Introduction

SY215CLC

7) When removing components, be careful

not to break or damage electrical wiring.
Damaged wiring may cause electrical fires.
8) When removing piping, stop fuel or oil from
spilling out. If any fuel or oil drips onto the
floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip and can
even start fires.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical
parts, in particular.
10) Be sure to assemble all parts again in their
original places. Replace any damaged
parts and non-reusable part. When install-
ing hoses and wires, be sure that they will
not be damaged by contact with other parts
when the machine is operated.
11) When installing high pressure hoses, make
sure they are not twisted. Damaged hoses
 SY215CL C
Crawler Hyd
Hydrauli
raulic
c Excavato
Excavator 
r 
Shop Ma
Manu
nual
al
 Table of Contents
SY215CLC

Table of Content
Contentss

1 Introduction
1.1 Safety Notice .....................
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...........................................
..........................................
..................... 1-3
1.2 How to Read the Shop Manual .....................
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............. 1-13
1.3 Terms for Maintenance Standard......................
...........................................
...........................................
................................
.......... 1-16
1.4 Handling Electrical and Hydraulic Components................................... .................. 1-19
1.4.1 Points to remember when
when handling electric components
components ......................
............................
...... 1-19
1.4.2 Points to remember when
when handling hydraulic equipment
equipment ......................
............................
...... 1-28
1.5 Hose Connector .....................
...........................................
............................................
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.............. 1-30
1.5.1 Ty
Type
pe of
of hose
hose connector
connector...................
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............................................
.......................................
................. 1-31
1.5.2 Hose connector tightening torque table ......................
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.................................
............ 1-31
1.5.3 Connection of O-rings .....................
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.......................................
................. 1-32
1.6 Table of Standard Tightenin
Tightening
g Torques .....................
...........................................
............................................
........................ 1-33
Table of Contents
SY215CLC

2.2.7 Removing Attachments ....................

..........................................
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................ 2-10
2.2.8 Cleaning the Machine ...................
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................... 2-10
2.2.9 Using the Correct Tools
Tools....................
..........................................
............................................
.......................................
.................2-1
2-11
1
2.2.10 Hoisting a Load ...................
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............................2-11
......2-11
2.2.11
2.2.11 Appropriate Working Apparel .....................
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.... 2-12
2.2.12 Safety Partners ...................
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...... 2-12
2.2.13 Two people when engine running ...................
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..................... 2-13
2.2.14 Driving Pins .....................
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......... 2-13
2.2.15 Aligning Parts or Components ...................
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..........................
.... 2-14
2.2.16 Fire Extinguisher
Extinguisher and Emergency Exits .....................
...........................................
................................
.......... 2-14
2.2.17 Personal Protective Equipment................................. ......................
.................................
........... 2-14
2.2.18 Running the Machine ......................
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................ 2-15
2.2.19 Accumulator ....................
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......... 2-16
2.2.20 Adding Fluids to a System .....................
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........ 2-16
2.2.21 Track Recoil Springs 2-17
 Table of Contents
SY215CLC

3.6 Engine Performance Curve ......................

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................... 3-9

4 Structure and Function

4.1 Engine and Cooling System .....................
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.........................................
................... 4-3
4.1.1 Engine-related parts........................
parts..............................................
............................................
.........................................
................... 4-3
4.1.2 Radiator and intercooler.............................. .....................
...........................................
..............................
........ 4-4
4.2 Power Train...................................... ......................
...........................................
...........................................
.............................
....... 4-5
4.2.1 Power transmission system .................................. .....................
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................... 4-5
4.2.2 Final drive AS (KYB) ...................
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........................ 4-6
4.2.3 Final drive AS (Nabtesco) ...................
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............... 4-8
4.2.4 Swing machinery...............................
machinery.....................................................
............................................
.....................................
............... 4-10
4.2.5 Swing bearing ......................
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....... 4-12
4.3 Undercarriage and Frame........................
Frame..............................................
............................................
........................................
.................. 4-13
4.3.1 Track frame and recoil spring........................
spring..............................................
............................................
.........................
... 4-13
4.3.2 Idler 4-15
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SY215CLC

4.5.3.1 When spool is in neutral position ....................

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.............. 4-48
4.5.3.2 Travel ...................
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............. 4-50
4.5.3.3 Arm...................
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................. 4-51
4.5.3.4 Boom....................
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...................................
............. 4-56
4.5.3.5 Bucket
Bucket ......................
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...........................................
................................
.......... 4-59
4.5.3.6 Swing ...................
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...................................
............. 4-61
4.5.3.7 Option ......................
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................................
.......... 4-63
4.5.3.8 Travel straight .....................
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............................................
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.................... 4-64
4.5.3.9 Lock valve function .....................
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..................................
............ 4-65
4.5.3.10 Main relief valve function ......................
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...................... 4-67
4.5.3.11
4.5.3.11 Port relief valve function ....................
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............................................
..........................
.... 4-68
4.5.4 Section view ......................
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...........................................
...............................
.......... 4-72
4.6 Hydraulic System, Part 3 ....................
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...........................................
...........................................
........................
.. 4-83
4.6.1 Swing motor ......................
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...........................................
...............................
.......... 4-83
4.6.2 Swing holding brake............................. 4-85
 Table of Contents
SY215CLC

4.6.12 Pump oil pressure sensor .....................

...........................................
............................................
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....... 4-125
4.6.13 Hydraulic cylinder.............................
cylinder...................................................
...........................................
..................................
............. 4-126
4.6.14 Work equipment ....................
..........................................
............................................
............................................
........................ 4-128
4.7 Air Conditioning System...........................
System.................................................
...........................................
......................................
................. 4-132
4.7.1 A/C components layout drawing .....................
...........................................
...........................................
..................... 4-133
4.7.2 Control panel..........................
panel................................................
...........................................
...........................................
.........................
... 4-134
4.7.3 Circuit diagram .....................
...........................................
...........................................
...........................................
...........................
..... 4-135
4.7.4 Refrigeration principle ......................
...........................................
...........................................
.....................................
............... 4-137
4.7.4.1 Refrigeration cycle diagram ...................
.........................................
...........................................
..................... 4-137
4.7.4.2 Heating cycle diagram ...................
.........................................
............................................
.............................
....... 4-137
4.7.5 Compressor .....................
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...........................................
...........................................
...............................
......... 4-138
4.7.6 Clutch...................
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.................... 4-140
4.7.7 Condenser ...................
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..................................
............ 4-141
4.7.8 Expansion valve...................
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...........................................
..........................
..... 4-142
4.7.9 Evaporator 4-142
Table of Contents
SY215CLC

4.9.3 Engine and

and pump composite control
control function ......................
............................................
...................... 4-175
4.9.4 Pump control function ...................
.........................................
...........................................
.......................................
.................. 4-179
4.9.4.1 Electrical positive