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Workshop Manual: Fiat Kobelco Construction Machinery S.P.A. - Engineering Print No. 604.13.123 Edition - December 2002
Workshop Manual: Fiat Kobelco Construction Machinery S.P.A. - Engineering Print No. 604.13.123 Edition - December 2002
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.
INTRODUCTION
TO THE READER
• This manual is written for an experienced techni- - If you have any questions or comments, or if you
cian to provide technical information needed to found any errors regarding the contents of this
maintain and repair this machine. manual, please contact:
ADDITIONAL REFERENCES
• The Workshop Manual consists of five parts: - The “Operational Performance Test” part includes
- “Safety Precautions” the information needed to carry out the machine
- “Operational Principle” operational performance test.
- “Operational Performance Test”
- “Troubleshouting”
- “Repair Instructions” - The “Troubleshooting” part includes the technical
information needed for troubleshooting and mal-
- The “Safety Precaution” part includes the recom- function detection.
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 “Repair Instruction” part includes information
needed for maintenance and repair of the machine,
- The “Operational Principle” part includes the techni- tools and devices needed for maintenance and
cal information concerning the operation of main repair, maintenance standards, removal/installa-
devices and systems. 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
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.
UNITS USED
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
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 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
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E215-E235 W1-1-1
SAFETY PRECAUTIONS E215-E235
INDEX
Section 1 GENERALITIES
GENERALITIES
GENERALITIES
machine to transport objects, unless proper securing If noise level is high and exceeds 90 dB (A) over 8
points are provided. hours at the operator’s ear, wear approved ear protec-
Do not carry riders on the machine. tion in compliance with local regulations.
Study and familiarise with escape routes alternative Do not operate the machine if you are extremely tired
to normal exit routes. or feel ill.
For your personal safety, do not climb on or off the Be especially careful towards the end of the working
machine while it is in motion. shift.
Make sure that bystanders are clear of the machine Where removable counterweights are provided, do not
operating range before starting the engine and oper- operate the machine if they have been removed.
ating the attachment. Sound the horn. When operating the machine, keep in mind height lim-
Obey all hand signals, safety indications and signs. its of overhead doors, arches, overhead cables and
When backing, always look to where the machine is lines as well as width limits of corridors, roads and
to be moved. Be alert of the position of bystanders. narrow passages. Also, get to know load limits of the
Should someone enter the work area, stop the ma- ground and paving type of the ramps you are to work
chine. on.
Maintain a safe distance from other machines or ob- Beware of fog, smoke or dust that obscure visibility.
stacles to ensure required visibility conditions. Always inspect the working area to identify potential
Always give way to loaded machines. risks such as: inclines, overhangs, trees, demolition
Maintain a clear vision of the surroundings of the rubble, fires, ravines, steep slopes, rough terrain,
travel or work area at all times. ditches, crowns, ridge trenches,diggings in traffic
Keep cab windows clean and repaired. areas, crowded parking lots, crowded service areas,
When pulling loads or towing through a cable or chain, fenced zones. In such conditions, proceed with ex-
do not start suddenly at full throttle. Take-up slack treme care.
carefully. Whenever possible, avoid crossing over obstacles
Avoid kinking or twisting chains or cables. such as very rough terrain, rocks, logs, steps,
Carefully inspect the towing items for flaws or prob- ditches, railroad tracks. When obstructions must
lems before proceeding. be crossed, do so with extreme care and at a
Do not pull through a kinked chain or cable as the square angle, if possible. Slow down. Ease up to
high anomalous stresses existing in this condition may the break-over point, pass the balance point slowly
induce failures in the kinked portion. and ease down the other side also using the at-
Always wear heavy gloves when handling chains or tachment, if necessary.
cables. To overcome deep trenches or sinking ground,
Chains and cables should be securely anchored us- place the machine perpendicular to the obsta-
ing suitable hooks. Anchor points should be strong cle, drastically reduce ground speed and start
enough to withstand the expected load. crossing using also the attachment if necessary,
Keep anyone clear of anchor points and cables or only after assessing that ground conditions al-
chains. Do not pull or tow unless the operator’s low the traverse safely and without risks.
compartments of the machines involved are prop- The gradient you may attempt to overcome is limited
erly protected against possible backlash in case by factors such as ground conditions, load being han-
of cable or chain failure or detachment. dled, machine type and speed, and visibility.
Be alert of soft ground conditions close to newly There is no substitute for good judgement and experi-
constructed walls. The fill material and machine ence when working on slopes.
weight may cause the wall to collapse under Avoid operating the attachment too close to an over-
the machine. hang or high wall, either above or below the machine.
In darkness, check area of operation carefully Beware of caving edges, falling objects and land-
before moving in with the machine. Use all lights slides. Remember that such hazards are likely to be
provided. Do not move into low visibility areas. concealed by bushes, undergrowth and such.
If the engine tends to slow down and stall for what- Avoid faggots, bushes, logs and rocks. Never drive
ever reason under load or at idle, immediately report over them, nor over any other surface irregularities
this problem to the maintenance managers for proper that discontinue adherence or traction with the ground,
action. Do not operate the machine until this condi- especially near slopes or drop-offs.
tion is corrected. Be alert to avoid changes in adherence conditions
Regularly check all exhaust system components, as that could cause loss of control. Work with extreme
exhaust fumes are toxic for the operator. care on ice or frozen ground and on stepped slopes
Operators must know the performance of the ma- or near drop-offs.
chine they are driving. The word “bulldozing” generally refers to work in
When working on slopes or near sudden level drops virgin rough terrain, characterised by the presence
in the terrain, pay attention not to lose adherence of all the perils and risks listed above. We empha-
and avoid loose soft ground since overturn or loss of sise the danger represented in these conditions by
machine control could result. large tree limbs (possibly falling on the machine)
E215-E235 S1-3
GENERALITIES
and large roots (which may act as a leverage un- Avoid travelling across slopes. Proceed from uphill
der the machine when up-rooted and cause the unit downhill and vice-versa. If machine starts slipping
to overturn). sideways when on a slope, lower the bucket and thrust
Position the machine dependent upon the loading and bucket teeth into the ground.
unloading areas in order to swing leftwards to load to Working on slopes is dangerous. Grade the working
obtain best visibility. area if possible. Reduce work cycle time if it is not
Never use the bucket or attachment as a man lift or possible to grade the working area.
carry riders.Never use the machine as a work platform Do not move full bucket or a load from uphill downhill
or scaffolding. The machine must not be improperly used as this would reduce machine stability. Do not work
for works not consistent with its features (such as push- with the bucket turned to the uphill side.
ing railway cars, trucks or other machines). Do not work with the bucket turned uphill as counter-
Always pay attention to people within the machine weights protruding downhill would reduce machine
operating range. stability on the slope and increase risk of overturn-
Never move or stop the bucket, other loads or the ing.
attachment above ground personnel or truck cabs. We recommend to work on slopes with the bucket
Ensure the truck driver is in a safe place before load- downhill, after checking machine stability with the
ing the truck. bucket empty and attachment retracted, by slowly
Load trucks from side or rear. swinging the upper structure by 360°.
Use only the type of bucket recommended consider- Position the carriage at a right angle relative to slopes,
ing machine type, materials to be handled, material hanging walls, etc. to exit the working area easily.
piling up and loading characteristics, ground type and Standard use, provides for the travel controls at the
other typical conditions of the work to be performed. front and travel motors at the back. Should travel
When transporting a loaded bucket, keep it as rolled- motors be positioned at the front with regard to the
back as possible. Keep boom and arm as low as actual travel direction. Remind relative to travel direc-
possible. tion that controls are reversed.
Ground speed should be adequate to the load and Always check travel motor position before moving off.
ground conditions. Properly judge ground conditions with particular at-
The load must always be properly arranged in the tention to consistency of the area you are going to
bucket; move with extreme care when transporting work on.
oversize loads. Keep the machine sufficiently far from the ditch edge.
Do not lift and move the bucket overhead where per- Never dig under the machine.
sons are standing or working, nor downhill when work- Should it be necessary to dig under the machine, al-
ing on a slope as this would decrease machine stabil- ways ensure that digging walls are opportunely
ity. Load the bucket from the uphill side. propped up against landslide to prevent the machine
Loads to be raised using the machine should be ex- from falling into the trench.
clusively hooked to the hitch specially provided. Do not swing the upperstructure, raise the load or
The excavator is no lifting and transportation means, brake abruptly if not required. This may cause acci-
therefore it should not be used to position loads accu- dents.
rately. Should it be exceptionally used to lift and lay Prior to beginning the work near gas distribution mains
building components, special caution must be taken or other public utilities:
as follows: - Contact the company owner of the gas mains or its
- The machine must be equipped without failure with nearest branch before starting the work. Look up
the appropriate variant supplied, upon request, by the number in the telephone directory.
FIAT KOBELCO. Also, totally comply with the - Define together which precautions should be taken
safety precautions for the operation of the excava- to guarantee work safety.
tor as a lifting equipment. - Decrease work speed. Reaction time could be too
- Secure the loads to be raised using cables or chains slow and distance evaluation wrong.
fastened with appropriate hooking mechanisms. - When working near gas mains or other public utili-
- Nobody should be allowed to remain under the raised ties installations, appoint a person in charge of sig-
load or within the excavator operating range for any nalling duties. This person will have the responsibil-
reason whatever. ity of observing the machine, any part of it and/or
Never exceed specified loading capacity. Incorrect fas- the load approaching the gas mains from a stand-
tening of slings or chains may cause boom/arm fail- point more favourable than the Operator’s. This sig-
ure or failure of the lifting means with consequent bodily nal man (flag-man) must be in direct communica-
injuries and even death. tion with the Operator and the Operator must pay
Always ensure that slings and chains used for lifting undivided attention to the signals supplied.
are adequate to the load and in good condition. - The gas distributing Company, if previously advised
All loading capacities are referred to the machine and involved in the work, as well as machine Opera-
on a level surface and should be disregarded when tor, Owner and/or any natural person or legal entity
working on a slope. having rent or leased the machine or being responsi-
S1-4 E215-E235
GENERALITIES
ble at the time by contract or by law, are liable for the STOPPING
adoption of the necessary precautions.
Working near electric lines can be very dangerous, When the machine is to be stopped for whatever reason,
therefore some special precautions must be ob- always check that all controls are in the neutral position
served. and that the safety lever is on the lock position to guaran-
Within this Manual, “work near electric lines” means tee risk-free start-up.
when the attachment or load raised by the excava- Never leave the machine unattended with the engine run-
tor (in any position) may reach the minimum safety ning.
distance established by local or international Safety Prior to leaving the driver’s seat, and after making
Regulations. sure that all people are clear of the machine, slowly
To work without risks, keep maximum possible dis- lower the attachment until resting it safely to the
tance from electric lines and never trespass minimum ground. Retract possible auxiliary tools to the closed
safety distance. safety position.
- Contact the Company owner of the electric lines or Check that all controls are in the neutral position. Move
its nearest branch before starting the work. engine controls to the shut-down position. Switch off
Look up the in the telephone directory. the key-start switch. Consult the Operation and Main-
- Define together with the Company representative tenance Instruction Manual.
which precautions should be taken to guarantee work Park the machine in a non-operating and no-traffic area.
safety. Park on firm level ground. If this is not possible, posi-
- All electric lines should be considered as operative tion the machine at a right angle to the slope, making
live lines even though it might be well known that sure there is no danger of uncontrolled sliding.
the line in question is out of work and visibly con- If parking in traffic lanes cannot be avoided, provide
nected to the ground. appropriate flags, barriers, flares and other signals as
- The Electric Power Company, if previously advised required to adequately warn the oncoming drivers.
and involved in the work, as well as machine Op- Always switch off the key-start switch before clean-
erator, Owner and/or any natural person or legal ing, repairing, or parking the machine to prevent acci-
entity having rent orleased the machine or being dental unauthorised start-up.
responsible at the time by contract or by law, are Never lower the attachment or auxiliary tools other
liable for the adoption of the necessary precautions. than from sitting in the operator’s seat. Sound the horn.
- Decrease work speed. Reaction time could be too Make sure that nobody is within the machine operat-
slow and distance evaluation wrong. ing range. Lower the attachment slowly.
- Warn all ground personnel to keep clear of the ma- Securely block and lock the machine every time you
chine and/or load at all times. If the load has to be leave it unattended. Return keys to the safe place
guided down for laying, consult the Electric Power previously agreed upon. Perform all necessary opera-
Company to know which precautions should be tions for stopping as detailed in the Operation and
taken. Maintenance Instruction Manual.
- Appoint a person in charge of signalling duties. Drive the machine far from pits, trenches, rocky hang-
This person will have the responsibility of observ- ing walls, areas with overhead electric lines, and slopes
ing the machine, any part of it and/or the load ap- before stopping it at the end of the working day.
proaching the electric lines from a standpoint more Align the upperstructure to the tracks in order to allow
favourable than the Operator’s. This signal man (flag- to easily get on and off the driver’s compartment.
man) must be in direct communication with the Move all controls to the position specified for machine
Operator and the Operator must pay undivided at- stopping. Refer the Operation and Maintenance In-
tention to the signals supplied. struction Manual.
When working in or near pits, in ditches or very high Never park on an incline without accurately blocking
walls, check that the walls are sufficiently propped up the machine to prevent unexpected movement.
to avoid cave-in hazards. Follow stopping instructions contained in the Opera-
Pay the utmost attention when working near overhang tion and Maintenance Instruction Manual.
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. MAINTENANCE
Always check ground conditions and conditions of the
material to be removed. Support everywhere it is re- GENERALITIES
quired to prevent possible cave-ins or landslides when:
- digging near previous trenches filled with material Carefully read the Operation and Maintenance Instruc-
- digging in bad ground conditions tion Manual before starting, operating, maintaining,
- digging trenches subject to vibration from railroads, fuelling or servicing the machine in any manner.
working machines or highway traffic. Read all safety plates mounted on the machine and
E215-E235 S1-5
GENERALITIES
observe instructions they contain before starting, op- When service or maintenance require access to ar-
erating, repairing, fuelling or servicing the machine. eas that cannot be reached from the ground, use a
Do not allow unauthorised personnel to repair or serv- ladder or step platform conforming to local or national
ice the machine. regulations to reach the working area. If such means
Follow all recommended maintenance and service are not available, use machine grab rails and steps.
procedures. Always perform all service or maintenance work with
Do not wear rings, wrist watches, jewellery, loose or the greatest care and attention.
hanging garments, such as ties, torn clothing, Shop and/or field service platforms or ladders should
scarves, unbuttoned or unzipped jackets that can get be manufactured and maintained in accordance with
caught in moving parts. Wear certified safety clothes local or national safety regulations in force.
such as: hard hat, no-slip footwear, heavy gloves, ear Disconnect batteries and label all controls to warn that
protection, safety glasses, reflector vests, respirators service work is in progress, according to local and
when required. Ask your employer about safety regu- national safety regulation requirements
lations in force and protective equipment. Block the machine and all attachments to be raised
Do not use controls or hoses as hand holds. Hoses according to local and national safety regulation re-
and controls are movable parts and do not provide quirements.
solid support. Besides, controls may be inadvert- Do not check or fill fuel tanks or install batteries near
ently moved and cause unexpected movement of the burning or smoking materials and open flames due to
machine or its attachments. the presence of flammable vapours.
Do not jump on or off the machine. Always keep both The fuel filler pipe nozzle must be constantly kept in
hands and one foot, or both feet and one hand in contact with the filler neck and this even before fuel
contact with steps and/or grab rails. starts flowing in. Keep this contact from the begin-
Never service the machine with someone sitting in ning to the end of the fuelling operation to avoid pos-
the driver’s seat, unless this person is an authorised sible generation of sparks due to static electricity.
operator assisting in the maintenance being carried Use a truck or trailer to haul a failed machine. Should
out. it be necessary to tow it, provide for suitable danger
Keep the operator’s compartment, step plates, grab signals as required by the local norms and regula-
rails and handles clear of foreign objects, oil, grease, tions and observe recommendations given in the Op-
mud orsnow to minimise the danger of slipping or stum- eration and Maintenance Instruction Manual. Load/
bling. unload the machine on firm level ground providing safe
Clean mud or grease from your shoes before climbing support to the wheels of the truck or trailer. Use strong
on the machine or driving it. access ramps, with adequate height and angle. Keep
Never attempt to operate the machine or its attach- the trailer flatbed free of mud, oil or slippery materi-
ments from any position other than sitting in the op- als. Tie the machine securely to the trailer and block
erator’s seat. carriages and upperstructure.
Keep the driver’s seat free from foreign objects, espe- Never align holes or slots using your fingers;
cially if these are not secured. alwaysuse appropriate aligning tools.
Should it be necessary to move the attachment for Remove all sharp edges and burrs from re-worked
maintenance purposes, do not raise or lower the at- parts.
tachment from any other position than sitting in the Use only approved and effectively grounded auxiliary
operator’s seat. Before starting the machine or mov- power sources for heaters, battery chargers, pumps
ing its attachment, sound the horn and require that and similar equipment to reduce electrical shock haz-
nobody remains near the machine. ard.
Raise the attachment slowly. Lift and handle heavy components using hoisting de-
Always lock all moving components or parts of the vices of appropriate capacity. Ensure the parts are
machine that must be lifted for maintenance purposes supported by appropriate straps and hooks.
using adequate external means as required by local Use lifting eyes provided to this aim.
and national regulations. Do not allow anyone to pass Pay attention to bystanders near the lifting area.
or stay near or below a raised attachment. If you are Never pour gasoline or diesel fuel into open contain-
not absolutely sure about your safety, do not stay or ers. Never use gasoline, solvents or other flammable
walk under a raised attachment. fluids to clean parts. Use proprietary certified non-
Do not place head, body, limbs, hands, feet or fingers flammable, non-toxic solvents only.
near articulated cutting edges deprived of the neces- When using compressed air to clean parts, wear safety
sary guards, unless they are suitably and safely glasses with side shields. Limit pressure to max. 2
locked. bars, in accordance with local and national safety regu-
Never lubricate, repair or adjust the machine with the lations in force.
engine running, except when this is specifically re- Do not run the engine of this machine in closed build-
quired by the Operation and Maintenance Instruction ings without proper forced ventilation capable to re-
Manual. move toxic exhaust gases concentrating in the air.
Do not wear loose clothing, jewellery near rotating parts. Do not smoke, nor allow open flames or sparks nearby
S1-6 E215-E235
GENERALITIES
while refuelling the unit or handling highly flammable arc-cutting. Wear dark safety glasses when you are
materials. near a welding in progress. Do not look the welding
Do not use open flames as light sources to look for arc without proper eye protection.
leaks or inspect anywhere on the machine. Become acquainted with all your jacking equipment
Make sure that all mechanical tools provided are in and their capacity.
good condition at all times. Never use tools with mush- Ensure that the jacking point on the machine is ap-
roomed or damaged heads. Always wear eye protec- propriate for the load applied. Also, be sure the sup-
tions with side shields. ports under the jack and between the jack and the
Move with extreme care when working under, on or machine are appropriate and stable.
near the machine or its attachments. Any equipment supported by a jack represents a pos-
In case of attachment tests during which the engine sible hazard. Always support the load onto appropri-
should be kept running, a qualified operator must sit ate blocking means as a safety measure before pro-
in the driver’s seat at all times while the mechanic is ceeding with service or maintenance work, in compli-
at work. ance with local or national safety regulations.
Keep hands and clothes far OFF moving parts. Metal cables produce steel splinters. Always wear
Stop the engine and move the safey lever to the lock certified protection clothes such as safety gloves and
position before starting adjusting or repairing an as- glasses while handling them.
sembly. Do not use makeshift jacks to adjust track sag. Fol-
Do not carry out any work on the attachment without low instructions given in the Repair Manual.
prior authorisation. Observe maintenance and repair Handle all parts carefully. Keep hands and fingers
procedures. away from gaps, gears, and similar. Always use and
In case of field service, move the machine to level wear certified safety clothes such as safety glasses,
ground and block it. If work on an incline cannot be gloves and footwear.
avoided, securely block the machine and its attach- The attachment is kept constantly in position by an
ments. Move the machine to level ground as soon as oil column trapped into the high pressure circuit. Lower
possible. Do not twist chains and cables. Never use a the attachment to the ground and relieve pressure from
twisted chain or cable for lifting or pulling. Always wear all circuits prior to carrying out any type of mainte-
safety gloves to handle chains or cables. nance or repair work.
Be sure chains and cables are firmly fastened and Do not service or repair the machine if it is parked
that the anchor point is strong enough to withstand downhill. If this is unavoidable, in case of emergency,
the expected load. Keep all bystanders clear of the block the carriages to prevent unexpected movement,
anchor point, cables or chains. Do not pull or tow particularly if the work is to be carried out on the final
unless the operator’s compartments of the ma- reduction units or travel motors.
chines involved are fitted with proper guards Consult the Operation and Maintenance Instruction
against cable or chain backlash. Manual for correct maintenance procedure.
Keep the maintenance area clean and dry at all times. Areas near articulated cutting edges where mechani-
Clean immediately all water and oil spillage. cal parts are in motion are where personal injuries are
Do not pile up oily or greasy rags as they represent a most likely to occur. Pay attention to prevent possible
major fire hazard. Always store them in closed metal part movements by means of blocks or by keeping
containers. clear of such zones when motion may take place dur-
Before starting the machine or its attachment, check, ing maintenance or repair.
adjust and lock the operator’s seat. Also ensure that Move the hydraulic system lock safety lever to the
nobody is within the machine or attachment operating lock position when stopping the machine for what-
range before starting or operating the machine and/or ever reason.
its attachments. Always install the safety stays for the hood and other
Sound the horn. hinged covers before performing any maintenance or
Rust inhibitors are volatile and flammable. repair work in the engine compartment.
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. TRANSFERS AND TRANSPORTATION
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments. Before moving or transporting the machine, block
Wear appropriate safety clothing such as hard hat, upperstructure swing to prevent accidental move-
safety shoes and gloves, safety glasses when splin- ment.
ters or other particles may be ejected. Pay particular attention during transfer on inclines,
Wear the appropriate welder’s equipment such as dark both uphill and downhill. Keep the bucket in a posi-
safety glasses or mask, hard hat, protective clothing, tion to provide a possible anchor point into the
safety gloves and footwear always while welding or ground in case of slipping.
E215-E235 S1-7
GENERALITIES
During transfers on inclines, both uphill and downhill, Do not lubricate the machine with the engine running.
keep the upperstructure aligned with the carriages. Do not run the engine with the air intakes open and
Do not travel across the slope. not protected. If this cannot be avoided for service
Never transfer the machine in the working site, in a reasons, place protection meshes on all intakes be-
crowded area, or near people without having at least fore servicing the engine.
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 ELECTRICAL SYSTEM
be exceeded. You should also know machine height,
width, and weight. Have a signal-man help you when Pay attention to connect connecting cables to cor-
clearances are limited. rect poles (+ to +) and (- to -) at both ends. Do not
Check distance between boom/arm and dimensional short-circuit terminals. Thoroughly follow instruc-
limits during transfer or transportation. tions given in Operation and Maintenance Instruc-
Rough terrain may cause the machine to sway and tion Manual.
roll to such an extent that boom/arm could get to con- Always move the key-start switch in the lock posi-
tact electric lines or other obstacles. Cross obstacles tion before servicing or repairing the machine.
at a right angle at low speed. Pay attention to ma- Batteries contain SULPHURIC ACID. Protect the
chine shaking when the centre of gravity overcomes eyes when working near the batteries against pos-
the obstacle. sible sprays of the acid solution. Should acid con-
Keep the bucket down at all times during transfers. tact skin, eyes, or clothes, RINSE IMMEDIATELY
Drive with the lights on and use appropriate signals IN WATER FOR AT LEAST 15 MINUTES. Immedi-
and flags. ately seek medical attention.
Get to know and respect local and national regula- Battery released gas is highly flammable. Leave
tions. the battery compartment cover open during recharg-
Consider boom/arm and upperstructure dimensions ing to improve ventilation. Never check battery
while turning. charge by placing metal objects across the posts.
Use a ramp to load the machine on a trailer. If a ramp Keep sparks or open flames away from batteries.
is not available, fabricate one using blocks. The ramp Do not smoke near the battery to prevent explo-
should be sufficiently strong to support machine sion hazard.
weight. Always load and unload on level surface. Before any maintenance or repair, make sure that
Tow the machine following the instructions contained there are no fuel or electrolyte leaks from the bat-
in the Operation and Maintenance Instruction Manual. 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.
ENGINE Disconnect batteries before working on the electri-
cal system or carrying out any other type of work.
Do not run the engine in closed buildings without proper
ventilation capable to remove harmful exhaust fumes.
Do not place head, body, limbs, feet, hands or fingers
near rotating fans or belts. Be especially careful near
blower fans. HYDRAULIC SYSTEM
Loosen the radiator cap very slowly to relieve system
pressure before removing it. Always top-up coolant Pressure fluid escaping from a very small hole can
level with the engine off or idling if hot. See the Op- be almost invisible and still have sufficient force to
eration and Maintenance Instruction Manual. penetrate the skin. Always check any suspected
Keep the exhaust manifold and tube free from com- pressure leaks using a piece of cardboard or wood.
bustible matters. Fit the machine with shields and Do not use hands. If injured by escaping fluid, ob-
guards when working in the presence of combustible tain medical attention immediately or serious in-
matter free in the air. fection or reaction may develop.Stop the engine
Do not refuel with the engine running, especially if and ensure pressure is relieved from all systems
hot, as this increases fire hazard in case of fuel spill- before removing side panels, housings, guards and
age. covers. See the Operation and Maintenance In-
Never attempt to check or adjust fan belt tensions struction Manual.
when the engine is running. Always use gauges of adequate capacity for pres-
Do not adjust the fuel injection pump when the ma- sure testing. Refer to the Operation and Mainte-
chine is operating. nance Instruction Manual or Repair Manual.
S1-8 E215-E235
GENERALITIES
TOOLS ting in the driver’s seat. Sound the horn before start-
ing the machine or moving the attachment. Require
Always keep head, body, limbs, feet, hands, and fin- that nobody remain near the machine. Raise the at-
gers away from the bucket and attachments, when in tachment slowly.
the raised position. Do not use the machine to transport loose objects,
Prior to any maintenance or repair work, install all unless proper securing devices are provided.
supports necessary to this aim according to local and Never use gases other than nitrogen to charge the
national safety regulations. accumulators.
In case the attachment is to be operated for mainte- Refer to the Operation and Maintenance Instruction
nance or repair purposes, do so exclusively while sit- Manual.
E215-E235 S2-1
SAFETY PRECAUTIONS
S0021
ENVIRONMENTAL PROTECTION
S0024
S2-2 E215-E235
SAFETY PRECAUTIONS
S0023
E215-E235 S2-3
SAFETY PRECAUTIONS
S0026
SAFETY PRECAUTIONS
S0028
- Be careful of slippery conditions of platforms,
steps, and handrails when leaving the machine.
- If not, move the seat fore and aft, and check again.
S0029
E215-E235 S2-5
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
S0033
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
WRONG
S0005
E215-E235 S2-9
SAFETY PRECAUTIONS
AVOID OVERTURNING
• 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.
S0047
• 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
• 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
S0036
E215-E235 S2-11
SAFETY PRECAUTIONS
S0035
S2-12 E215-E235
SAFETY PRECAUTIONS
S0008
S0205
E215-E235 S2-13
SAFETY PRECAUTIONS
S0044
S0045
AVOID UNDERCUTTING
S0011
S2-14 E215-E235
SAFETY PRECAUTIONS
S0048
SAFETY PRECAUTIONS
SAFETY TRANSPORTING
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.
SAFETY PRECAUTIONS
S0055
S0056
S2-18 E215-E235
SAFETY PRECAUTIONS
S0166
S0167
E215-E235 S2-19
SAFETY PRECAUTIONS
S0153
S0058
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
PREVENT BURNS
S0177
S2-22 E215-E235
SAFETY PRECAUTIONS
SA0018
SAFETY PRECAUTIONS
S0046
S0050
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
S0060
S0061
SAFETY PRECAUTIONS
SAFETY PLATES
R0697
SAFETY PLATES
10
4 5 6
13
11
8
12
R0698
SAFETY PLATES
S0074
S0076
S0075
S3-4 E215-E235
SAFETY PLATES
4 - Read-your-manual plate
S0077
S0139
S0079
E215-E235 S3-5
SAFETY PLATES
S0080
S0081
SAFETY PLATES
S0088
S0095
S0096
S0097
OPERATIONAL PRINCIPLE
R0077
OPERATIONAL PRINCIPLE E215-E235
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
GENERAL
CONTENTS
SPECIFICATIONS
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
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
M0123
(Dimensions in mm)
SPECIFICATIONS
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
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
M0124
(Dimensions in mm)
SPECIFICATIONS
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
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)
SPECIFICATIONS
M0123
(Dimensions in mm)
SPECIFICATIONS
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
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
SPECIFICATIONS
M0124
(Dimensions in mm)
SPECIFICATIONS
EXCAVATOR PERFORMANCE
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
Model KR3G-9TFL
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
SWING MOTOR
Model M5X130CHB–10A–17B/285–122
Weight kg 49
Model M2X120B
Weight kg 158.5
SPECIFICATIONS
TRAVEL DEVICE
Model 710 C3 K
Max. output torque (theoretical) 705.8 Nm at 343 bar 807.1 Nm at 343 bar
static 470 Nm
Parking brake torque
dynamic 370 Nm
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
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
COMPONENT LAYOUT
.75-
D R0443
COMPONENT LAYOUT
12
1
14 3
4
11 15
5
6
7
8
13 9
10
R0444
COMPONENT LAYOUT
1
3
13
5
12
6
11
10 9 8 7
R0445
COMPONENT LAYOUT
6
1
7 8 9 10 11 12
2
5 4 3
R0446
COMPONENT LAYOUT
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
CONTROLLER Mechatro
7 10
BACK UP Controller Back up
8 / / /
WIPER
14 Wiper Washer 20
WASHER
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
5 1
60 A
4 3 2 R0448
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
COMPONENT LAYOUT
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
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
3 R0451
SYSTEM
CONTENTS
OUTLINE
ELECTRIC: CONTROLLER
INPUT SIGNAL
678
HYDRAULIC: PILOT SECONDARY
PRESSURE
SOLENOID PROPORTIONAL
VALVE SECONDARY PRESSURE
: 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
LEVER LOCK
SW-11
VOLTAGE 24V
R0370
T2-1-3
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
A2 A1
Pi
P2 BYPASS CUT
PILOT SIGNAL PROCESS PROPORTIONAL Pi
VALVE
PSV - B
Pi
P2 PUMP
PILOT SIGNAL PROCESS PROPORTIONAL Pi
VALVE
PSV - P2
Pi
P1 PUMP
PILOT SIGNAL PROCESS PROPORTIONAL Pi
VALVE
PSV - P1
MECHATRO CONTROLLER
Pi ; PROPORTIONAL VALVE
SECONDARY PRESSURE R0371
E215-E235 T2-1-5
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
ARM
VALVE
BOOM
P2 P1
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
P2 PUMP PRESSURE
Pi
Pi
P2 PUMP
PILOT SIGNAL PROCESS PROPORTIONAL Pi
VALVE
PSV - P2
1. If load increases and the load pressure of the pump 3. When the travel straight valve is changed over, the
rises above set pressure during arm in operation, parallel passage on the P1 side connects with the
the output voltage of the high pressure sensor parallel passage on the P2 side.
(SE-23) is put into the mechatro controller. When the P1 bypass cut valve is changed over, the
The mechatro controller processes pilot signals oil delivered by the P1 pump is combined with that
and puts out a command current that cuts off the by the P2 pump by arm operation.
variable recirculation, to the variable recirculation
proportional valve.
2. The travel straight proportional valve and the P1 4. The pure hydraulic command switches the arm
bypass cut proportional valve put out the sec- main spool. Then a command from the mechatro
ondary pilot pressure according to a command controller switches the P2 pump, and the variable
current of the mechatro controller and switches recirculation valve. This causes the returned oil of
the travel straight valve and the P1 bypass cut the arm cylinder rod side to be recirculated to the oil
valve. delivered by the P2 pump.
T2-1-8 E215-E235
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
Pi
Pi
VARIABLE ARM VARIABLE
PILOT RECIRCULATION Pi
RECIRCULATION
SIGNAL PROCESS VALVE COMMAND VALVE
PSV - A
Pi
P2 PUMP Pi
PILOT SIGNAL PROCESS PROPORTIONAL
VALVE
PSV - P2
1. If the arm in is performed, the secondary pilot 4. Also, the mechatro controller puts out a command
pressure for arm operation switches the arm spool current to the variable recirculation proportional
and is put into the low pressure sensor. valve according to the input voltage from the accel
potentiometer.
2. An engine speed command put out from the accel-
eration potentiometer is put into the mechatro 5. Each proportional valve puts out a secondary pilot
controller. pressure according to a command current from the
mechatro controller. This controls the variable
3. The output voltage from the low pressure sensor is recirculation valve to provide a spool stroke ac-
put into the mechatro controller, and processes the cording to the engine speed and changes the
pilot signal and puts out a command current ac- recirculation ratio. This holds down cavitation when
cording to the input voltage to the P2 pump propor- the engine speed is low and the delivery rate of the
tional valve. pumps is low.
E215-E235 T2-1-9
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
A2 A1
MECHATRO CONTROLLER
Pi
P1 BYPASS CUT Pi
PILOT SIGNAL PROCESS PROPORTIONAL
VALVE PSV - D
Pi
P2 PUMP Pi
PILOT SIGNAL PROCESS PROPORTIONAL
VALVE
PSV - P2
Pi
PILOT SIGNAL PROCESS
P1 PUMP Pi
PROPORTIONAL
VALVE PSV - P1
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.
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
A2 A1
TRAVEL STRAIGHT
SIGNAL
MECHATRO CONTROLLER
Pi
Pi
Pi
Pi
Pi
TRAVEL UNLOAD Pi
PILOT SIGNAL PROCESS PROPORTIONAL
VALVE
PSV - F
TRAVEL STRAIGHT
1. Start ATTs work operations (boom, arm, bucket, P1 bypass cut valve command
swing) in travel operation (right and left), and the
pilot pressure switches respective spools, and is The P1 bypass cut valve does not operate if the boom
input into respective low pressure sensors. 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.
ATT operation
Boom Bucket Arm Swing
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
Pi
P1 BYPASS CUT P1
PILOT SIGNAL PROCESS PROPORTIONAL
Pi
VALVE
PSV - D
1. If swing operation is performed during arm in (or 5. Delivery oil of P2 pump flows into swing and arm
arm in is performed during swing), the secondary sections of P2 side, but it flows preferentially into
pilot pressure for arm operation switches arm spool swing side because the operation pressure of arm
and swing spool. Respective pressure is simulta- cylinder is higher than swing side pressure.
neously put into each low-pressure sensor (SE-7,
SE-5). 6. On the other hand, as travel straight spool is shifted
to travel straight position and P1 bypass cut spool
2. The output voltage of the low pressure sensor is put is switched, delivery oil of P1 pump flows into
into the mechatro controller. parallel circuit of P2 side and confluxes with swing
The mechatro controller processes pilot signals. circuit, and swing priority is accelerated.
The command currents according to the input
voltage are put out to the P1 pump proportional 7. By this operation, delivery oil of P2 pump preferen-
valve(PSV-P1), P2 pump proportional valve (PSV- tially flows into swing side which pressure is lower
P2), travel straight proportional valve (PSV-C), P1 than arm.
bypass cut proportional valve (PSV-D) and the arm Therefore arm working speed keeps required
variable recirculation valve (PSV-A). speed because recirculation oil is used to arm
cylinder, and as P1 pump delivery oil confluxes with
3. Each proportional valve puts out a secondary pilot swing circuit, swing priority control is more avail-
pressure according to a command current from the able.
mechatro controller and switches the delivery rate of
the P1&P2 pumps. At the same time, the pressure 8. If arm in or swing operation are performed, ener-
moves the P1 bypass cut spool to full stroke posi- gized signal from mechatro controller to swing
tion, and switches the arm variable recirculation parking brake solenoid valve (SV-1) is cut, and
valve to the forced recirculation position. swing parking brake is released.
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
Pi
Pi
Pi
Pi
Pi
Pi
MECHATRO CONTROLLER
1. When the hydraulic pressure release switch is 4. The mechatro controller senses the output voltage
switched, the mechatro controller judges it as Pres- of the high pressure sensor of the main pump,
sure Releasing Control. judges it as pump pressure and displays "DRAIN-
ING HYD. PRESS" or "FAIL DRAIN HYD. PRESS"
2. If the mechatro controller judges it pressure releas- on the gauge cluster.
ing control, the mechatro controller performs the
following regardless of input signals (From opera- 5. Since the unload valve is in the pressure releasing
tion pilot valve, accel potentiometer, etc.): position, the oil delivered by each pump is un-
loaded to the tank passage.
a. Puts out a minimum tilting angle command to the If the operating levers are operated and the spools
P1 and P2 pump proportional valve (PSV-P1) switched, the pressure remaining in the actuators
and (PSV-P2). may be discharged.
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
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
1. If any operation performed, the secondary pilot 1. The output voltage of the high pressure sensor
pressure switches the spools and is put into the low attached to each pump piping is put into the
pressure sensors. mechatro controller, which processes pilot signals
and computes command current according to input
2. The output voltage of the low pressure sensor is put voltage (load pressure).
into the mechatro controller which processes pilot
signals and puts out command current to the pro- 2. The lower of the command current computed by
portional valve of each pump according to the input positive control and the command value (1) com-
voltage. 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 3. The proportional valve of each pump puts out a
current from the mechatro controller, switches the secondary pilot pressure according to a command
tilting angle of the pump and controls the delivery current of the mechatro controller, switches the
rate of the pump. tilting angle of the pump and controls the delivery
rate of the hydraulic pressure.
4. This causes the delivery rate according to a lever
stroke to be supplied to the actuator, thus an 4. This increases the load of the actuator, enabling
operating speed according to a lever stroke is the engine to keep running even if the pump is
achieved. highly loaded.
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
Pi Pi
R0379 R0380
T2-1-18 E215-E235
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 T2-1-19
1. An engine rotation command put out of the accel 4. If the engine speed increases an intermediate rpm,
potentiometer is put into the mechatro controller. command current from the mechatro controller
become constant, with the result that the delivery
2. The mechatro controller processes pilot signals rate of each pump rises linearly as the engine
and puts out a command current to the proportional speed increases.
valve of each pump so as to make the delivery rate
of the pump constant when the engine speed is 5. The result is that the motion of the lever at the start
below an intermediate rpm. of each operation becomes the same as that when
a standby flow is available. Also, if the engine
3. The proportional valve of each pump puts out a revolution is increased, the operating feeling ac-
secondary pilot pressure according to a command cording to each revolution is available.
current of the mechatro controller, changes the
tilting angle of the pump till the engine speed
arrives at an intermediate rpm.
Pi Q
R0382 R0383
T2-1-20 E215-E235
NOTE:
E215-E235 T2-2-1
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
MECHATRO CONTROLLER
MECHATRO CONTROLLER
MECHATRO CONTROLLER
10 : 05
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 T2-2-5
MECHATRO CONTROLLER
low pressure sensor, governor motor, propor- machine is faulty, or if the machine condition must
tional valve, solenoid valve, etc. be notified to the operator, the below warning items
are indicated each time it is necessary.
4. Service diagnosis display
Displays the information output by the mechatro
controller such as the pressure sensor detec-
tion, proportional valve, solenoid valve, etc.
1 11 32
CPU PR
2 12 37
4 13 38
!
5 14
6 15
7 19
MECHATRO CONTROLLER
1. Summary
It performs self diagnosis of control inputs and the connector numbers and the pin numbers, refer
outputs of pressure sensors and proportional to the C-1 Mechatro Controller which describes
valves while the machine is in operation. Errors later. Wire numbers and colors may be confirmed
coming out of the self diagnosis are displayed on on the electric circuit diagram or on the harnesses
the multi display of the gauge cluster. Regarding diagram.
2. I/O configuration
INPUT
Pressure sensor
Control SERIAL COMMUNICATION
Proportional valve
Gauge cluster
Selector valve (SOL)
(Buzzer alarm)
Governor motor
Battery relay
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
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. 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
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.
MECHATRO CONTROLLER
Symbol Display
MONITOR SYSTEM OK
E215-E235 T2-2-11
MECHATRO CONTROLLER
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
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
1. Contrast enhancement
Press the mode switch:
LCD indication is enhanced.
Press the buzzer stop switch:
LCD indication becomes dim.
2. Contrast complete
22 : 00
CONTRAST 50
E215-E235 T2-2-13
MECHATRO CONTROLLER
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
26 14 16 9 22 12
CN39F CN40F CN41F
R0386
2. List of connectors
MECHATRO CONTROLLER
MECHATRO CONTROLLER
MECHATRO CONTROLLER
NOTE:
E215-E235 T2-3-1
HYDRAULIC CIRCUIT
SUMMARY
The hydraulic circuits are built up with the following ability, safety, mass volume handling and low fuel
functions and features in order to achieve easy oper- consumption.
Perfor-
mance Device Function Features
• Reverse rotation protective function • Easy positioning to protect it from swinging back
when stops swinging
Easy operability and safety
Swing
• Timer-operated pilot safety lock type • Shut-off of pilot circuit one second after the
safety lock lever is operated
• Lock valve (boom/arm) • Protect boom and arm from unexpected drop
(Natural fall)
• Pressurized hydraulic oil tank • To prevent hydraulic oil from entering dust and
to promote self suction ability of pump
• Suction strainer • Remove dust on suction side
• Line filter; pilot circuit • To prevent pilot operating circuit from malfunc-
Others
tioning
• Return circuit • To prevent hydraulic oil from contamination
• Cooling hydraulic oil by oil cooler • To prevent hydraulic oil from being deteriorated
• Pressure draining circuit • To release the main circuit pressure for piping
repair work
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
• 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
( ) Feed, drain, tank circuit: oil pressure less than 245 kPa
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: On the regulator attached on the pump, the spool
(652) through piston (643) is pushed leftward, and
1. Safety lock lever and pilot circuit.
stops at the position where being in proportion to the
2. Pump positive flow control. force of pilot spring (646).
3. Pump P-Q (Pressure-Quantity) curve control. 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).
1. SAFETY LOCK LEVER AND PILOT CIRCUIT The servo piston (532) and the sleeve of the spool
(652) are connected to feedback lever (611), and
Purpose: servo piston moves to leftward according to the spool
(652) moves to rightward by motion of the feed back
To protect attachment from unexpected motion for lever. By this movement of the spool, opening of spool
safety. and sleeve begin to close gradually and servo piston
stands still at full closed position.
Principle:
Cut pressure source of pilot valve for operation. <Flow rate reduction operation
(Eg. P1 pump)>
Operation: As the current value I of mechatro controller reduces,
If the safety lock lever is turned forward after the the secondary pressure of solenoid proportional val-
engine starts, the limit switch (SW-11) is turned on. ve reduces, and spool (652) is moved rightward by the
The timer relay is actuated one second later which force of pilot spring (646). With the movement of
causes the solenoid (SV-4) of the solenoid valve spool, the delivery pressure P1 usually flows into the
block (14) to be energized and makes the pilot large diameter of servo piston (532) through the spool
operating circuit to stand by. (652).
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
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
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 T2-3-7
HYDRAULIC CIRCUIT
TRAVEL CIRCUIT
This section describes the following: 2. 2nd SPEED TRAVEL SOLENOID COMMAND
CIRCUIT AND AUTO 1 st SPEED RETURN
1. Travel forward pilot simultaneous operation circuit.
FUNCTION
2. 2nd speed travel solenoid command circuit and auto
1st speed return function. Purpose:
3. Travel main circuit. Change travel motor speed with switch.
4. Travel motor function.
Principle:
If the switch is turned, an electric signal is issued.
1. TRAVEL FORWARD PILOT SIMULTANEOUS It excites the travel 1-2 speed changeover solenoid
OPERATION CIRCUIT (SV-3) which in turn converts the primary pilot
pressure and the self pressure to a tilting angle of
Purpose: the variable displacement motor.
Light operating force and shockless operation.
Operation:
Mechatronics If the rabbit marked switch on the gauge cluster is
pressed, the solenoid (SV-3) of the proportional
1. If the travel lever with damping mechanism is
valve block (14) is excited and changes the propor-
operated for travel right, left and forward motions,
tional valve. Then the solenoid command pressure
the secondary pilot proportional pressure comes
is issued from A7 port, enters the P port of the travel
out of the 2 and 4 ports of pilot valve (11). The
motor (4), opens the oil passage to the 2nd speed
higher of the pressures is selected, comes out of
select piston, and causes the motor to run in the 2nd
the 5 and 6 ports and acts upon the low pressure
speed tilting mode by its self pressure. However,
sensors (SE-9) and (SE-10).
when the main circuit pressure rises above
2. The pilot secondary pressure flows to PAr and PAL 27.4 MPa, the motor's self pressure pushes the 2nd
ports of the control valve (2), moves the travel speed select piston back to the 1st speed.
spool, and switches the main circuit.
The other hand, travel straight valve (24) is
switched simultaneously to full stroke position at
one stroke. 3. TRAVEL MAIN CIRCUIT
HYDRAULIC CIRCUIT
BUCKET CIRCUIT
10
8
R
H
2
SV-4
PSV-P1
1
R0288
E215-E235 T2-3-9
HYDRAULIC CIRCUIT
BUCKET CIRCUIT
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
20
10
5
R
R
H
H
25
29
2
14
PSV-B
SV-4
1
R0289
E215-E235 T2-3-11
HYDRAULIC CIRCUIT
BOOM CIRCUIT
This section describes the boom raise conflux opera- 2. BOOM UP 2 PUMPS CONFLUX MAIN CIRCUIT
tion: IN CONTROL VALVE
1. Boom up pilot circuit.
Purpose:
2. Boom up 2 pumps conflux main circuit in control
Boom up speed up.
valve.
Principle:
Confluxing oil from 2 pumps.
1. BOOM UP PILOT CIRCUIT
Operation:
Mechatronics:
1. The oil delivered through A1 port of P1 pump flows
1. If boom up operation is performed, the secondary into control valve (2) P1 port, and branches into
pilot proportional pressure from the right pilot valve bypass circuit and parallel circuit. However since
(10) gets out of port 4 and acts upon the low the boom spool is moved and bypass circuit is
pressure sensor (SE-3). At the same time, the closed, the oil opens load check valve LCb through
pressure acts upon the PAb and PB1 ports of parallel circuit and flows into boom spool.
control valve (2).
2. Then the oil passes through boom spool, opens
2. The voltage output of the low pressure sensor lock valve of boom lock valve CRb, and is led into
(SE-3) is put into the mechatro controller and (H) side of boom cylinders through control valve (2)
processed. The controller then puts out a current Ab port.
command to the P2 bypass cut solenoid propor-
3. Meanwhile, the oil delivered from the A2 port of the
tional valve (PSV-B). The valve puts out a second-
P2 pump enters the P2 port of control valve (2) and
ary proportional pressure that acts upon the PCa
is branched to the bypass circuit and the parallel
port of the control valve (2).
circuit. If the P2 bypass cut valve (29) is changed
3. Next, the secondary pressure which enters the over, the center bypass circuit is closed. The oil
PAb port of the control valve (2) shifts the boom then passes through the parallel circuit and via the
spool. The secondary pressure which enters the restrictor on the circumference of the boom conflux
PB1 port shifts the boom conflux valve (25). spool (25), pushes the load check valve CCb open
Meanwhile, the secondary solenoid proportional from the boom conflux circuit, and combines the oil
pressure which enters the PCa port changes over delivered by the P1 pump internally.
the P2 bypass cut valve (29).
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 T2-3-13
HYDRAULIC CIRCUIT
This section describes boom lower operation: When the boom spool is at neutral, the drain line on
the lock valve CRb poppet spring chamber is
3. Boom down pilot circuit.
closed which causes the poppet closed.
4. Prevention of natural fall by lock valve. The result is that the oil returning from the boom
5. Constant recirculation function of boom down main cylinder head (H) to the boom spool is held and
circuit. makes the leakage from the boom spool zero.
Thus the boom cylinder is prevented from making
a natural fall.
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.
T2-3-14 E215-E235
HYDRAULIC CIRCUIT
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.
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
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: 2. ARM IN, LIGHT-LOAD VARIABLE NORMAL
RECIRCULATION MAIN CIRCUIT
1. Arm in, light-load operating pilot circuit.
2. Arm in, light-load variable normal recirculation Operation:
main circuit.
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.
1. ARM IN, LIGHT-LOAD OPERATING PILOT 2. Since the passage to the tank is restricted by the
CIRCUIT arm variable recirculation spool, the oil returning
from the arm cylinder (R) arrives at the load check
Purpose: valve CAr.
Speed-up and Anticavitation when the arm is at 3. Since the (R) side pressure of the cylinder is higher
light loaded. than the (H) side pressure of it when working load
is light, the pressure pushes the load check valve
Principle: open and is recirculated to the (H) side so as to
speed up the light-load digging operation.
The oil returning from the arm cylinder rod (R) is
recirculated variably to the head (H) at inside of
Cavitation prevention control in arm in
control valve.
operation
Operation: If the engine speed and the arm in pilot pressure
are processed in the controller, the controller puts
1. If the arm digging operation is performed, the out a current command to the arm variable solenoid
secondary pilot proportional pressure gets out of proportional valve, and brings the arm to its forced
port 4 of the left pilot valve (10) and acts upon the variable recirculation position to prevent cavitation
low pressure sensor (SE-7). from occurring.
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 Arm variable recirculation valve (26)
valve selector and release closed poppet CRa.
From arm spool
2. The voltage output by the low pressure sensor is
input into mechatro controller, and is pilot signal- To tank
HYDRAULIC CIRCUIT
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 T2-3-19
HYDRAULIC CIRCUIT
This section describes the following operations: 4. ARM IN, HEAVY LOAD OPERATING
SEQUENCE CONFLUXED MAIN CIRCUIT
3. Arm in, heavy load operating pilot circuit
(recirculation cut).
Purpose:
4. Arm in, heavy load operating sequence confluxed
Speed up for arm in operation
main circuit.
Principle:
P1 pump flow is confluxed with P2 pump flow in
3. ARM IN, HEAVY LOAD OPERATING PILOT control valve (2).
CIRCUIT (RECIRCULATION CUT)
Operation:
Mechatronics:
1. P2 pump delivery oil flows in the travel left section
1. In the arm digging operation, if the heavy load is through P2 port of control valve (2) and separated
applied to the arm, the current of arm variable into by-pass circuit and parallel circuit. Conse-
recirculation solenoid proportional valve is mini- quently the arm spool is switched and pushes and
mized and the arm variable recirculation is cut. opens load check valve LCa through parallel cir-
cuit, and flows in the arm spool.
2. The travel straight solenoid proportional valve
(PSV-C) and P1 by-pass cut solenoid proportional 2. On the other hand, P1 pump delivery oil flows into
valve (PSV-D) are energized at the same time P1 port of control valve (2), and the travel straight
when the command current of arm variable section, and opens load check valve CT2, then the
recirculation solenoid proportional valve (PSV-A) delivery oil confluxes with the oil delivered from
is minimized, the secondary pressure of respective load check valve CP2 on P2 parallel circuit, and
solenoid proportional valve is delivered and the flows in the arm spool.
pressure acts on PTb and PCb ports of control
3. Next, oil is supplied to the arm cylinder (H) side via
valve (2), switches the travel straight valve (24) and
the arm spool and the Aa port of control valve (2).
P1 by-pass cut valve (28), enabling the circuit for
arm sequence to be confluxed. 4. Meantime, the oil returning from the arm cylinder
(R) side enters the Ba port and reaches the arm
3. With the arm digging operation, the function of pilot
lock valve CRa.
valve is the same as that in light loading.
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
10
7
21
R
H
27
2
28
14
PSV-D
SV-4
1
R0294
E215-E235 T2-3-21
HYDRAULIC CIRCUIT
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 T2-3-23
HYDRAULIC CIRCUIT
COMBINED OPERATION
This section describes only the difference in com- 2. BOOM UP/TRAVEL, MAIN CIRCUIT
bined operation:
Purpose:
1. Boom up/travel, pilot circuit.
To insure straight travel movement during travel
2. Boom up/travel, main circuit.
operation even if the attachment is operated.
Principle:
1. BOOM UP/TRAVEL, PILOT CIRCUIT
The travel action and the attachment action are
actuated by separate pumps.
Mechatronics:
<Pilot circuit other than independent operation> Operation:
1. If the mechatro controller processes low pressure 1. The oil delivered by the P1 and P2 pumps runs into
sensors signals, a current command is put out to the travel straight section from the P1 and P2 ports
two valves; the travel straight solenoid proportional of control valve (2). Since the travel straight spool
valve (PSV-C) and the P2 bypass cut solenoid is shifted, the oil delivered by the P2 pump is
proportional valve (PSV-B). These valves put out branched off to the P1 and P2 bypass lines.
secondary pressure which acts upon the PTb and In the meantime, the oil delivered by the P1 pump
the PCa ports of control valve (2). flows through travel straight valve and flows into
2. The pilot pressure of solenoid proportional valve load check valve CT1 and CT2 and flow to the P1
(PSV-C) enters to the PTb port of control valve (2) and P2 parallel circuits.
and changes over the travel straight valve (24). 2. Next, since the travel right and left actions are
Meanwhile, the solenoid proportional valve (PSV-B) operated by the P2 pump delivery oil. Meantime,
which enters the PCa port of control valve (2) since the boom spool and other spools operate on
changes over the P2 bypass cut valve (29). 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
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
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).
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
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
This section describes the following operations: 2. PRESSURE RELEASE MAIN CIRCUIT
1. Pressure drain (releasing) pilot circuit.
Operation:
2. Pressure drain (releasing) main circuit.
If the operating lever is shifted to neutral during
engine running and the hydraulic pressure release
switch is kept,"FAIL DRAIN HYD. PRESS"or
1. PRESSURE RELEASE PILOT CIRCUIT "DRAINING HYD. PRESS" is displayed on the
gauge cluster. If the operating levers of the right
Purpose: and left four to five times to their full stroke, pres-
sure may be released. If the pump pressure is
To release the main circuit pressure for piping
determined to be more than 970 kPa by the output
repair work.
value of the high pressure sensor (SE-22, SE-23),
in that case repeat the pressure releasing proce-
Mechatronics:
dure once again.
When the hydraulic pressure release switch is
switched, mechatro controller judges this is pres- Operation:
sure release control and out puts the following
ATT & travel unload valves are switched to the
command:
pressure releasing position, consequently the de-
1. Puts out the minimum tilting command value to the livery oil unloads to tank passage. If the spools are
pump proportional valves (PSV-P1, PSV-P2). switched by pilot operation, the remaining pressure
2. Puts out a pressure release control revolution from the actuators may be relieved to the tank
command value to the governor motor. (electric circuit, i.e. the main circuit pressure may be re-
system). leased.
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
Outline
2
1 3 4
5
6
8 7
10
11
Replacing the
breaker with the
crusher is possible.
12
15
13
14
R0389
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.
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.
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
HYDRAULIC CIRCUIT
HYDRAULIC DIAGRAM FOR CRUSHER & BREAKER: at crusher single flow operating
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
HYDRAULIC CIRCUIT
HYDRAULIC CIRCUIT
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
HYDRAULIC CIRCUIT
3. BREAKER
• Bring the selector valve (2) to the position so as Procedure of setting the maximum flow:
to return the oil from the breaker directly to the oil
1. Turn ON the starter switch (without starting the
tank.
engine) and bring the machine to the breaker A
• Adjust the pressure of the port relief valve in the mode. If the screen change switch on the gauge
option valve, according to the specifications of cluster is pressed between 3 seconds and 10
the breaker to be mounted to the machine. seconds, the machine is brought to the adjust
mode.
1. Pilot circuit
• If the operating pedal (4) for the Crusher &
Breaker is depressed on your heel, secondary NOTE - The adjust mode is not available if the above
pilot pressure enters the PBo2 port of the control step is taken after the engine has been started up.
valve from the A port and changes over the spool
of the option valve.
2. A previously stored flow rate is displayed on the
• Concurrently, the secondary pilot pressure en- multi display.
ters the low-pressure sensor (SE-11) from the
C2 port. The voltage output from the pressure 3. The flow increases as the operation mode select
sensor enters the mechatro controller where switch is pressed, while it decreases as the buzzer
pilot signal processing takes place. The stop switch is pressed.
mechatro controller then puts out current com- 4. The flow changes two seconds after either switch
mands according to the voltage inputs, to the P2 is kept pressed. It changes by the 10 L min-1
pump and P2 bypass cut proportional valves (20 L min-1 with conflux selected); let the switch go
(PSV-B). at a desired reading.
• The proportional valve for the P2 pump puts out
secondary pressure to the pump regulator to 5. The flow may be set in the range of the max. to min.
change the delivery rate of it. 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
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
HYDRAULIC CIRCUIT
POSITIONING 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
ELECTRICAL SYSTEM
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
ELECTRICAL SYSTEM
ACCESSORY CIRCUIT
(Key Switch in ACC position)
ELECTRICAL SYSTEM
1
2
7
10
8
9 R0453
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
14
4
7
5
10
15 8
11 17
12 R0454
ELECTRICAL SYSTEM
STARTING CIRCUIT
(Key Switch in START position)
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).
ELECTRICAL SYSTEM
1
2
15
7
10
8
9 16
11
5
12 R0455
ELECTRICAL SYSTEM
CHARGING CIRCUIT
(Key Switch in ON position)
ELECTRICAL SYSTEM
14
19
7
10
8
15
11 17
12 R0456
ELECTRICAL SYSTEM
PREHEATING CIRCUIT
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.
ELECTRICAL SYSTEM
5
1
2
4
3
18
R0457
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
1
2
7
9 8
11
5
12 R0458
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
1
2
11
5
12 R0459
ELECTRICAL SYSTEM
NOTE:
SECTION 3 E215-E235
COMPONENT OPERATION
CONTENTS
OUTLINE
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
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
a4 Dr Regulator a5
B1
Regulator
Gear pump
for pilot
a3
(Dr) B3 D3 A3
R0144
E215-E235 T3-1-3
Specifications
Model KR3G-9TFL
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
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
546
725
724
325
407
VIEW A
SECTION B-B
R0145
E215-E235 T3-1-5
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
T3-1-6 E215-E235
434
B3
728
435
312
311
A3
732
a3
117
128
827
115
826
P1 P2
Pump Pump
side side
R0147
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
141
313
124
312
111
116
124
314
141
157
156
153
151
152
211
R0149
E215-E235 T3-1-9
R0151
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
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
801
E
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
T3-1-12 E215-E235
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
654
651 652
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".)
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
Q
L/min
2150 min-1
H/M
100 W
0 P MPa
10 20 30
R0165
T3-1-20 E215-E235
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
Specifications
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
NOTE:
E215-E235 T3-2-1
PILOT VALVE
Weight Approx. 2 kg
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
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
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
PILOT VALVE
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
1 3
P T
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
216
T
201
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
PILOT VALVE
NOTE:
E215-E235 T3-2-7
PILOT VALVE
Outside view
Tightening
Port torque Port Function 4 3
size name
Nm
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
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.)
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
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
PILOT VALVE
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
CONTROL VALVE
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
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
View A
R0259
E215-E235 T3-3-3
CONTROL VALVE
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
CONTROL VALVE
PBL PAL
PAs PBs
PBs
Pss
PB1
PBa PAa
PCa Pis
162 (4pc)
PBo PAo
169 155
P2 P1
PTb
973 973
PBr PAr
PBc PAc
973 973
PBb PAb
973
973
PA1 PCb
162 (4pc)
164 154
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
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
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
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
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
CONTROL VALVE
123 124 125 561 562 611 104 103 614 661 613
512 541 521 121 122 621 663 163 664 673 652 671
R0196
302 - Spool
359 - Plug
E215-E235 T3-3-11
CONTROL VALVE
564 563 161 123 124 125 101 162 621 661 612
301 541 511 522 521 561 562 611 102 651 671
R0198
CONTROL VALVE
L101
L541
L162 PLC1(PLC2)
L163
L171 Drc(Drd)
L511
L512
L161
L201
R0200
CONTROL VALVE
P202
P334
PA0 PA0
P337
P323
P324
P333
P271
Po'
P337
P161
Bo
TB' TB
PA0 P262
PBo P603 PBo
CONTROL VALVE
HYDRAULIC CIRCUIT
303
54
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
CONTROL VALVE
CONTROL VALVE
OPERATION
Control valve in neutral
The oil delivered from the hydraulic pump P1 flows The oil delivered from the hydraulic pump P2 also
into P1 port of the control valve, passes through the passes through main passage (54) and is led into
travel straight spool (307) and main passage (51), is bypass circuit (55) which passes through the travel
led into bypass circuit (52) which passes through the left swing, boom conflux and arm control sections and
travel right, bucket and boom control sections and P1 P2 bypass cut spool (310) like the oil delivered from
bypass cut spool (309). the hydraulic pump P1. And the oil is returned to
And the oil is returned to hydraulic tank from tank hydraulic tank from tank port T.
port T.
307 T 309
T2
P1
P2
T
CONTROL VALVE
AT INDEPENDENT TRAVEL
If travel operation (forward) is performed, the second- to port AL and is supplied to the left travel motor VB
ary pilot pressure from ports 2 and 4 of the travel side, the same way as the pressure oil by pump P1.
pilot valve acts upon ports PAr and PAL of the control Meanwhile, the oil which has returned from the right
valve and moves the right and left travel spools (306). and left travel VA side passes between the outer
The pressurized oil delivered by pump P1 flows into circumference of the right and left travel spool (306)
the main passage (51) past the travel straight spool and the casing and returns to the hydraulic tank via
(307), passes between the outer circumference of the the tank port T of the low pressure circuit D.
right travel spool (306) and the casing and is supplied At reverse travel action (when the secondary pilot
to the right travel motor B by way of port Ar. pressure acts upon ports PBr and PBL of the control
In the meantime, the pressurized oil delivered by valve), the pressurized oil works the same way as in
pump P2 passes between the outer circumference of the forward travel action.
the left travel straight spool (306) and the casing, runs
VA VB
306
Br Ar
PILOT PORT
PBr
PAr
51 52 51
R0204
T3-3-18 E215-E235
CONTROL VALVE
P2 P1
CMR2 CMR1
CA
T
PTb
DB
T
T C D A B Usual Position ( I )
CA
T
DB
CA
T
DB
R0205
E215-E235 T3-3-19
CONTROL VALVE
Bucket
PILOT PORT
PAc PBc
Ac Bc
U-SHAPED PASSAGE
LCc
R H
BUCKET CYLINDER
R0206
T3-3-20 E215-E235
CONTROL VALVE
PBc
PAc
Ac
U-SHAPED PASSAGE
Ac Bc
LCc
R H
BUCKET CYLINDER
R0207
E215-E235 T3-3-21
CONTROL VALVE
Boom
CHAMBER E
PAb PBb
H H
R0208
T3-3-22 E215-E235
CONTROL VALVE
Pca
U-SHAPED PASSAGE
PB1
R0209
E215-E235 T3-3-23
CONTROL VALVE
CHAMBER
D 301 E
CONFLUX
PASSAGE
BOOST CHECK IN CASING (52) (53)
LOCK VALVE
SELECTOR SPOOL
PBb
PLC1
Drc
LOCK VALVE
SELECTOR
Bb
(Ab)
CHAMBER 514 LCb U-SHAPED PASSAGE
BOOM CYLINDER BH
R R
H H
R0210
T3-3-24 E215-E235
CONTROL VALVE
Arm
ARM CYLINDER
H R
CHAMBER
302 LCa 514 AR
(Ba)
Aa
PAa
PBa
CONTROL VALVE
PCb
PA1
(53) CCa
R0212
T3-3-26 E215-E235
CONTROL VALVE
CONTROL VALVE
PLc2
Drd
LOCK VALVE
SELECTOR
ARM CYLINDER
LOCK VALVE
H R CHAMBER SELECTOR
514 AR SPOOL
Aa
PAa
Pis
D
(60)
D
Pis
(61)
CAr
Position ( II )
Usual recirculation
R0213
T3-3-28 E215-E235
CONTROL VALVE
CONTROL VALVE
PLc2
Drd
LOCK VALVE
SELECTOR
ARM CYLINDER
PAa
311
Pis
(60)
D
D
Pis
(61)
CAr
Position (I)
Recirculation cut
R0214
T3-3-30 E215-E235
CONTROL VALVE
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
PAa
(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 the U-shaped passage in the swing spool (303),
pressure from port c or e of the LH pilot valve acts passes between the outer surface of the swing spool
upon port PAs, PBs1 or PBs2 of the control valve and (303) and the casing and is supplied to A or B of the
shifts the swing spool (303) rightward or leftward. swing motor from the As port or the Bs port.
The oil delivered by pump P2 enters the bypass circuit In the meantime, the oil which has returned from the
(55) past the main passage (54), but since the circuit B or A side of the swing motor passes between the
is shut off as the swing spool (303) is shifted, the outer circumference of the swing spool (303) and the
pressure pushes the check valve CP2 open, enters casing through the port Bs or As, flows from the low
the parallel circuit (56) and pushes the swing load pressure circuit D to the tank port T and returns to the
check valve LCs open. The pressure, which enters hydraulic oil tank.
303
PBs2
Pss PAs
PBs1
(55)
R0216
E215-E235 T3-3-33
CONTROL VALVE
The lock valve (514) is housed in between the arm WHEN MAIN SPOOL IS AT NEUTRAL POSITION
cylinder rod side (R) and the arm spool (302) on the
control valve, and the leak is reduced by the hold The following explains the boom spool (301).
pressure from the cylinder. (Same as the arm spool (302) )
Similarly, the lock valve (514) is housed in between When the boom spool (301) is placed on the neutral
the boom cylinder rod side (H) and the boom spool position, it is held on the position shown in the Figure
(301) on the control valve, and the leak is reduced below.
caused by the hold pressure from the cylinder. 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.
Sb
Sa
a b L541
(301) R0217
T3-3-34 E215-E235
CONTROL VALVE
Sb
Sa
Pressurized
part of poppet a b L541
(514)
PBb { PAa
301
R0218
E215-E235 T3-3-35
CONTROL VALVE
PL 621
611
R0220
512 611 PL
R0221
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
511 541
R0223
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
(SH)
IP
PG
RELIEF VALVE
(A PORT SIDE)
A
DB
PA
R0227
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
Weight kg 49
Model M2X120B
Weight kg 158.5
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
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
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
•
• •
• 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
DIRECTIONAL VALVE
R0234
Operation of relief valve
SWING DEVICE
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
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
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
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
SWING DEVICE
Operation
10
23
12
9 1
R0247
E215-E235 T3-5-1
TRAVEL DEVICE
OUTLINE
Characteristics
Model 710 C3 K
Max. output torque (theoretical) 705.8 Nm at 343 bar 807.1 Nm at 343 bar
static 470 Nm
Parking brake torque
dynamic 370 Nm
TRAVEL DEVICE
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
P1
P2
R0754
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
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.
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
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
SWIVEL JOINT
OPERATION
The swivel joint consists mainly of body (1) and stem The body (1) and the stem (2) rotate mutually. The oil
(2) that rotate mutually, thrust plate (3) preventing flowing in from body (1) or stem (2) keeps on flowing
both components from falling off, cover (4) closing to stem (2) or body (1) past the circumferential groove
one side of body (1), seal (5) that partitions off the between body (1) and stem (2); the oil flow is never
circuits and seal assy (6) and O-Ring (7) that prevent shut off because of rotation. Further, an oil groove for
external leaks. lubrication that connects with the drain port is pro-
Four ports for the travel main circuits are provided on vided, in order to prevent the body (1) from seizure
body (1) and stem (2). Further, four oil passing with the stem (2).
grooves are arranged in the inner surface of body (1), This construction keeps on connecting the circuits
with seal (5) fixed above and below the circumferen- between the swing bodies by means of a swivel joint.
tial groove.
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
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
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)
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
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)
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
CYLINDERS
Bucket cylinder
25 24 12 24 25
B
100_00.5
100_00.5
PS1/8
1055
PS1/8
27
45° SLIT
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
CYLINDERS
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
R0257
T3-7-6 E215-E235
CYLINDERS
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
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
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
Heater circuit
IN OUT
OUT IN
R0302
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
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
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
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
Cooling circuit
AIR CONDITIONER
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
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
OPERATIONAL PERFORMANCE
TEST
CONTENTS
Group 1 - Introduction
INTRODUCTION
Use the data for the criterion, for the purpose of DETERMINING CORRECTION, ADJUSTMENT
correction, adjustment and replacement. OR REPLACEMENT
WHEN PERFORMANCES ARE DETERIORATED Machine performances deteriorate with time as parts
wear and some deteriorated performances may be
Determine whether it is caused by a fault or end of restored to new levels. Therefore, determine correc-
service life after long hours of operation, to be used for tion, adjustment or replacement, depending upon the
safety and economical considerations. operating hours, kind of work and circumstances in
which the machine is placed, and condition the ma-
WHEN MAIN COMPONENTS ARE REPLACED chine performances to its most desirable levels.
For example, use data to restore performances of
pumps and others. Other Cautions to be Exercised
INTRODUCTION
The machine
Test area
Precautions
STANDARD PERFORMANCES
NOTE - The mode is already "W" mode when power is thrown. Unless otherwise specified, measure it on "H/M"
mode.
Cleanliness of hydraulic oil Hydraulic oil in tank NAS 8 or less Class — Sampling
Std. Measuring condition
— —
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
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
Warming up of engine
PICK UP
R0318
6 LOW E/G
OIL PRESS
BUZZER STOP
Engine speed measured value through service SWITCH
diagnosis
TEST PROCEDURES
MEASUREMENT OF 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
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.
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.
quired.
Main circuit No. 14
Pilot secondary pressure No. 9~13
E215-E235 T4-3-3
TEST PROCEDURES
R0323
R0324
T4-3-4 E215-E235
TEST PROCEDURES
a3
PR1
Dr3
B3
R0325
R0326
E215-E235 T4-3-5
TEST PROCEDURES
R0329
T4-3-6 E215-E235
TEST PROCEDURES
3
R
1 turn Approx. 10
R0331
E215-E235 T4-3-7
TEST PROCEDURES
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.
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.
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.
TEST PROCEDURES
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
TEST PROCEDURES
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.
R0339
E215-E235 T4-3-11
TEST PROCEDURES
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
R0341
T4-3-12 E215-E235
TEST PROCEDURES
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:
TEST PROCEDURES
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
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
TEST PROCEDURES
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.
Drain rate of
swing motor Unit: L/30 s R0347
TEST PROCEDURES
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.
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
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.
TEST PROCEDURES
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.
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
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
STARTER
SWITCH
GAUGE
GOVERNOR
CLUSTER
MOTOR
ENGINE
PUMP
ENGINE
SPEED
BUZZER WORK MODE SENSOR
STOP SW. SELECT SW.
R0356
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
Speed sensor
R0360
Installing place: engine flywheel housing
R0361
E215-E235 T4-4-3
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
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
Stop at A position
R0364
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
R0077
TROUBLESHOOTING E215-E235
Section 5 TROUBLESHOOTING
Group 1 Mechatro Control
Group 2 Hydraulic System
Group 3 Electrical System
SECTION 5 E215-E235
TROUBLESHOOTING
CONTENTS
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.
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
MECHATRO CONTROL
Independent operation
E215-E235
Bucket dump
Bucket digging
Swing operation
TROUBLE DIAGNOSIS
{
{
{
{
{
{
{
{
{
{
{
{
{
22
E
S
{
{
{
{
{
{
{
{
{
{
{
{
{
23
E
S
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
solenoid proportional valve
P2 bypass cut
B
V
S
P
{
solenoid proportional valve
Electric
P1 bypass cut
V
S
P
{
{
{
{
{
{
{
{
{
{
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
{
{
Swing motor
{
{
{
Boom
{
{
{
{
{
Arm
Cylinder
{
{
Bucket
{
{
{
{
MECHATRO CONTROL
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
MECHATRO CONTROL
PUMP RELATION
PSV-P1 - Pump 1
proportional SOL
Pump assy
Pump high pressure sensor SE-22, SE-23
Pump proportional valve PSV-P1, PSV-P2 R0135
R0138
MECHATRO CONTROL
R0136
UPPER HARNESS
MECHATRO CONTROL
Components
Travel straight
P1 bypass cut
P2 bypass cut
Swing P/B
Tightening torque
7.0 Nm
P2 P1
T
HYDRAULIC SYMBOL
P2 P1
P2
A8 A8 A7 A6 A5 A4 A3 A2 A1
2–Ø11
DIRECTIONAL VALVE
CONNECTOR
A8 A7 A6 A5 A4 A3 A2 A1
DETAIL OF DIRECTIONAL
VALVE CONNECTOR R0140
MECHATRO CONTROL
22x25.4 HEX
PF3/8
PF1/4
Vcc GND
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
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
Down { { { { { {
Fine
4 Boom
Up { { { { { { { { { { { {
Arm in and out { { { { { { { { { { { {
5 Travel 1, 2 speed change impossible { { { {
Travel operation
HYDRAULIC SYSTEM
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
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
YES
YES
HYDRAULIC SYSTEM
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
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
HYDRAULIC SYSTEM
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
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
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
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.
T5-2-6 E215-E235
HYDRAULIC SYSTEM
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
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.
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.
HYDRAULIC SYSTEM
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)
Hasn't the weight changed by the change NO Change ATT to normal one
of ATT's? and reconfirm.
YES
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
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.
HYDRAULIC SYSTEM
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
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
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
HYDRAULIC SYSTEM
YES
(Service Diagnosis No. 24, 25)
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
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
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
HYDRAULIC SYSTEM
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
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
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.
HYDRAULIC SYSTEM
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
HYDRAULIC SYSTEM
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)
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
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
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
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
HYDRAULIC SYSTEM
Machine can not perform fine operation of bucket digging and dump
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.
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
HYDRAULIC SYSTEM
Machine can not perform fine operation of boom raise and lower motions
To electrical troubleshooting.
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
HYDRAULIC SYSTEM
Machine gets normal if connector of P2 bypass cut proportional valve is YES To electrical troubleshoot-
disconnected. ing.
NO
YES
Return spring of arm spool is broken. Replace arm spool assy.
NO
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
To electric troubleshoot-
ing.
Is it OK after connector of unload pro- The secondary pressure for Check unload proportional
YES NO
portional valve was disconnected? unloading is approx. 2.4MPa valve for possible damage
or more. (Travel & ATT). or replace it.
NO
YES
HYDRAULIC SYSTEM
(continue)
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
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
Relief pressure value when traveling NO Check travel motor relief valve for possible damage or
are within standard values. replace it.
YES
HYDRAULIC SYSTEM
Engine idling speed in travel operation NO Refer to Article "Travel Deviation" or "Travel speed is
is within standard values. poor".
YES
HYDRAULIC SYSTEM
(continue)
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
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
HYDRAULIC SYSTEM
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
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
HYDRAULIC SYSTEM
(continue)
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 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
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 travel straight spool moves smoothly by NO There is flaw around the travel straight YES
Replace travel straight spool.
hand. spool.
YES NO
Machine can not be held on a slope when YES Inspect or replace travel mo-
engine is off. tor.
NO
HYDRAULIC SYSTEM
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
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
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
HYDRAULIC SYSTEM
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
Is the motion slow if pump delivery ports P1 and NO Inspect or replace P2 pump
P2 are exchanged? proportional valve.
NG
HYDRAULIC SYSTEM
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
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
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 relief pressure lies within standard level. NO Inspect or replace swing mo-
27.9MPa. tor relief valve.
YES
Machine drifts very much when swing parking YES Inspect or replace swing mo-
is released (arm in action) on a slope. tor.
NO
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 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
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
HYDRAULIC SYSTEM
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
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.
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
All operation
Bucket digging
3
Electrical system
Boom up
Arm in
impossible
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
All operation
All operation
3 Sealed grounding
•
5
4
{
{
P1 bypass cut proportional valve D
•
7
6
{
{
{ {
{ {
{ {
{
{ {
P2 bypass cut proportional valve B
{
{
{
{
Travel straight proportional valve C
{
• • •
{
{ {
16 18 20
C1 mechatro controller
{
Swing parking SOL
Governor motor & proportional valve & SOL
Battery relay
Cluster gauge
CN-16
{ {
{ {
{ {
{ {
{ {
{ {
{ {
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
{ {
{
{
{
{
{
{
{
V
S
P
{
{
{
{
V
S
P
{
{
{
{
{
{
{ {
{ {
{
{
3
V
S
{
{
{
{
7
E
S
{
{
{
{
{ { { { { { {
{
{
{
Accel potentio
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING
No motions operate
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
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
ELECTRICAL SYSTEM
NO
(Service Diagnosis No. 9,10,11,12,13)
YES
Replace proportional valve.
NG
ELECTRICAL SYSTEM
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.
NO
(Diagnosis No. 24,25)
YES
Inspect electric wiring of faulty
sensor or pilot valve.
ELECTRICAL SYSTEM
YES
Replace proportional valve.
NG
ELECTRICAL SYSTEM
NO
Replace high pressure sensor
for pump pressure.
NG
YES
Replace proportional valve.
NG
ELECTRICAL SYSTEM
To hydraulic troubleshooting.
E215-E235 T5-3-11
ELECTRICAL SYSTEM
YES YES
Replace pump proportional
valve.
NG
NO
Replace high pressure sensor
for pump pressure.
NG
ELECTRICAL SYSTEM
Is the speed in empty bucket single operation NO Refer to "Only bucket motion
normal? is slow".
YES
To hydraulic troubleshooting.
Is the speed in empty bucket single operation NO Refer to "Only boom up speed
normal? motion is slow".
YES
YES YES
Replace proportional valve.
NG
To hydraulic troubleshooting.
E215-E235 T5-3-13
ELECTRICAL SYSTEM
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 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
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
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)
YES YES
Replace P1 pump propor-
tional valve.
NG
YES
YES
Replace proportional valve.
NG
ELECTRICAL SYSTEM
YES YES
Replace P1 pump propor-
tional valve.
NG
YES
YES
Replace proportional valve.
NG
ELECTRICAL SYSTEM
YES YES
Replace P2 pump propor-
tional valve.
NG
YES
(Diagnosis No. 9,10,11,12,13)
YES
Replace proportional valve.
NG
ELECTRICAL SYSTEM
YES
YES
Replace proportional valve.
NG
ELECTRICAL SYSTEM
YES
YES
Inspect electric wiring of faulty
sensor or pilot valve.
YES
Replace proportional valve.
NG
ELECTRICAL SYSTEM
Machine does not travel straight. (Check ATT and travel actions at full lever stroke.)
YES
Replace proportional valve.
NG
ELECTRICAL SYSTEM
YES
(Service Diagnosis No. 47, No. 48)
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 mechatrocontroller.
To hydraulic troubleshooting.
E215-E235 T5-3-21
ELECTRICAL SYSTEM
To hydraulic troubleshooting.
ELECTRICAL SYSTEM
NO
Refer to "Swing motion does
not work".
NO
Are actual relief pressure readings normal? To hydraulic troubleshooting.
YES
ELECTRICAL SYSTEM
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
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
ELECTRICAL SYSTEM
NOTE:
REPAIR INSTRUCTIONS
R0077
REPAIR INSTRUCTIONS E215-E235
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
GENERAL INFORMATION
CONTENTS
2) Check the seal ring face (A) for scuffing, scoring, B SM1001
b b
a=b a≠b
SM1003
W1-1-4 E215-E235
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
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
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.
R0114
W1-1-8 E215-E235
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
SM1005
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.
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
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.
SM1009
Nut and Bolt Lockings
RIGHT WRONG
• Lock Plate
• 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
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°
SM1013
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
IMPORTANT
1. Be sure to replace O-Ring (6) with a new one when
reconnecting.
TIGHTENING TORQUE
Screwed-In Connection PT PF
30°
SM1018 SM1019
E215-E235 W1-2-7
TIGHTENING TORQUE
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
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
CAB
Removal of cab
WARNING
Approximate mass of the cab: 270 kg
380001057
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
CAB
NOTES:
E215-E235 W2-2-1
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.
AIR CONDITIONER
3
2. Assembly blower unit
4
a. Assembly is the reverse order of disassembly.
8 7
IMPORTANT - Do not separate the fan from the blower R0004
motor.
14
IMPORTANT - Do not disassemble the blower control- 9
ler in any circumstances.
12
6. Assembly the blower controller 13 R0005
AIR CONDITIONER
15
13
12
R0008
W2-2-4 E215-E235
AIR CONDITIONER
1
R0010
E215-E235 W2-2-5
AIR CONDITIONER
4 1 R0011
11 R0013
15. Assembly the motor actuator
AIR CONDITIONER
NOTES:
E215-E235 W2-3-1
COUNTERWEIGHT
Removal of counterweight
2
WARNING
Approximate weight of counterweight: 4400 kg
R0014
R0015
R0016
W2-3-2 E215-E235
COUNTERWEIGHT
Installation of counterweight
WARNING
Approx. weight of counterweight: 4400 kg
: 46 mm
R0017
: 46 mm
: 1570 Nm
6 7 R0018
E215-E235 W2-4-1
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.
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
Front
SM1143
SM1144
14
SM1380
E215-E235 W2-4-3
MAIN FRAME
SM1146
W2-4-4 E215-E235
MAIN FRAME
13
WARNING
Massa approssimativa del telaio superiore:
5875 kg
Upperstructure side
: 563 ± 56 Nm
14
3. Install the centre joint performing the operations SM1380
SM1147
E215-E235 W2-5-1
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. 3. Remove hydraulic oil tank cap. Connect a vacuum
pump to maintain negative pressure in the hydrau-
2. Cut-off the engine. Press the valve located on the lic oil tank.
hydraulic oil tank to release the residual pressure
present inside the tank itself.
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.
WARNING
Hydraulic pump device weight: 131 kg
W2-5-2 E215-E235
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
PUMP DEVICE
Disassembly
: 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).
362
352
R0751
: 8 mm
R0701
W2-5-4 E215-E235
PUMP DEVICE
R0702
R0703
R0704
E215-E235 W2-5-5
PUMP DEVICE
10. Remove socket bolt (406) and seal cover (261). 406
: 5 mm
261
R0705
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
312
314 (313)
R0709
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
R0711
R0712
W2-5-8 E215-E235
PUMP DEVICE
111 R0713
: 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
R0715
E215-E235 W2-5-9
PUMP DEVICE
312
NOTE - Do not mistake the suction and delivery sides
of the valve plate.
314 (313)
R0716
PUMP DEVICE
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)
R0719
Gap between piston and caulked 0 ~ 0.1 0.3 Replace piston shoe assy.
part of shoe (δ)
R0720
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)
PUMP DEVICE
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
PUMP DEVICE
Disassembly
PUMP DEVICE
R0726
439
641
655 R0727
814 (653)
R0728
615
614
R0729
W2-5-16 E215-E235
PUMP DEVICE
614
R0730
613 (875)
R0731
R0732
611
R0733
E215-E235 W2-5-17
PUMP DEVICE
Assembly
623
1. Assembly is the reverse order of disassembly. Do
the work paying attention to the following: 622 621
R0736
W2-5-18 E215-E235
PUMP DEVICE
NOTE - Make sure that the spool and the sleeve move
smoothly in the casing.
Beware of the direction of the spool.
R0737
613 (875)
R0739
R0740
E215-E235 W2-5-19
PUMP DEVICE
R0741
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
PUMP DEVICE
414
117 128
126 435
826 886 711
326
128
414
115
827 886 262
728
125 468
118
125
825
435
435
R0745
PUMP DEVICE
Disassembly
R0746
PTO
Gear casing
R0747
W2-5-22 E215-E235
PUMP DEVICE
R0748
5. Remove snap ring (825) and draw out 3rd gear (118)
and ball bearing (125).
118
R0749
Assembly
Maintenance standard
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. Refer to “Bleed Pressure from Hydraulic Circuit” on
2. Cut-off the engine. Actuate the manual and pedal page W4-2-12.
pilot valves to release any residual pressure from 3. Remove hydraulic oil tank cap. Connect a vacuum
insidet he hydraulic system. Press the valve lo- pump to maintain negative pressure in the hydrau-
cated on the hydraulic oil tank to release any lic oil tank.
residual pressure present inside the tank itself.
NOTE - Be sure to run the vacuum pump continu-
ously while working.
Removal of Control valve 1. Install control valve to frame and tighten the bolts.
2. Connect all hoses, pipes and connectors to the
control valve.
NOTE - Attach caps to hoses and pipes.
3. Install the panel protecting the control valve using
Attach labels or tags to hoses and pipes, to aid in
the relevant securing screws.
assembly.
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
CAUTION
Control valve assembly weight: 180 kg
CONTROL VALVE
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
CONTROL VALVE
Preliminary operations
Disassembly
CONTROL VALVE
: 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
CONTROL VALVE
R0438
R0439
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
CONTROL VALVE
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).
R0469
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
CONTROL VALVE
R0472
R0473
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
CONTROL VALVE
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).
R0477
: 10 mm
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
CONTROL VALVE
R0481
R0482
324
305
323
R0483
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
CONTROL VALVE
R0485
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
CONTROL VALVE
R0489
R0490
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
CONTROL VALVE
: 6 mm
203(262)
R0493
102
R0494
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
CONTROL VALVE
203(262)
R0497
307(327,329,332,334,337)
R0498
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
CONTROL VALVE
R0501
R0502
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
CONTROL VALVE
R0505
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
CONTROL VALVE
R0508
R0509
602
R0510
E215-E235 W2-6-29
CONTROL VALVE
R0511
552
(512,522)
R0513
CONTROL VALVE
: 22 mm 611
562 663
621
561 122
125 121
521
124 541
123 512
R0515
: 32 mm
e. Separate snap ring (121) and spacer (122)
from plug (103).
541(121) 103
R0516
E215-E235 W2-6-31
CONTROL VALVE
511
563
564 301 R0517
101
R0518
W2-6-32 E215-E235
CONTROL VALVE
CONTROL VALVE
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
CONTROL VALVE
: 16-18 Nm : 88-98 Nm
NOTE - Before tightening bolts (334), coat them with NOTE - Use care so parts are assembled in correct
Loctite #262. Use care so as not to distort cut spool positions and make sure that each plunger slides
(309, 310) by overtightening it in the vise. lightly in boom spool (301).
: 10 mm
d. Attach O-Rings (261) to the spring side of the
: 16-18 Nm boom spool assy. Then fit spring cover (201) to
the assy and tighten socket bolts (273) (Q.ty 2)
NOTE - When tightening bolts (333), coat them with to the specified torque.
Loctite #262. Take care so as not to distort arm spool
(302) by overtightening it in the vise. : 6 mm
: 25-34 Nm
b. Fit the arm spool assy to casing A (101).
CONTROL VALVE
7. Assembling boom conflux spool. c. Fit O-Ring (261) to the spring side of the bucket
spool assy and attach spring cover (201) to the
a. Fix spring cover (207) in a vise, put O-Ring (166)
assy. Then tighten socket bolts (273) (Q.ty 2) to
in plug and fasten it to the specified torque.
the specified torque.
: 27 mm
: 6 mm
: 69-78 Nm
: 25-34 Nm
b. Put a protective plate (aluminum plate, etc.) and
hold the middle of boom conflux spool (305) in 9. Assembling swing spool.
the vise. Set spring seat (331),(Q.ty 2) springs
(323 and 324) and stopper (339) and tighten bolts a. Put a protective plate (aluminum plate, etc.) to
(333) to the specified torque. the vise and hold the middle of swing spool
(303). Set spring seat (331) (Q.ty 2), springs
: 10 mm (321 and 322) and stopper (336) and tighten bolts
(333) to the specified torque.
: 16-18 Nm
: 10 mm
NOTE - When tightening bolts (333), coat them with
Loctite #262. Use care so as not to distort boom : 16-18 Nm
conflux spool (305) by overtightening it in the vise.
NOTE - When tightening bolts (333), coat them with
c. Fix the boom conflux spool assy into casing A Loctite #262. Be careful so as not to distort swing
(101). spool (303) by overtightening it in the vise
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
CONTROL VALVE
NOTE - When tightening bolts (334), coat them with NOTE - When assembling the rod spool (312) into
Loctite #262. Be careful so as not to distort travel casing A (101), do it slowly and carefully; never force
spool (306) by overtightening it in the vise. it in.
b. Assemble the travel spool assy into casing A c. Fit O-Ring (264) to the spool cover (205) to the
(101), B (102). assy and tighten socket bolts (273) (Q.ty 2) to
the specified torque.
NOTE - When assembling the travel spool assy into
casings A (101), B (102), do it slowly and carefully, : 6 mm
never force it in. : 25-34 Nm
CONTROL VALVE
15. Assembling overload relief valve. d. Put O-Ring (P261) to the spring side of the
option spool assy, attach spring cover (P202)
a. Assemble spring seat (612) with poppet (611),
to the assy and tighten socket bolts (P271)
spring (621) and O-Ring (661), into plug (102)
(Q.ty 2) to the specified torque.
that is fitted with O-Rings (162), (561) and
backup ring (562). Then temporarily assemble : 6 mm
adjust screw (651) and locknut (671).
: 25-34 Nm
NOTE - Make certain that poppet (611) is snugly fitted e. Install spool cover (P204) with O-Ring (P262)
in the seat of plug (102). and fasten socket bolt (P271) (Q.ty 4) to the
specified torque.
b. Fit O-Ring (563) and backup ring (564) to seat f. Install overload relief valve (P603) to casing
(541) and attach the seat to plunger (511) and (214) and fasten it to the specified torque.
assemble piston (301) and springs (521, 522). : 32 mm
c. Assemble the seat (541) assy into body (101) : 69-78 Nm
and tighten the plug (102) assy in par. 1) to the
specified torque. g. Fit O-Ring (P161) (Q.ty 3) into casing (214).
CONTROL VALVE
MAINTENANCE STANDARD
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, 1. If a defect detectable with your fingernail
rusting and corrosion. is found on the sliding part of the outer
circumference, replace the spool.
2. Inspect ends that are sealed 2. If the sliding part is damaged, replace
with an O-Ring. the spool.
3. Insert the spool in the casing 3. If the spool damages the O-Ring or
bore, and move it while turning does not move smoothly, repair or
it. replace the spool.
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.
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
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
SWING DEVICE
Removal
WARNING 7
Swing unit weight: 205 kg 8
R0282
E215-E235 W2-7-3
SWING DEVICE
Installation
WARNING
Swing unit weight: 205 Kg.
SWING DEVICE
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
SWING DEVICE
Preliminary operations
Disassembly
5 18
R0285
E215-E235 W2-7-7
SWING DEVICE
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
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.
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).
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.
28 34 5 18
R0397
W2-7-10 E215-E235
SWING DEVICE
28 18
5
R0398
5
R0399
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
"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.
: 14 mm
: 334 Nm
SWING DEVICE
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
SWING DEVICE
Preliminary operations
160
Disassembly 290 R0403
15
6. Draw out #2 sun gear (15) and remove the #2
spider assy.
R0406
W2-7-14 E215-E235
SWING DEVICE
180
350±10
R0407
8 R0408
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
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.
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
R0413
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
4. Heat sleeve (2) to 100-120 °C, fit O-Ring (5) and fix 5
it into pinion shaft (1).
13
12
19
9
R0417
W2-7-18 E215-E235
SWING DEVICE
Motor Side
29
R0418
25
28
17
29 26
R0419
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
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).
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
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
Standard Recommended
Item Dimension Value for Remedy
(mm) Replacement (mm)
Clearance between piston and cylinder bore
(D-d)
R0427
R0428
R0429
Replace a spherical
H 5.5 5.0 bushing and a retainer
h plate as a pair.
R0430
R0431
W2-7-22 E215-E235
SWING DEVICE
OIL
LEVEL
D
C
LOCTITE 515
LOCTITE 515
R0432
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
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.
Removal
5 1
1. Free and lift rubber cap (5) complete with plate (4) 6
unlocking its hooks using a screwdriver. 7
3
8
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
: 22 mm R.H. R0116
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
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.
Removal
8 3
NOTE - Attach a cap on each of disconnected hose
ends. 4
7
: 17 mm
W2-8-4 E215-E235
PILOT VALVE
Installation
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
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
PILOT VALVE
R0120
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
R0122
22
R0123
7 R0124
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
28
R0126
23
22
R0127
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
7 9
R0130
18. Remove inside seal (6) from plug (7) with small
driver.
6 R0261
Cleaning parts
PILOT VALVE
NOTES:
W2-8-12 E215-E235
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
PILOT VALVE
19
R0264
R0265
W2-8-14 E215-E235
PILOT VALVE
7
6
9
HYDRAULIC OIL
R0266 R0267
9 7 10 11
R0268
22 7 R0269
R0270
E215-E235 W2-8-15
PILOT VALVE
22 380001055
R0271
9
R0273
W2-8-16 E215-E235
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
PILOT VALVE
PILOT VALVE
24
5
41
R0276
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
: 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
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
: 58.8 ± 4.9 Nm
R0279
E215-E235 W2-8-21
PILOT VALVE
PILOT VALVE
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.
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 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
: 22 39.2 Hose
W2-9-2 E215-E235
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).
SECTION A-A
2
3
1
4
A A
A8 A7 A6 A5 A4 A3 A2 A1
R0109
UNDERCARRIAGE
CONTENTS
SWING BEARING
Removal
Mark
1. Put alignment marks on swing bearing (1) and track
frame (2).
1 2
SM1307
: 30 mm
3 R0062
WARNING
Swing bearing weight: 245 kg
4 SM1309
W3-1-2 E215-E235
SWING BEARING
Installation
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
SM1310
3
R0062
E215 W3-2-1
TRAVEL 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. 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.
WARNING 2
Travel device weight:
Approx. 300 kg
TRAVEL DEVICE
Preliminary operations
TRAVEL DEVICE
Gearbox disassembly
2. Unscrew the socket bolts (1) (Q.ty 10) which fix the
end cover (2) to the gearbox housing (3). 2
: 8 mm
R0520
R0521
W3-2-4 E215
TRAVEL DEVICE
4. Remove the O-Ring seal (1) from the end cover (2).
1
R0522
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
R0527
10. Take out the spacers (3) from the pin of the
hydraulic motor (4). 3
R0528
W3-2-6 E215
TRAVEL DEVICE
R0529
R0530
R0531
R0532
E215 W3-2-7
TRAVEL DEVICE
15
movement of the unit. Remove the safety retainer A
when the unit is positioned (scketch below).
10
40
A-A
R0534
R0533
R0535
16. Take out the spacer from the hydraulic motor (2).
R0536
W3-2-8 E215
TRAVEL DEVICE
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
R0540
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
R0544
2
R0545
6. Remove the O-Ring seal (3) from its seat in the plug
(2). 3
2
R0546
R0547
E215 W3-2-11
TRAVEL DEVICE
R0548
2. Take out the free piston (3) from the relief valve (1).
R0549
R0550
R0551
W3-2-12 E215
TRAVEL DEVICE
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
R0558
R0559
W3-2-14 E215
TRAVEL DEVICE
R0560
nd
10. Take out the 2 flanged plug (2).
R0561
R0562
R0563
E215 W3-2-15
TRAVEL DEVICE
13. Take out the 2nd spring seat (1) from the counter-
balance valve spool (2).
2
R0564
R0566
6
5
R0567
W3-2-16 E215
TRAVEL DEVICE
R0569
5
R0570
R0571
E215 W3-2-17
TRAVEL DEVICE
R0572
R0573
R0574
R0575
W3-2-18 E215
TRAVEL DEVICE
R0576
R0577
R0578
R0579
E215 W3-2-19
TRAVEL DEVICE
R0580
R0581
R0582
R0583
W3-2-20 E215
TRAVEL DEVICE
1
R0584
R0585
R0586
R0587
E215 W3-2-21
TRAVEL DEVICE
R0588
R0589
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
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
R0600
E215 W3-2-25
TRAVEL DEVICE
Preliminary operations
R0601
R0602
W3-2-26 E215
TRAVEL DEVICE
R0603
R0604
R0605
R0606
E215 W3-2-27
TRAVEL DEVICE
R0607
R0608
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
R0611
2
R0612
R0613
R0614
R0615
E215 W3-2-29
TRAVEL DEVICE
R0616
R0617
R0618
R0619
W3-2-30 E215
TRAVEL DEVICE
2
R0620
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
R0624
R0626
4
5
R0627
W3-2-32 E215
TRAVEL DEVICE
R0628
R0629
R0630
R0631
E215 W3-2-33
TRAVEL DEVICE
380001065
R0632
R0633
R0634
R0635
W3-2-34 E215
TRAVEL DEVICE
R0636
R0638
R0639
E215 W3-2-35
TRAVEL DEVICE
R0641
R0642
R0643
W3-2-36 E215
TRAVEL DEVICE
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
R0648
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
R0655
E215 W3-2-39
TRAVEL DEVICE
R0656
Backup ring
R0658
O-Ring
R0657
2
4
R0659
W3-2-40 E215
TRAVEL DEVICE
5. Insert the relief valve (1) inside the base plate (2).
2
R0660
380001068
R0662
R0663
E215 W3-2-41
TRAVEL DEVICE
3. Insert the two speed spool (1) in the base plate (2). 2
1
R0664
R0665
R0666
W3-2-42 E215
TRAVEL DEVICE
380001068
2
R0667
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).
c
1
135
a
b
20
Ø 244.5
20 Ø 260.5
R0669
a b
R0670
W3-2-44 E215
TRAVEL DEVICE
R0671
380001069
R0672
E215 W3-2-45
TRAVEL DEVICE
2
R0673
3
R0674
R0675
R0676
W3-2-46 E215
TRAVEL DEVICE
R0677
A
10
40
A-A
R0534
R0533
R0678
E215 W3-2-47
TRAVEL DEVICE
R0679
R0680
Stake
Ø 4 to 5 mm
(depth 1 to 1.5 mm)
R0681
R0682
R0683 R0684
W3-2-48 E215
TRAVEL DEVICE
R0685
R0686
R0687
R0688
nd
21. Assemble the 2 reduction assembly (4).
4
R0689
E215 W3-2-49
TRAVEL DEVICE
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
R0693
W3-2-50 E215
TRAVEL DEVICE
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
Sprocket
E
A
SM1103
IMPORTANT - Consult FIAT KOBELCO S.p.A. for any inqueries concerning welding procedures.
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. 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
pilot valves to release any residual pressure from hydraulic oil tank.
inside the hydraulic system. Press the valve
located 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
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
1
2
4
8
7
5
6
R0038
W3-3-2 E215-E235
SWIVEL JOINT
R0039
R0040
9
R0041
E215-E235 W3-3-3
SWIVEL JOINT
: 6.8 Nm 3
4
R0042
WARNING
Swivel joint weight: 31 kg
Installation
R0043
WARNING
Swivel joint weight: 31 kg
W3-3-4 E215-E235
SWIVEL JOINT
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
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.
3. Remove cover (4) from body (1) and draw out O-Ring
(7) from cover (4).
R0046
R0047
W3-3-6 E215-E235
SWIVEL JOINT
A
R0048
R0049
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
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 mm
: 30.4 Nm
R0053
R0054
E215-E235 W3-3-9
SWIVEL JOINT
MAINTENANCE STANDARD
Sliding surface
Scored or something hurt it. Replace
and sealed parts
Cover Sliding surface ring 2. Wear less than 0.5 mm. Repair
Replace (with
back-up ring)
R0055
1.5 mm (max)
R0056
R0057
W3-3-10 E215-E235
SWIVEL JOINT
TRACK ADJUSTER
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.
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.
SM1802
W3-4-2 E215
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
SM1161
WARNING
Track adjuster weight: 103 kg
R0098
E215 W3-4-3
TRACK ADJUSTER
11 10
R0099
1
3 R0100
: 75 mm
R0101
W3-4-4 E215
TRACK ADJUSTER
11
R0102
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
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
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.
TRACK ADJUSTER
NOTES:
W3-4-8 E235
TRACK ADJUSTER
6 7 8
4
3
SM1803
TRACK ADJUSTER
WARNING 12
13
Do not attempt to eject the piston from cylinder
using compressed air. SM1804
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.
2 1 3 4
R0021
TRACK ADJUSTER
8 Vs
13 Vr
SM1806
FRONT IDLER
Disassembly
8
6
5
4
R0089
R0090
380001052
6
3
1
R0091
W3-5-2 E215
FRONT IDLER
380001052
6 3
R0092
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
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
FRONT IDLER
Front Idler
C D
A
B
SM1189
Unit: mm
A 84 66
B 159 -
D 540 -
E 20 -
IMPORTANT - Consult FIAT KOBELCO for any inqueries concerning welding procedures.
FRONT IDLER
WARNING
Front idler weight: 130 kg
9
SM1807
2
6
4 5
7 3
5 8
FRONT IDLER
4
7
5
3
5
6
1 2
2
6
4
7
SM1809
FRONT IDLER
WARNING
Wear safety glasses with side shields or goggles, to
reduce the danger of personal injury from flying
particles.
FRONT IDLER
Front Idler
C D
A
B
SM1810
Unit: mm
A 85 67
B 175 -
D 590 -
E 20 -
IMPORTANT - Consult FIAT KOBELCO for any inqueries concerning welding procedures.
E215 W3-6-1
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
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.
4
SM1828
SM1827
W3-6-2 E215
R0024
Installation
2-4 1 3-4
R0025
SM1230
E215 W3-6-3
SM1234
8. Add engine oil via plug (3) hole on cover (4). Apply
sealant (Loctite 503 or equivalent) to plug (3).
Tighten plug (3).
4
R0026
W3-6-4 E215
NOTES:
E235 W3-6-5
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
SM1811
WARNING 3
4
SM1828
SM1827
W3-6-6 E235
: 24 mm
SM1232
WARNING
Upper roller weight: 21 kg
3
SM1233
Installation
WARNING
Upper roller weight: 21 kg
SM1232
SM1230
E235 W3-6-7
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).
SM1812
W3-6-8 E215-E235
Removal
5
1. Remove the roller guard and loosen bolts (5).
: 30 mm
SM1236
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
E235
3
3
4
R0019
WARNING
Lower roller weight:
35 kg (E215)
48 kg (E235)
Installation
2 1
1. Securely hold the lower roller using a fork lift.
Put lower rollers (1) on the tracks as illustration.
SM1239
SM1240
: 27 mm
: 400 Nm
4
SM1236
W3-6-10 E215-E235
3
4
R0019
Grease Outlet
R0020
SM1234
E215 W3-6-11
5. Loosen two socket bolts (9) and draw out plate (4)
from roller (1).
R0027
: 8 mm
380001047
380001045
R0028
W3-6-12 E215
R0029
7
IMPORTANT - Collar (3) is press fitted into shaft (2) by
means of press.Therefore do not disassemble it. 3
R0030
380001045
R0031
E215 W3-6-13
R0033
R0034
W3-6-14 E215
6. Coat shaft (2) with a thin film of oil and insert it into PUSH
upper roller (1). WITH PRESS
R0035
10. Fix snap ring (11) into upper roller (1), using snap
ring pliers.
R0036
12. Wind seal tape around plug (10) and screw it into
the plug hole of cover (5).
: 6 mm 1
: 23 Nm
R0037
E235 W3-6-15
SM1241
W3-6-16 E215
3
2
4
5
8
6
7
6
5
4
3
2
1
SM1242
: 6 mm
: 14 mm
SM1243
SM1245
W3-6-18 E215
2 7 6 5 4 3 1
8
SM1246
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
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
7
1
4 3
A 2
6 1
7
A
SM1813
: 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
SM1818
W3-6-22 E235
2 7 3 6 1 4 5
SM1819
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.
3. Install floating seal (1) into roller (6) and support (7).
7 4 SM1821
1 7
SM1822
7
SM1823
Recommended oil:
SAE 40
Quantity: 0.4 kg
SM1824
W3-6-24 E215
Upper Roller
A
B SM1251
Unit: mm
A 84 -
B 150 - Replace
C 140 130
Lower Roller
C A C
B
SM1252
Unit: mm
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 Roller
A
B
SM1825
Unit: mm
A 84 -
B 153 - Replace
C 150 140
Lower Roller
C A C
B
SM1826
Unit: mm
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
NOTES:
E215-E235 W3-7-1
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
SM1254
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
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
SM1259
SM1260
E215-E235 W3-7-3
TRACKS
Installation
SM1261
SM1262
SM1263
SM1264
W3-7-4 E215-E235
TRACKS
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
: 19 mm
: 59 Nm
: 24 mm
: 147 Nm
TRACKS
MAINTENANCE STANDARD
A
SM1266
Unit: mm
Standard Allowable Limit Remedy
E 215 E 235 E 215 E 235
Master Pin
E215 E235
B
A
A
R0087 SM1269
Unit: mm
TRACKS
Master Bushing
B C
A
SM1267
Unit: mm
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
A 220 222.5 - -
C 25.5 28 15 14
SECTION 4 E215-E235
FRONT ATTACHMENT
CONTENTS
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
SM1317
Removal
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
Wooden Block
SM1320
: 36, 41 mm 7 8
SM3504
: 19 mm
R0072
E215-E235 W4-1-3
FRONT ATTACHMENT
11
10
9
R0059
WARNING
Approximate mass of the front equipment:
3450 kg
SM1323
10. Pull out the boom lower pivot pin (1) to the frame
using the appropriate puller (380001031).
380001031
R0060
SM1325
W4-1-4 E215-E235
FRONT ATTACHMENT
Installation
WARNING
Approximate mass of the front equipment:
3450 kg
SM3504
WARNING
Boom cylinder weight: 177 kg
SM1326
E215-E235 W4-1-5
FRONT ATTACHMENT
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
: 24 mm
: 270 Nm
SM5521
W4-1-6 E215-E235
FRONT ATTACHMENT
MAINTENANCE STANDARD
F E
G
C
H
D J
A
I
K
B
SM1328
Unit: mm
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
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
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.
NOTE - Hit the lock pin (1) with the drift (2) on the pin
tapered portion to drive it out of its seat. 4
SM1329
• 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
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
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
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
SM1357
Removal
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
FRONT ATTACHMENT
Wooden block
SM1320
32 8 31
R0061
R0072
E215-E235 W4-1-13
FRONT ATTACHMENT
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.
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).
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
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
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
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.
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
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
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
FRONT ATTACHMENT
NOTES:
E215-E235 W4-2-1
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
: 24 mm
6 SM3506
W4-2-2 E215-E235
CYLINDERS
14
SM1333
WARNING
Bucket cylinder weight: 17
153 kg
10
12
CYLINDERS
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
5. Install bolt (5), onto pin (6) and stopper (18); tighten
lock nuts (4).
: 24 mm
6 3 4
: 270 Nm
SM3506
CYLINDERS
2 1
4. Remove pin (9) and thrust plate (13).
10
R0064
SM1337
16
R0065
E215-E235 W4-2-5
CYLINDERS
WARNING 1
Arm cylinder weight:
251 kg
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
WARNING
Arm cylinder weight:
251 kg
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 - For easy alignment, start the engine and use SM1337
the arm control lever.
: 24 mm
2
: 270 Nm 1
10 R0064
E215-E235 W4-2-7
CYLINDERS
: 19 mm
1
WARNING
Boom cylinder weight:
177 kg
WARNING
Boom cylinder weight: 11 11
177 kg
9 9
10 10
8 8
R0068
W4-2-8 E215-E235
CYLINDERS
WARNING
Boom cylinder weight:
177 kg
2. Install adjusting shims (10) and pin (9), then tighten SM1342
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).
CYLINDERS
PREPARATION
REMOVAL 5 6
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
R0070
W4-2-10 E215-E235
CYLINDERS
WARNING 1
Positioning arm cylinder weight:
251 kg
11
R0071
E215-E235 W4-2-11
CYLINDERS
INSTALLATION 12
1 10
WARNING
Positioning arm cylinder weight:
251 kg
CYLINDERS
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.
CYLINDERS
6 1
5 2
8
4
R0075
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
CYLINDERS
Disassembly of Boom and Bucket Cylinders 5. Remove set screw (22) and steel ball (23).
SM1366
SM1364 7. Remove seal ring (17), slide rings (19), (20), O-ring
(18) and backup rings (16) from piston (15).
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
CYLINDERS
Disassembly of Arm Cylinder 5. Remove set screw (22) and steel ball (23).
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
380001025
SM1365
W4-2-18 E215-E235
CYLINDERS
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
CYLINDERS
Disassembly of Positioning Cylinder 5. Remove set screw (22) and steel ball (23).
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).
380001025
SM1365
W4-2-20 E215-E235
CYLINDERS
ASSEMBLY CYLINDERS
Boom Cylinder
18 23
1 2 3 4 56 7 8 9-10 11 12 13 14 1516 17 19 20 21 22 24
Bucket Cylinder
18 23
1 2 3 4 5 6 7 8 9-10 11 12 13 14 15 16 17 19 20 21 22 24
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)
2. Install seal (3), back-up ring (2), elastic ring (6) and
seal (4) on the cylinder front sleeve (7).
SM1365
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
CYLINDERS
Arm Cylinder
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
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)
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)
15
CYLINDERS
18 23
1 2 3 4 5 6 7 8 9-10 11 12 15 16 17 19 20 21 22 24
R0086
CYLINDERS
Assembly of Positioning Cylinder 8. Install shim (21) to cylinder rod (11). Tighten nut
(triple articulation version) (24) using special tool (380001025).
15
11. Install cylinder head (7) to cylinder tube (12).
Tighten socket bolts (8).
SM1367
: 17 mm
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
CYLINDERS
SPECIAL TOOLS
SM1369
Tool for the installation and removal of the rod guide bushing:
CYLINDERS
NOTES:
E215-E235. Schematic Wiring diagram reading key
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.