (11) and nut (24).
ring (17), slide ring (19) (Q.ty 2), (20) (Q.ty 2) to Insert steel ball (23) into the hole, and tighten set
piston (15). screw (22) into the hole.
Special tools for seals assembly: Mushroom the head of set screw (22) at two places
- (Boom): (380001041) using a punch and hammer.
- (Bucket): (380001035)
: 10 mm
: 56.9 ± 10.7 Nm

IMPORTANT - Be sure to align cylinder rod (11) with

the center of cylinder tube (12) when inserting, in order
to avoid damaging the rings.

10. Secure cylinder tube (12) horizontally using a work

15 bench. Insert cylinder rod (11) into cylinder tube
(12).
SM1367
11. Install cylinder head (7) to cylinder tube (12).
Tighten socket bolts (8).
6. Install cylinder head (7) to cylinder rod (11).
Special tools: : 14 mm
- (Boom): (380001049)
- (Bucket): (380001050) : 267 Nm

IMPORTANT - Be sure that the cushion seal slit faces

toward the piston and that the cushion bearing oil
groove faces the correct direction.
W4-2-22 E215-E235

CYLINDERS

Arm Cylinder

Notch side toward

the piston

18 23
1 2 3 4 5 6 7 8 9-10 11 12 13 14 15 16 17 19 20 21 22 24 25 26
27
28

Be sure that oil groove faces

the correct direction when
assembling
R0085

1 - Wiper Ring 11 - Cylinder Rod 21 - Shim

2 - Backup Ring 12 - Cylinder Tube 22 - Set Screw
3 - Seal 13 - Cushion Bearing 23 - Steel Ball
4 - Seal 14 - Cushion Seal 24 - Nut
5 - Bushing 15 - Piston 25 - Snap Ring
6 - Snap Ring 16 - Backup Ring (Q.ty 2) 26 - Cushion Seal
7 - Cylinder Head 17 - Seal Ring 27 - Cushion Bearing
8 - Socket Bolt (Q.ty 12) 18 - O-Ring 28 - Stopper
9 - Backup Ring 19 - Slide Ring (Q.ty 2)
10 - O-Ring 20 - Slide Ring (Q.ty 2)
E215-E235 W4-2-23

CYLINDERS

Assembly of Arm Cylinder 8. Install shim (21) to cylinder rod (11). Tighten nut
(24) using special tool (380001025).
1. Install bushing (5) to cylinder head (7) using a
press.
Special tools for bushing installation (5):
380001025
(380001042)

IMPORTANT - Be sure that the rings are installed

correctly.
SM1365

2. Install seal (3), back-up ring (2), elastic ring (6) and Be sure to align the machine mark on the rod with
seal (4) on the cylinder front sleeve (7). that on the nut.
Nut Turning Special Tools (24):
- 100 mm (380001022)
3. Install wiper ring (1) to cylinder head (7) using a
plastic hammer. : 10280 Nm
Special tools for wiper ring installation: (380001032)

9. Align the holes on cylinder rod (11) and nut (24).

4. Install O-Rings (10) and backup ring (9) to cylinder Insert steel ball (23) into the hole, and tighten set
head (7). screw (22) into the hole.
Mushroom the head of set screw (22) at two places
using a punch and hammer.
5. Install O-Ring (18) backup ring (16) (Q.ty 2), seal : 10 mm
ring (17), slide ring (19) (Q.ty 2), (20) (Q.ty 2), to
piston (15). : 56.9 ± 10.7 Nm
Special tool for seals assembly: (380001038)

IMPORTANT - Be sure that the cushion seal slit faces

toward the piston and that the cushion bearing oil
groove faces the correct direction.

10. Install snap ring (25) and cushion seal (26) to

cylinder rod (11). Install cushion bearing (27) and
stopper (28) to cylinder rod (11).

15

IMPORTANT - Be sure to keep cylinder rod (11)

SM1367
aligned with the center of cylinder tube (12) when
inserting, in order to avoid damaging the rings.
6. Install cylinder head (7) to cylinder rod (11).
Special tools for cylinder head installation:
(380001034) 11. Secure cylinder tube (12) horizontally using a
vise. Insert cylinder rod (11) into cylinder tube
(12).
IMPORTANT - Be sure that the cushion seal slit faces
toward the piston and that the cushion bearing oil
12. Install cylinder head (7) to cylinder tube (12).
groove faces the correct direction.
Tighten socket bolts (8).
: 14 mm
7. Install cushion seal (14) to cylinder rod (11). Install : 367 Nm
cushion bearing (13) and piston (15) to cylinder rod
(11).
W4-2-24 E215-E235

CYLINDERS

Positioning Cylinder (triple articulation version)

18 23
1 2 3 4 5 6 7 8 9-10 11 12 15 16 17 19 20 21 22 24

R0086

1 - Wiper Ring 9 - Backup Ring 19 - Slide Ring (Q.ty 2)

2 - Backup Ring 10 - O-Ring 20 - Slide Ring (Q.ty 2)
3 - Seal 11 - Cylinder Rod 21 - Shim
4 - Seal 12 - Cylinder Tube 22 - Set Screw
5 - Bushing 15 - Piston 23 - Steel Ball
6 - Snap Ring 16 - Backup Ring (Q.ty 2) 24 - Nut
7 - Cylinder Head 17 - Seal Ring
8 - Socket Bolt (Q.ty 12) 18 - O-Ring
E215-E235 W4-2-25

CYLINDERS

Assembly of Positioning Cylinder 8. Install shim (21) to cylinder rod (11). Tighten nut
(triple articulation version) (24) using special tool (380001025).

1. Install bushing (5) to cylinder head (7) using a

press.
Special tools for bushing installation (5): 380001025
(380001044)

IMPORTANT - Be sure that the rings are installed

correctly. SM1365

Be sure to align the machine mark on the rod with

2. Install seal (3), back-up ring (2), elastic ring (6) and that on the nut.
seal (4) on the cylinder front sleeve (7). Nut Turning Special Tools: (24):
- 115 mm (380001018)

3. Install wiper ring (1) to cylinder head (7) using a : 9900 Nm

plastic hammer.
Special tools for wiper ring installation: (380001040)
9. Align the holes on cylinder rod (11) and nut (24).
Insert steel ball (23) into the hole, and tighten set
4. Install O-Rings (10) and backup ring (9) to cylinder screw (22) into the hole.
head (7). Mushroom the head of set screw (22) at two places
using a punch and hammer.
: 12 mm
5. Install O-Ring (18) backup ring (16) (Q.ty 2), seal
ring (17), slide ring (19) (Q.ty 2), (20) (Q.ty 2) to : 56.9 ± 10.7 Nm
piston (15).
Special tool for seals assembly: (380001028)

IMPORTANT - Be sure to keep cylinder rod (11)

aligned with the center of cylinder tube (12) when
inserting, in order to avoid damaging the rings.

10. Secure cylinder tube (12) horizontally using a vise.

Insert cylinder rod (11) into cylinder tube (12).

15
11. Install cylinder head (7) to cylinder tube (12).
Tighten socket bolts (8).
SM1367
: 17 mm

6. Install cylinder head (7) to cylinder rod (11). : 520 Nm

Special tools for cylinder head installation:
(380001043)

7. Install piston (15) to cylinder rod (11).

W4-2-26 E215-E235

CYLINDERS

MAINTENANCE STANDARD

Rod

SM1356

Unit: mm
Cylinders STANDARD (A) Remedy
Boom 85 ± 0.03
Replace or
Arm 95 ± 0.03
plate with
Bucket 80 ± 0.03
chromium
Positioning (*) 100 ± 0.03

(*) Triple articulation version

E215-E235 W4-2-27

CYLINDERS

SPECIAL TOOLS

Piston nut socket wrench:

380001007 for boom cylinders (95 mm)

380001024 for bucket cylinder (90 mm)
380001022 for arm cylinder (100 mm)
380001018 for positioner arm cylinder (115 mm) (triple articulation version)
SM1366
Use nut loosening/tightening workbench: 380001025

Tools kit seals installation:

380001041 for boom cylinders

380001035 for bucket cylinder
380001038 for arm cylinder
380001028 for positioner arm cylinder (triple articulation version)

SM1369

Wiper installation tool:

380001033 for boom cylinders

380001039 for bucket cylinder
380001032 for arm cylinder
380001040 for positioner arm cylinder (triple articulation version)
SM1370

Tool for the installation and removal of the rod guide bushing:

380001036 for boom cylinders (Ø 85 mm)

380001094 for bucket cylinder (Ø 80 mm)
380001042 for arm cylinder (Ø 95 mm)
380001044 for positioner arm cylinder (Ø 100 mm) (triple articulation version)
SM1371

Head installation tool:

380001049 for boom cylinders

380001050 for bucket cylinder
380001034 for arm cylinder
380001043 for positioner arm cylinder (triple articulation version)
SM1372
W4-2-28 E215-E235

CYLINDERS

NOTES:
E215-E235. Schematic Wiring diagram reading key

1 - Fuse box (E-4) 74 - Rotary Bucket (Extra) Right switch (SW-55)

2 - Fuse link 7 (60 A) (E-27) 75 - Diode 18
3 - Mega fuse box (E-24) 76 - Diode 19
4 - Preheating (Grid heater) relay (R-3) 77 - Rotary Bucket (Extra) Left switch (SW-56)
5 - Mechatro Controller (C-1) 78 - Operating lever lock solenoid valve (SV-4)
6 - Preheating (Grid heater) control relay (R-29) 79 - Rotary Bucket (Extra) solenoid valve (A) (SV-16)
7 - Battery (E-1) 80 - Lever lock switch (SW-11)
8 - Battery relay (R-1) 81 - Step Motor (M-2)
9 - Key switch (SW-1) 82 - Swing parking release switch (SW-4)
10 - Starter motor assembly (M-1) 83 - Swing parking brake solenoid valve (SV-1)
11 - Engine stop solenoid (SV-13) 84 - Two speed select solenoid valve (SV-3)
12 - Engine stop relay (R-28) 85 - Power boost solenoid valve (SV-2)
13 - Engine oil level switch (SW-23) 86 - P2 By-pass cut proportional solenoid valve (PSV-B)
14 - Water separator heater (E-19) 87 - Travel straight proportional solenoid valve (PSV-C)
15 - Starter relay (R-2) 88 - P1 By-pass cut proportional solenoid valve (PSV-D)
16 - Safety relay (R-4) 89 - Arm variable recirculation proportional solenoid valve
17 - Alternator assembly (E-2) (PSV-A)
18 - Glow Plug (Grid heater) (E-12) 90 - Attachment unload proportional solenoid valve
19 - Fuel filter heater relay (R-23) (PSV-E)
20 - Engine stop solenoid (SV-13) (Only for E135, E165 and 91 - Travel unload proportional solenoid valve (PSV-F)
E195) 92 - Pump P1 proportional solenoid valve (PSV-P1)
21 - Diode 14 93 - Pump P2 proportional solenoid valve (PSV-P2)
22 - Fleet link (Opt) 94 - Resistor (E-15) (Only for E135, E165 and E195)
23 - Antenna 95 - KPSS MODE release switch (SW-5) (Only for E135,
24 - Speakers E165 and E195)
25 - Socket 12 V D.C. (E-23) 96 - Pump P1 proportional solenoid valve (PSV-P1) (Only
26 - Converter 24 V/12 V (E-22) for E135, E165 and E195)
27 - Hour meter (E-3) 97 - Pump P2 proportional solenoid valve (PSV-P2 (Only for
28 - Diode 16 E135, E165 and E195)
29 - Diode 17 98 - Coolant thermo sensor (SE-14)
30 - Fuse link box A e B (E-25) 99 - Engine coolant temperature indicator
31 - Diode 15 100 - Cluster gauge (C-2)
32 - Fuel filter heater (E-20) 101 - Fuel sensor (SE-15)
33 - Diode 11 102 - Fuel meter
34 - Diode 2 103 - Boom/dozer select relay (R-11) (Only for E135)
35 - Diode 3 104 - Boom/dozer select solenoid valve (SV-17) (Only for
36 - Diode 4 E135)
37 - Antenna GSM 105 - Boom/dozer select switch (SW-28) (Only for E135)
38 - Antenna GPS 106 - Boom/dozer select switch (SW-29) (Only for E135)
39 - Water separator restriction switch (SW-47) 107 - Prevent spark relay
40 - Accelerator potentiometer (SE-16) 108 - Wiper motor relay
41 - Bucket digging sensor (SE-1) 109 - Wiper motor relay
42 - Bucket dump sensor (SE-2) 110 - Wiper motor relay
43 - Boom raising sensor (SE-3) 111 - Wiper relay assembly (R-7)
44 - Boom lowering sensor (SE-4) 112 - Wiper motor (M-3)
45 - Arm in sensor (SE-7) 113 - Washer motor (M-4)
46 - Arm out sensor (SE-8) 114 - Wiper interlock switch (SW-19)
47 - Swing sensor (SE-5) 115 - Quick coupler operation switch (SW-40)
48 - Travel right sensor (SE-9) 116 - Quick coupler operation solenoid valve (SV-14)
49 - Travel left sensor (SE-10) 117 - 9P Connector (CN-6M)
50 - Pump P1 sensor (SE-22) 118 - Working light switch (SW-20)
51 - Pump P2 sensor (SE-23) 119 - Frame working light (L-2)
52 - P1 Opt sensor valve (SE-20) 120 - Boom working light right (L-6)
53 - P2 Opt sensor valve (SE-11) 121 - Boom working light left (L-1)
54 - Power boost switch (SW-21) 122 - Cab working light switch (SW-26) (Opt)
55 - Engine revolution sensor (SE-13) 123 - Cab back working light right (L-9) (Opt)
56 - Radio (E-7) 124 - Cab front working light right (L-7) (Opt)
57 - Load momentum alarm switch (SW-39) 125 - Cab front working light left (L-8) (Opt)
58 - Load alarm select switch (SW-12) 126 - Room light (L-5)
59 - Engine coolant temperature switch (SW-6) 127 - Room light switch
60 - Engine oil pressure switch (SW-7) 128 - Cigarette lighter (E-14)
61 - Air filter restriction switch (SW-8) 129 - Auto grease controller (C-6)
62 - Thermo-switch for heater (SW-57) 130 - Grease motor (M-8)
63 - Engine coolant level switch (SW-24) 131 - Horn relay (R-5)
64 - Hydraulic level switch (SW-25) 132 - Horn
65 - Pressure switch for OPT 1 (SW-44) 133 - Horn switch (SW-10)
66 - Pressure switch for OPT 2 (SW-43) 134 - Seat heater (Opt) (E-26)
67 - Hydraulic pressure remove switch (SW-50) 135 - Air conditioning AMP (C-4)
68 - Heavy lift switch (SW-35) 136 - Receiver drier (E-10)
69 - Mode Cancel switch (SW-2) 137 - Air compressor clutch (E-11)
70 - Rotary Bucket (Extra) Right relay (R-26) 138 - Air conditioning switch (SW-13)
71 - Rotary Bucket (Extra) solenoid valve (B) (SV-15) 139 - Engine room light switch (SW-16)
72 - Rotary Bucket (Extra) Left relay (R-27) 140 - Engine room light (L-12)
73 - Timer (R-20) 141 - Fuel supply pump (M-11)
FRAME HARNESS E215-E235
E215-E235. Hydraulic circuit reading key

1 - Hydraulic pump assy

2 - Main control valve
3 - Swing motor unit
4 - Travel motor unit
5 - Boom cylinder (RH)
6 - Boom cylinder (LH)
7 - Arm cylinder
8 - Bucket cylinder
9 - Swivel joint
10 - Pilot valve (ATT)
11 - Pilot valve (TRAVEL)
12 - Pilot filter
13 - Return filter
14 - Solenoid valve assy
15 - By-pass valve
16 - Suction strainer
17 - Air breather
18 - Boost check valve
19 - By-pass check valve
20 - Restrictor
21 - Restrictor
22 - Unload valve
23 - Unload solenoid valve
24 - Travel straight valve
25 - Boom conflux valve
26 - Arm variable recirculation valve
27 - Arm conflux valve
28 - By-pass cut valve P1
29 - By-pass cut valve P2
 4

22
23
1
3

2 24 19 18
12

17
13
15

16

25
20 10

21
14
8
7
26 6

5 20
11

28 27 29
COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.

Reproduction of text or illustrations,

in whole or in part, is strictly prohibited

Print No. 604.13.123 - English - XII - 2002

Printed by Satiz - Turin (Italy)
Coordinamento Editoriale Satiz - Torino