SAFETY PRECAUTIONS
M0103
SAFETY PRECAUTIONS
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INDEX
Section 1
GENERALITIES
Section 2
SAFETY PRECAUTIONS
Section 3
SAFETY PLATES
GENERALITIES
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SAFETY PRECAUTIONS
GENERALITIES
Read the Operation and Maintenance Instruction Manual carefully before starting, operating, maintaining, fuelling or servicing the machine.
Do not leave the machine until it has come come to to a complete stop. Always check height, width and weight limitations which may be encountered in the working site and ensure the machine does not exceed them.
Carefully read the explanation to each and all safety signs in the special section of this Manual before starting, operating, maintaining, fuelling or servicing the machine. Machine-mounted safety plates are colour coded yellow with black borders when when they refer to points where special ATTENTION must ATTENTION must be paid and failure to observe them may cause a serious DANGER to the integrity of machine operators. They are white with red borders and black lettering when they refer to a FORBIDDEN practice. FORBIDDEN practice.
Assess exact paths of gas ducts, water mains, telephone lines, sewers, overhead and underground electric lines and all other possible obstacles. Such paths should be opportunely defined by competent Authorities. If necessary, require that the service is interrupted or said installations are moved prior to starting the work. You must know the working capacity of the machine. Define the rear upperstructure swing area and provide for opportune barriers to prevent access into it.
It is fundamental that all machine operators know very well the meaning of each safety plate as this considerably decreases operating hazards and accidents.
Never exceed machine lifting capacity. Remain within the limits shown in the loading capacity chart which located on the machine.
Do not allow unauthorised personnel to operate or service this machine. Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, no-slip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators every time the job requires it. Ask your employer about safety regulations in force and protective equipment.
STARTING Never start or operate a failed machine. Walk all around the machine before mounting. Before operating the machine, make sure that any possible dangerous condition has been properly removed. Before starting machine, check that steering and attachment controls are in the neutral position and the safety lever is in the LOCK position. Immediately report any malfunction of parts or systems to the the maintenance managers for proper action.
Always keep the operator’s compartment, step plates, grab-rails and handles clean and clear of foreign objects, oil, grease, mud or snow to minimise the danger of slipping or stumbling. Remove mud or grease from your shoes before operating the machine.
Prior to starting the engine, check, adjust and lock the driver’s seat for maximum riding comfort and control accessibility. Prior to operating the machine and/or its attachments, check that bystanders are outside the machine operating range. Sound the horn.
Do not jump on or off the machine. Always keep both hands and one foot, or both feet and one hand in contact with steps and/or grab rails.
Obey all hand signals, safety indications and signs.
Do not use controls or hoses as hand holds. Hoses and controls are movable parts and do not provide solid support. Besides, Besides, controls may be inadvertently moved and cause unexpected movement of the machine or its attachments. Never operate the machine or its attachments from any position other than sitting in the driver’s seat. Keep head, body, limbs, hands and feet inside the operator’s compartment at all times to reduce exposure to external hazards.
Due to the the presence of flammable fluids, never check fuel level, refuel, charge the batteries in the presence of smoking materials, open flames or sparks. Ensure that nobody is within the excavator operating area before starting the machine, swinging the upper structure or moving in any direction. Adjust all rear-view mirrors for maximum visibility of the area behind the machine.
Be careful of possible slippery conditions of the steps and hand rails as well as of the ground around the machine. Wear protective boots or shoes with the soles made of highly no-slip rubber
Ensure that engine speed is appropriate to the job to be carried out.
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If any hydraulic control or system exhibits erratic performance or responds abnormally, have the machine checked for air in the system.
properly protected against possible backlash in case of cable or chain failure or detachment. Be alert of soft ground conditions close to newly constructed walls. The fill material and machine weight may cause the wall to collapse under the machine.
Air in these circuits may cause incorrect movements with consequent accident hazard. Refer to the Operation and Maintenance Instruction Manual about corrective action to be taken.
In darkness, check area of operation carefully c arefully before moving in with the machine. Use all lights provided. Do not move into low visibility areas. If the engine tends to slow down and stall for whatever reason under load or at idle, immediately report this problem to the maintenance managers for proper action.
OPERATING Do not run the engine of this machine in closed buildings without proper ventilation capable to remove harmful exhaust gases which concentrate in the air.
Do not operate the machine until this condition is corrected. Regularly check all exhaust system components, as exhaust fumes are toxic for the operator.
Keep the operator’s compartment free of foreign objects, especially if not firmly secured. Never use the machine to transport objects, unless proper securing points are provided.
Operators must know the performance of the machine they are driving. When working on slopes or near sudden level drops in the terrain, pay attention not to lose adherence and avoid loose soft ground since overturn or loss of machine control could result.
Do not carry riders on the machine. machine. Study and familiarise with escape routes alternative to normal exit routes. For your personal safety, do not climb on or off the machine while it is in motion.
If noise level is high and exceeds 90 dB (A) over 8 hours at the operator’s ear, wear approved ear protection in compliance with local regulations.
Make sure that bystanders are clear of the machine operating range before starting the engine and operating the attachment. Sound the horn. Obey all hand signals, safety indications and signs.
Do not operate the machine if you are extremely tired tired or feel ill. Be especially careful towards the end of the working shift.
When backing, always look to where where the machine is to be moved.
Where removable counterweights are provided, do not operate the machine if they have been removed.
Be alert of the position of bystanders. Should someone enter the work area, stop the machine. Maintain a safe distance from other machines or obstacles to ensure required visibility conditions. conditions.
When operating the machine, keep in mind height limits of overhead doors, arches, overhead cables and lines as well as width limits of corridors, roads and narrow passages.
Always give way to loaded machines.
Also, get to know load limits of the ground and paving type of the ramps you are to work on.
Maintain a clear vision of the surroundings of the travel or work work area at all times. Keep cab windows clean and repaired.
Beware of fog, smoke or dust that obscure visibility.
When pulling loads or towing through a cable or chain, do not start suddenly at full throttle. Take-up slack carefully. Avoid kinking or twisting twisting chains or cables. Carefully inspect the towing items for flaws or problems before proceeding. Do not pull through a kinked chain or cable as the high anomalous ano malous stresses existing in this condition may induce failures in the kinked portion.
Always inspect the working area to identify potential risks such as: inclines, overhangs, trees, demolition rubble, fires, ravines, steep slopes, rough terrain, ditches, crowns, ridge trenches,diggings in traffic areas, crowded parking lots, crowded service areas, fenced zones. In such conditions, proceed with extreme care.
Always wear heavy gloves when handling chains or cables. Chains and cables should be securely anchored using suitable hooks. Anchor points should be strong enough to withstand the expected load. Keep anyone clear of anchor points and cables or chains. Do not pull or tow unless the operator’s compartments of the machines involved are S1 - 2
Whenever possible, avoid crossing over obstacles such as very rough terrain, rocks, logs, steps, ditches, railroad tracks. When obstructions must be crossed, do so with extreme care and at a square angle, if possible. Slow Slow down. Ease up to the break-over point, pass the balance point slowly and ease down the other side also using the attachment, if necessary. To overcome deep trenches or sinking ground, place the machine perpendicular to the obstacle, drastically reduce ground speed and start crossing using also
GENERALITIES
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the attachment if necessary, only after assessing that ground conditions allow the traverse safely and without risks.
The load must always be properly arranged in the bucket; move with extreme care when transporting oversize loads.
The gradient you may attempt to overcome is limited by factors such as ground conditions, load being handled, machine type and speed, and visibility. There is no substitute for good judgement and experience when working on slopes.
Do not lift and move the bucket overhead where persons are standing or working, nor downhill when working on a slope as this would decrease machine stability. Load the bucket from the uphill side. Loads to be raised using the machine should be exclusively hooked to the hitch specially provided.
Avoid operating the attachment too close to an overhang or high wall, either above or below the machine. Beware of caving edges, falling objects and landslides. Remember that such hazards are likely to be concealed by bushes, undergrowth and such.
The excavator is no lifting and transportation means, therefore it should not be used to position loads accurately. Should it be exceptionally used to lift and lay building components, special caution must be taken as follows:
Avoid faggots, bushes, logs and rocks. Never drive over them, nor over any other surface irregularities that discontinue adherence or traction with the ground, especially near slopes or drop-offs.
- The machine must be equipped compulsorily with the appropriate variant provided upon request. - Secure the loads to be raised using cables or chains fastened with appropriate hooking mechanisms.
Be alert to avoid changes in adherence conditions that could cause loss of control. Work with extreme care on ice or frozen ground and on stepped slopes or near drop-offs. The word “bulldozing” generally refers to work in virgin rough terrain, characterised by the presence of all the perils and risks listed above. We emphasise the danger represented in these conditions by large tree limbs (possibly falling on the machine) and large roots (which may act as a leverage under the machine when up-rooted and cause the unit to overturn). Position the machine dependent upon the loading and unloading areas in order to swing leftwards to load to obtain best visibility. Never use the bucket or attachment as a man lift or carry riders. Never use the machine as a work platform or scaffolding. The machine must not be improperly used for works not consistent with its features (such as pushing railway cars, trucks or other machines).
- Nobody should be allowed to remain under the raised load or within the excavator operating range for any reason whatever. Never exceed specified loading capacity. Incorrect fastening of slings or chains may cause boom/arm failure or failure of the lifting means with consequent bodily injuries and even death. Always ensure that slings and chains used for lifting are adequate to the load and in good condition. All loading capacities are referred to the machine on a level surface and should be disregarded when working on a slope. Avoid travelling across slopes. Proceed from uphill downhill and vice-versa. If machine starts slipping sideways when on a slope, lower the bucket and thrust bucket teeth into the ground.
Always pay attention to people within the machine operating range. Never move or stop the bucket, other loads or the attachment above ground personnel or truck cabs.
Working on slopes is dangerous. Grade the working area if possible. Reduce work cycle time if it is not possible to grade the working area. Do not move full bucket or a load from uphill downhill as this would reduce machine stability. Do not work with the bucket turned to the uphill side.
Ensure the truck driver is in a safe place before loading the truck.
Do not work with the bucket turned uphill as counterweights protruding downhill would reduce machine stability on the slope and increase risk of overturning.
Load trucks from side or rear. Use only the type of bucket recommended considering machine type, materials to be handled, material piling up and loading characteristics, ground type and other typical conditions of the work to be performed.
We recommend to work on slopes with the bucket downhill, after checking machine stability with the bucket empty and attachment retracted, by slowly swinging the upper structure by 360°.
When transporting a loaded bucket, keep it as rolled-back as possible. Keep boom and arm as low as possible.
Position the carriage at a right angle relative to slopes, hanging walls, etc. to exit the working area easily.
Ground speed should be adequate to the load and ground conditions.
Standard use, provides for the travel controls at the front and travel motors at the back. Should travel S1 - 3
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GENERALITIES
motors be positioned at the front with regard to the actual travel direction. Remind relative to travel direction that controls are reversed.
- Look up the in the telephone directory. - Define together with the Company representative which precautions should be taken to guarantee work safety.
Always check travel motor position before moving off.
- All electric lines should be considered as operative live lines even though it might be well known that the line in question is out of work and visibly connected to the ground.
Properly judge ground conditions with particular attention to consistency of the area you are going to work on. Keep the machine sufficiently edge.
far from the ditch
- The Electric Power Company, if previously advised and involved in the work, as well as machine Operator, Owner and/or any natural person or legal entity having rent orleased the machine or being responsible at the time by contract or by law, are liable for the adoption of the necessary precautions.
Never dig under the machine. Should it be necessary to dig under the machine, always ensure that digging walls are opportunely propped up against landslide to prevent the machine from falling into the trench. Do not swing the upperstructure, raise the load or brake abruptly if not required. This may cause accidents.
- Decrease work speed. Reaction time could be too slow and distance evaluation wrong. - Warn all ground personnel to keep clear of the machine and/or load at all times. If the load has to be guided down for laying, consult the Electric Power Company to know which precautions should be taken.
Prior to beginning the work near gas distribution mains or other public utilities: - Contact the company owner of the gas mains or its nearest branch before starting the work. Look up the number in the telephone directory.
- Appoint a person in charge of signalling duties. This person will have the responsibility of observing the machine, any part of it and/or the load approaching the electric lines from a standpoint more favourable than the Operator’s. This signal man (flag-man) must be in direct communication with the Operator and the Operator must pay undivided attention to the signals supplied.
- Define together which precautions should be taken to guarantee work safety. - Decrease work speed. Reaction time could be too slow and distance evaluation wrong. - When working near gas mains or other public utilities installations, appoint a person in charge of signalling duties. This person will have the responsibility of observing the machine, any part of it and/or the load approaching the gas mains from a standpoint more favourable than the Operator’s. This signal man (flag-man) must be in direct communication with the Operator and the Operator must pay undivided attention to the signals supplied. - The gas distributing Company, if previously advised and involved in the work, as well as machine Operator, Owner and/or any natural person or legal entity having rent or leased the machine or being responsible at the time by contract or by law, are liable for the adoption of the necessary precautions.
When working in or near pits, in ditches or very high walls, check that the walls are sufficiently propped up to avoid cave-in hazards. Pay the utmost attention when working near overhang walls or where landslides may take place. Make sure that the support surface is strong enough to prevent landslides. When digging, there is the risk of cave-ins and landslides. Always check ground conditions and conditions of the material to be removed. Support everywhere it is required to prevent possible cave-ins or landslides when: - Digging near previous trenches filled with material.
Working near electric lines can be very dangerous, therefore some special precautions must be observed.
- Digging in bad ground conditions.
Within this Manual, “work near electric lines” means when the attachment or load raised by the excavator (in any position) may reach the minimum safety distance established by local or international Safety Regulations. To work without risks, keep maximum possible distance from electric lines and never trespass minimum safety distance. - Contact the Company owner of the electric lines or its nearest branch before starting the work. S1 - 4
- Digging trenches subject to vibration from railroads, working machines or highway traffic.
STOPPING When the machine is to be stopped for whatever reason, always check that all controls are in the neutral position and that the safety lever is on the lock position to guarantee risk-free start-up.
GENERALITIES
Never leave the machine unattended with the engine running.
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Read all safety plates mounted on the machine and observe instructions they contain before starting, operating, repairing, fuelling or servicing the machine.
Prior to leaving the driver’s seat, and after making sure that all people are clear of the machine, slowly lower the attachment until resting it safely to the ground. Retract possible auxiliary tools to the closed safety position.
Do not allow unauthorised personnel to repair or service the machine. Follow all recommended maintenance and service procedures.
Check that all controls are in the neutral position. Move engine controls to the shut-down position. Switch off the key-start switch. Consult the Operation and Maintenance Instruction Manual.
Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, no-slip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators when required. Ask your employer about safety regulations in force and protective equipment.
Park the machine in a non-operating and no-traffic area. Park on firm level ground. If this is not possible, position the machine at a right angle to the slope, making sure there is no danger of uncontrolled sliding. If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and other signals as required to adequately warn the oncoming drivers.
Do not use controls or hoses as hand holds. Hoses and controls are movable parts and do not provide solid support. Besides, controls may be inadvertently moved and cause unexpected movement of the machine or its attachments.
Always switch off the key-start switch before cleaning, repairing, or parking the machine to prevent accidental unauthorised start-up.
Do not jump on or off the machine. Always keep both hands and one foot, or both feet and one hand in contact with steps and/or grab rails.
Never lower the attachment or auxiliary tools other than from sitting in the operator’s seat. Sound the horn. Make sure that nobody is within the machine operating range. Lower the attachment slowly.
Never service the machine with someone sitting in the driver’s seat, unless this person is an authorised operator assisting in the maintenance being carried out.
Securely block and lock the machine every time you leave it unattended. Return keys to the safe place previously agreed upon. Perform all necessary operations for stopping as detailed in the Operation and Maintenance Instruction Manual.
Keep the operator’s compartment, step plates, grab rails and handles clear of foreign objects, oil, grease, mud orsnow to minimise the danger of slipping or stumbling.
Drive the machine far from pits, trenches, rocky hanging walls, areas with overhead electric lines, and slopes before stopping it at the end of the working day.
Clean mud or grease from your shoes before climbing on the machine or driving it. Never attempt to operate the machine or its attachments from any position other than sitting in the operator’s seat.
Align the upperstructure to the tracks in order to allow to easily get on and off the driver’s compartment. Move all controls to the position specified for machine stopping. Refer the Operation and Maintenance Instruction Manual.
Keep the driver’s seat free from foreign objects, especially if these are not secured. Should it be necessary to move the attachment for maintenance purposes, do not raise or lower the attachment from any other position than sitting in the operator’s seat. Before starting the machine or moving its attachment, sound the horn and require that nobody remains near the machine.
Never park on an incline without accurately blocking the machine to prevent unexpected movement. Follow stopping instructions contained in the Operation and Maintenance Instruction Manual.
Raise the attachment slowly.
MAINTENANCE GENERALITIES
Always lock all moving components or parts of the machine that must be lifted for maintenance purposes using adequate external means as required by local and national regulations. Do not allow anyone to pass or stay near or below a raised attachment. If you are not absolutely sure about your safety, do not stay or walk under a raised attachment.
Carefully read the Operation and Maintenance Instruction Manual before starting, operating, maintaining, fuelling or servicing the machine in any manner.
Do not place head, body, limbs, hands, feet or fingers near articulated cutting edges deprived of the necessary guards, unless they are suitably and safely locked. S1 - 5
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Never lubricate, repair or adjust the machine with the engine running, except when this is specifically required by the Operation and Maintenance Instruction Manual.
flammable fluids to clean parts. Use proprietary certified non-flammable, non-toxic solvents only. When using compressed air to clean parts, wear safety glasses with side shields. Limit pressure to max. 2 bars, in accordance with local and national safety regulations in force.
Do not wear loose clothing, jewellery near rotating parts. When service or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform conforming to local or national regulations to reach the working area. If such means are not available, use machine grab rails and steps. Always perform all service or maintenance work with the greatest care and attention.
Do not run the engine of this machine in closed buildings without proper forced ventilation capable to remove toxic exhaust gases concentrating in the air. Do not smoke, nor allow open flames or sparks nearby while refuelling the unit or handling highly flammable materials. Do not use open flames as light sources to look for leaks or inspect anywhere on the machine.
Shop and/or field service platforms or ladders should be manufactured and maintained in accordance with local or national safety regulations in force.
Make sure that all mechanical tools provided are in good condition at all times. Never use tools with mushroomed or damaged heads. Always wear eye protections with side shields.
Disconnect batteries and label all controls to warn that service work is in progress, according to local and national safety regulation requirements.
Move with extreme care when working under, on or near the machine or its attachments.
Block the machine and all attachments to be raised according to local and national safety regulation requirements. Do not check or fill fuel tanks or install batteries near burning or smoking materials and open flames due to the presence of flammable vapours. The fuel filler pipe nozzle must be constantly kept in contact with the filler neck and this even before fuel starts flowing in. Keep this contact from the beginning to the end of the fuelling operation to avoid possible generation of sparks due to static electricity.
In case of attachment tests during which the engine should be kept running, a qualified operator must sit in the driver’s seat at all times while the mechanic is at work. Keep hands and clothes far off moving parts. Stop the engine and move the safey lever to the lock position before starting adjusting or repairing an assembly.
Use a truck or trailer to haul a failed machine. Should it be necessary to tow it, provide for suitable danger signals as required by the local norms and regulations and observe recommendations given in the Operation and Maintenance Instruction Manual. Load/unload the machine on firm level ground providing safe support to the wheels of the truck or trailer. Use strong access ramps, with adequate height and angle. Keep the trailer flatbed free of mud, oil or slippery materials. Tie the machine securely to the trailer and block carriages and upperstructure. Never align holes or slots using your fingers; alwaysuse appropriate aligning tools. Remove all sharp edges and burrs from re-worked parts.
Do not carry out any work on the attachment without prior authorisation. Observe maintenance and repair procedures. In case of field service, move the machine to level ground and block it. If work on an incline cannot be avoided, securely block the machine and its attachments. Move the machine to level ground as soon as possible. Do not twist chains and cables. Never use a twisted chain or cable for lifting or pulling. Always wear safety gloves to handle chains or cables. Be sure chains and cables are firmly fastened and that the anchor point is strong enough to withstand the expected load. Keep all bystanders clear of the anchor point, cables or chains. Do not pull or tow unless the operator’s compartments of the machines involved are fitted with proper guards against cable or chain backlash.
Use only approved and effectively grounded auxiliary power sources for heaters, battery chargers, pumps and similar equipment to reduce electrical shock hazard.
Keep the maintenance area clean and dry at all times.
Lift and handle heavy components using hoisting devices of appropriate capacity. Ensure the parts are supported by appropriate straps and hooks.
Clean immediately all water and oil spillage. Do not pile up oily or greasy rags as they represent a major fire hazard. Always store them in closed metal containers.
Use lifting eyes provided to this aim. Pay attention to bystanders near the lifting area. Never pour gasoline or diesel fuel into open containers. Never use gasoline, solvents or other
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Before starting the machine or its attachment, check, adjust and lock the operator’s seat. Also ensure that nobody is within the machine or attachment
GENERALITIES
operating range before starting or operating the machine and/or its attachments.
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injuries are most likely to occur. Pay attention to prevent possible part movements by means of blocks or by keeping clear of such zones when motion may take place during maintenance or repair.
Sound the horn. Rust inhibitors are volatile and flammable.
Move the hydraulic system lock safety lever to the lock position when stopping the machine for whatever reason.
Prepare parts in well ventilated areas. Keep open flames away. Do not smoke.
Always install the safety stays for the hood and other hinged covers before performing any maintenance or repair work in the engine compartment.
Store containers in a cool well ventilated place where they could not be reached by unauthorised people. Do not carry loose objects in your pockets that might fall unnoticed into open compartments. Wear appropriate safety clothing such as hard hat, safety shoes and gloves, safety glasses when splinters or other particles may be ejected.
TRANSFERS AND TRANSPORTATION Before moving or transporting the machine, block upperstructure swing to prevent accidental movement.
Wear the appropriate welder’s equipment such as dark safety glasses or mask, hard hat, protective clothing, safety gloves and footwear always while welding or arc-cutting. Wear dark safety glasses when you are near a welding in progress.
Pay particular attention during transfer on inclines, both uphill and downhill. Keep the bucket in a position to provide a possible anchor point into the ground in case of slipping.
Do not look the welding arc without proper eye protection.
During transfers on inclines, both uphill and downhill, keep the upperstructure aligned with the carriages. Do not travel across the slope.
Become acquainted with all your jacking equipment and their capacity. Ensure that the jacking point on the machine is appropriate for the load applied. Also, be sure the supports under the jack and between the jack and the machine are appropriate and stable.
Never transfer the machine in the working site, in a crowded area, or near people without having at least one person charged with hand-signals who could guide the Operator.
Any equipment supported by a jack represents a possible hazard. Always support the load onto appropriate blocking means as a safety measure before proceeding with service or maintenance work, in compliance with local or national safety regulations.
Sound the horn to inform that you are about to move off.
Metal cables produce steel splinters. Always wear certified protection clothes such as safety gloves and glasses while handling them. Do not use makeshift jacks to adjust track sag. Follow instructions given in the Repair Manual. Handle all parts carefully. Keep hands and fingers away from gaps, gears, and similar. Always use and wear certified safety clothes such as safety glasses, gloves and footwear. The attachment is kept constantly in position by an oil column trapped into the high pressure circuit. Lower the attachment to the ground and relieve pressure from all circuits prior to carrying out any type of maintenance or repair work. Do not service or repair the machine if it is parked downhill. If this is unavoidable, in case of emergency, block the carriages to prevent unexpected movement, particularly if the work is to be carried out on the final reduction units or travel motors.
It is necessary to know load limits of bridges and dimensional limits of tunnels. Such limits must never be exceeded. You should also know machine height, width, and weight. Have a signal-man help you when clearances are limited. Check distance between boom/arm and dimensional limits during transfer or transportation. Rough terrain may cause the machine to sway and roll to such an extent that boom/arm could get to contact electric lines or other obstacles. Cross obstacles at a right angle at low speed. Pay attention to machine shaking when the centre of gravity overcomes the obstacle. Keep the bucket down at all times during transfers. Drive with the lights on and use appropriate signals and flags. Get to know and respect local and national regulations. Consider boom/arm and upperstructure dimensions while turning. Use a ramp to load the machine on a trailer. If a ramp is not available, fabricate one using blocks. The ramp should be sufficiently strong to support machine weight. Always load and unload on level surface.
Consult the Operation and Maintenance Instruction Manual for correct maintenance procedure. Areas near articulated cutting edges where mechanical parts are in motion are where personal S1 - 7
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Tow the machine following the instructions contained in the Operation and Maintenance Instruction Manual.
Before any maintenance or repair, make sure that there are no fuel or electrolyte leaks from the batteries. If any, correct prior to proceeding with further work. Do not recharge batteries in confined spaces. Ensure proper ventilation is provided to avoid accidental explosions due to build-up of explosive gas released during charging.
ENGINE
Disconnect batteries before working on the electrical 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 level with the engine off or idling if hot. See the Operation and Maintenance Instruction Manual.
Pressure fluid escaping from a very small hole can be almost invisible and still have sufficient force to penetrate the skin. Always check any suspected pressure leaks using a piece of cardboard or wood.
Keep the exhaust manifold and tube free from combustible matters. Fit the machine with shields and guards when working in the presence of combustible matter free in the air.
Do not use hands. If injured by escaping fluid, obtain medical attention immediately or serious infection or reaction may develop. Stop the engine and ensure pressure is relieved from all systems before removing side panels, housings, guards and covers. See the Operation and Maintenance Instruction Manual.
Do not refuel with the engine running, especially if hot, as this increases fire hazard in case of fuel spillage. Never attempt to check or adjust fan belt tensions when the engine is running. Do not adjust the fuel injection pump when the machine is operating.
Always use gauges of adequate capacity for pressure testing. Refer to the Operation and Maintenance Instruction Manual or Repair Manual.
Do not lubricate the machine with the engine running. Do not run the engine with the air intakes open and not protected. If this cannot be avoided for service reasons, place protection meshes on all intakes before servicing the engine. ELECTRICAL SYSTEM
TOOLS Always keep head, body, limbs, feet, hands, and fingers away from the bucket and attachments, when in the raised position.
Pay attention to connect connecting cables to correct poles (+ to +) and (- to -) at both ends. Do not shortcircuit terminals. Thoroughly follow instructions given in Operation and Maintenance Instruction Manual.
Prior to any maintenance or repair work, install all supports necessary to this aim according to local and national safety regulations. In case the attachment is to be operated for maintenance or repair purposes, do so exclusively while sitting in the driver’s seat. Sound the horn before starting the machine or moving the attachment. Require that nobody remain near the machine. Raise the attachment slowly.
Always move the key-start switch in the lock position before servicing or repairing the machine. Batteries contain SULPHURIC ACID. Protect the eyes when working near the batteries against possible sprays of the acid solution. Should acid contact skin, eyes, or clothes, RINSE IMMEDIATELY IN WATER FOR AT LEAST 15 MINUTES. Immediately seek medical attention.
Do not use the machine to transport loose objects, unless proper securing devices are provided. Never use gases other than nitrogen to charge the accumulators.
Battery released gas is highly flammable. Leave the battery compartment cover open during recharging to improve ventilation. Never check battery charge by placing metal objects across the posts. Keep sparks or open flames away from batteries. Do not smoke near the battery to prevent explosion hazard. S1 - 8
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SAFETY PRECAUTIONS
RECOGNISE SAFETY INFORMATION • This is your SAFETY ALERT SYMBOL - When you see this symbol on your machine or in this Manual, be alert of the potential for personal injury. - Follow recommended precautions and safe operating practices.
UNDERSTAND SIGNAL WORDS • In this Manual you will find the following words referring to different hazard risks: - DANGER; - WARNING; - CAUTION.
DANGER
These words are always accompanied by the safety alert symbol. DANGER: indicates
an imminent hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING: indicated
CAUTION
CAUTION: indicates a potential hazardous situation
IMPORTANT
a potential hazardous situation which, if not avoided, could result in death or serious injury.
which, if not avoided, may result in minor or moderate injury. IMPORTANT: indicates a situation which, if not
avoided, may cause damage to the machine. NOTE: indicates an additional explanation for
information purposes.
ENVIRONMENTAL PROTECTION • This Manual also contains this symbol accompanying instructions for correct behaviour as regards environmental protection.
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NOTE
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SAFETY PRECAUTIONS
FOLLOW SAFETY PRECAUTIONS • Carefully read and observe all safety signs on the machine and read all safety precautions in this Manual. • Safety signs should be installed, maintained, and replaced when necessary. - If a safety sign or this Manual are damaged or missing, obtain a replacement from your Dealer in the same way you order a spare part (be sure to detail machine model and serial number upon ordering). • Learn how to operate the machine and its controls correctly and safely. • Allow only trained, qualified, authorised personnel to operate the machine. • Keep the machine in proper working conditions. - Unauthorised changes to the machine may impair function and/or safety and affect machine life. • Safety messages in this Chapter “SAFETY PRECAUTIONS ”, are intended to illustrate basic safety procedures of the machine. However, it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any doubts, consult your direct supervisor prior to operating or servicing the machine.
PREPARE FOR EMERGENCIES • Be prepared if a fire starts or an accident occurs. - Keep the first-aid kit and fire extinguisher on hand. - Thoroughly read and understand the label attached to the fire extinguisher to use it properly. - Establish emergency priority procedures to cope with fires and accidents. - Keep emergency numbers for doctors, ambulance service, hospitals and fire department posted near the telephone.
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SAFETY PRECAUTIONS
WEAR PROTECTIVE CLOTHING • Wear close-fitting clothing and safety equipment appropriate to the job. You need: - A hard hat; - Safety shoes; - Safety glasses or face shield; - Heavy gloves; - Ear protection; - Reflective clothing; - Waterproof clothing; - Respirator or filter mask; Be sure to correctly wear equipment and clothing for the job. - Do not take any chances. - Avoid wearing loose clothing, jewellery, or other items that can catch on control levers or other parts of the machine.
• Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.
PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. - Wear a suitable hearing protection such as earmuffs or earplugs to protect objectionable or uncomfortably loud noise.
INSPECT THE MACHINE • Inspect the machine carefully every day or workshift by an attentive visual inspection of machine outside prior to starting it to prevent damages and personal injuries.
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SAFETY PRECAUTIONS
USE HAND HOLDS AND STEPS • Falling is one of the major causes of personal injury. - When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. - Prior to climbing or leaving the machine, check that the fasteners of stepping points and the handrails are tightened and are undamaged. Repair them as required. - Keep the access to the machine clear of foreign objects and clean. Remove grease or mud from stepping points and rails to minimise the danger of slipping or stumbling. - Do not use the controls or the safety lever as hand holds when climbing on or off th e machine. - Do not climb or leave the machine running. Do not jump on or off the machine. - Do not climb or leave the machine while holding tools or other objects in your hands. - Do not climb or leave the machine while it is moving.
ADJUST THE OPERATOR'S SEAT • A seat poorly adjusted for operator or work requirements may quickly fatigue the operator leading to improper operations. - The seat should be adjusted whenever machine operator changes. - The operator should be able to fully press the pedals and correctly move the control levers with his back resting against the seat back. - If not, move the seat fore and aft, and check again.
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SAFETY PRECAUTIONS
FASTEN SEAT BELT • Should the machine overturn, the operator may become injured and/or thrown from the cab. Not only, the operator may be crushed by the overturning machine resulting in serious injury or even death. - Prior to operating the machine, thoroughly examine belt webbing, buckle, and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. - Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimise injury hazard in case of accident. - After a significant accident, replace the seat belts even though they do not look damaged.
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over. - Pay the utmost attention not to run over bystanders. - Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. Sound horn to inform bystanders that the machine is going to be operated. - When operating, swinging, or moving the machine in a congested area use a signal man.
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SAFETY PRECAUTIONS
OPERATE ONLY FROM THE DRIVER'S SEAT • Inappropriate engine starting procedures may cause the machine unexpected movement, possibly resulting in serious injury and even death. - Start the engine only from the operator’s seat. - NEVER start the engine while standing on the track or on the ground. - Do not start the engine by shorting across starter motor terminals. - Before starting the engine, ensure that all control levers are in the neutral position.
DO NOT CARRY PERSON ON THE MACHINE • Riders on the machine are exposed to serious injuries. - DO NOT carry riders on the machine. Besides precluding a full vision by the operator, there is the possibility of serious bodily harm or death due to accidental falls from the machine.
CONFIRM DIRECTION WHERE THE MACHINE IS TO BE DRIVEN • Incorrect travel controls operation may result in serious injury and even death. - Before driving the machine, be aware of the undercarriage position relative to the operator’s position. If travel motors are located at the front of the cab, the machine will move reverse when travel controls are moved towards cab front.
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SAFETY PRECAUTIONS
AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. • To avoid back-over and swing accidents: - Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR .
- ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE .
- USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW.
- Use hand signals, which conform to your local regulations, when work conditions require a signal person. - No machine motions shall be made unless signals are clearly understood by both signalman and operator. - Learn the meanings of all flags, signs, and markings used on the job and confirm with the person in charge of signalling. - Always make sure that rear mirrors are clean and correctly adjusted. - Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.
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SAFETY PRECAUTIONS
DRIVE MACHINE SAFELY • Before moving the machine, confirm which way to move travel pedals/levers for the corresponding direction you wish to go. - Pushing down on the front of the travel pedals or pushing the levers forward moves the machine towards the idlers. • Traveling on a grade may cause the machine to slip or to overturn, possibly resulting in serious injury or death. - When traveling up or down a grade, keep the bucket in the direction of travel, approximately 20 to 30 cm (A) above the ground. - If machine starts to skid or becomes unstable, lower the bucket immediately. - Traveling across the face of a slope may cause the machine to skid or to overturn. When travelling (ascending/descending) on a slope, be sure to point the tracks uphill/downhill.
- Turning on an incline may cause the machine to tip over. If turning on an incline is absolutely unavoidable, do so at a place where the slope is gentle and the surface is firm. - Do not travel on slopes with an angle exceeding 30°. Do not travel across hill on slopes exceeding an angle of 15°.
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SAFETY PRECAUTIONS
AVOID OVERTURNING • When working on a slope or on unstable terrain, the danger of tipping over is present with the possibility of subsequent serious damages or fatal injuries. - Pay the utmost attention when working on a slope. If possible, level first the work area. - Avoid swing or steering the machine on a slope. - Decrease the operating speed and actuate the controls carefully, to prevent sudden movements that could result in slipping or tipping over. - In case the engine is cut-off, lower the bucket to the ground, move the controls in neutral and restart the engine. • Pay the utmost attention when operating the machine on frozen ground or in snowy conditions. - Frozen ground, when the ambient temperature increases, tends to be less firm jeopardising the stability of the machine. - Operate carefully when in snowy conditions. The snow could hide invisible dangerous spots. - Actuate the controls slowly and carefully to prevent the machine from making unwanted slippery manoeuvres or movements. - Even on minor slopes, when snow is present and on frozen ground, unwanted slippery manoeuvres or movements of the machine could occur.
PARK MACHINE SAFELY • To avoid accidents: - Park machine on a level surface. - Lower bucket to the ground. - Pull the safety lever (pilot-control shut-off lever) to the LOCK position. - Turn auto-idle switch off. - Run engine at slow idle speed without load for 5 minutes. - Turn key-start switch to OFF to stop engine. - Remove the ignition key from the key switch. - Prior to leaving the machine, close the windows, the cab door and all panels.
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SAFETY PRECAUTIONS
INVESTIGATE JOB SITE BEFORE OPERATING THE MACHINE • Explore the working area to identify potential risks before starting and operating the machine. Make sure that the structure and the conditions of the ground are safe before starting operations. - Make sure that the digging area is sufficiently stable and firm to support the weight of the machine during the work operations. - Working near edges and ditches presents a risk for the stability of the machine. Check first that edges and the walls of the digging are sufficiently strong. If necessary, prop the edges appropriately to prevent caving-ins. - DO NOT dig too near the machine. - Always position the tracks perpendicular to the edge of the digging with the travel motors on the rear side. - When working on a slope or near the edge of the road, have a flagman available.
PROTECTING AGAINST THE FALL OF ROCKS AND LANDSLIDES • When operating in zones where the possibility of falling rocks or landslides exists or when there is the risk for front impacts with objects that could penetrate the cab, make sure that protection structures are installed: F.O.P.S. (Falling Object Protection Structure) and FRONT GUARD . - DO NOT install any cab lifting device to the protection structures. - DO NOT weld, drill or modify protective structures. Any type of modification could weaken the structural integrity of the safety system, with serious consequences for the operator, in case of collision, falling objects or landslides. - After an accident, DO NOT try to straighten or repair protective structures. Contact a Dealer to verify the functionality, to repair or to completely or partially replace the protective structures.
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SAFETY PRECAUTIONS
DIG WITH CAUTION • Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. - Before digging, check the location of cables, gas lines, and water lines. - Keep the minimum distance required by law from cables, gas lines, and water lines. If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury. - Contact local authorities and/or the utility companies directly (electric power, gas, telephone, water, sewers, telecommunications, etc.) to obtain information about underground utility lines.
OPERATE WITH CAUTION • If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may results as well. - Take care to avoid hitting overhead obstacles with the boom or arm.
AVOID ELECTRIC LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. - When operating near an electric line, NEVER MOVE any part of the machine or load closer than 5 m plus twice the line insulator length ( L). - Check and comply with any local regulations that may apply. - Wet ground will expand the area that could cause any person on it to be affected by electric shock. - Keep all bystanders or co-workers away from the site.
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SAFETY PRECAUTIONS
KEEP PERSONNEL CLEAR FROM WORKING AREA • A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. - Keep all persons clear from the area of operation and machine movement. - Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.
NEVER MOVE THE BUCKET OVER ANY ONE • Never lift, move, or swing bucket above anyone or a truck cab. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.
SP0030
DO NOT OPERATE IN TUNNELS • DO NOT operate the machine in enclosed spaces or, in any case, without appropriate ventilation. Operations in tunnels or underground sites where potential explosive conditions exist are not allowed. There is a danger for explosions and potentially deadly injuries. Please comply with the ATEX regulation relative to devices to be used in a potentially explosive environment.
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SAFETY PRECAUTIONS
NEVER UNDERCUT A HIGH BANK • The edges could collapse or a land slide could occur causing serious injury or death.
SAFETY LOADS MOVING • The excavator is a machine designed specifically to perform digging/loading works, thus it must not be used to handle suspended loads. In the event, under exceptional conditions, it becomes necessary to handle materials, the following indications must be strictly implemented: - The machine must be equipped compulsorily with the appropriate variant provided upon request. Also, totally comply with the safety precautions for the operation of the excavator as a lifting equipment. - Secure the loads to be raised using cables or chains fastened with appropriate hooking mechanisms. - Never hook cables or chains to the bucket teeth. - Nobody should be allowed to remain under the raised load or within the excavator operating range for any reason whatever. - Never exceed specified loading capacity. Incorrect fastening of slings or chains may cause boom/arm failure or failure of the lifting means with consequent bodily injuries and even death. - Always ensure that slings and chains used for lifting are adequate to the load and in good condition. - All loading capacities are referred to the machine on a level surface and should be disregarded when working on a slope. - In any case, comply with the current national or local regulations on this matter.
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SAFETY PRECAUTIONS
AVOID EXCESSIVE DIGGING EFFORTS • Operate the machine complying with the load limits in accordance with the "table of lifting loads" located inside the cab. - Do not exceed the prescribed load limits. - Do not use the strength of the attachment to travel or move the machine. - Do not try digging exploiting the mass of the machine.
PAY ATTENTION WHEN DIGGING DEEPLY
• When digging deeply, pay special attention to prevent contacts of the attachment and the relevant hydraulic hoses with the ground. • DO NOT swing the turret or the undercarriage when the attachment boom is fully lowered. Under these conditions there is the danger that the boom collides with the track chains.
DO NOT USE THE TRACTION FORCE OF THE MACHINE FOR DIGGING • Do not travel the machine to dig. In doing this, an excessive stress on the front attachment could results in damages to the structure. Use the undercarriage for travelling only.
DO NOT USE THE TURRET SWING FOR DIGGING • Do not use the turret swing for digging or moving rocks. An excessive stress on the front attachment could results in damages to the structure reducing the operating life of the swing system. Also, this inappropriate use of the machine could cause serious injuries or fatalities.
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SAFETY PRECAUTIONS
DO NOT USE THE BUCKET AS A HAMMER • The use of the bucket as a hammer or for piling operations could cause serious damages to the bucket itself and the components of the front attachment. Also, this inappropriate use of the machine could cause serious injuries or fatalities.
AVOID OPERATING THE CYLINDERS TO FULL STROKE • Do not extend repeatedly the bucket and the arm cylinders full stroke with the purpose of cleaning the bucket from residual materials. This could cause damages to the cylinders. To remove residues from the bucket, use water under pressure or remove them manually. Tolerance A ≥ 50 mm
PROVIDE SIGNALS FOR JOBS INVOLVING A NUMBER OF MACHINES
For jobs involving several machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to co-ordinate the job site. Make sure that all personnel obey the signal person’s directions.
TRANSPORTING THE MACHINE UNDER SAFE CONDITIONS
• During loading or unloading operations of the machine on a truck or trailer the danger for tipping over is always present. - Use a truck or trailer appropriate for transporting the machine. - Secure safely the machine to the trailer with appropriate chains or cables. Please refer to the chapter "TRANSPORTATION " of this Manual for the safe loading and unloading procedures. - Make sure that you comply with National and local regulations when transporting the machine on open roads.
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SAFETY PRECAUTIONS
SAFE MAINTENANCE • To avoid accidents: - Understand maintenance starting the work.
procedure
before
- Keep the working area clean and dry. - Do not spray water or steam inside the cab. - Do not lubricate or service the machine when it is in motion. - Keep hands, feet and clothes far from moving parts. Prior to service in the machine: 1. Park the machine on the level ground. 2. Lower the bucket to the ground. 3. Move the safety lever (pilot-control shut-off lever) to the LOCK position. 4. Switch off the Auto-Idle. 5. Let the engine idle with no load for at least five minutes until it has cooled down. 6. Move the key-start switch position to stop the engine.
to the OFF
7. Remove the ignition key from the start switch. 8. Apply the "Maintenance in progress" tag (see SAFETY PLATE in this Chapter). This tag can be applied o the left-hand control lever, safety lever or cab door. 9. Let the engine cool down. - Do not leave the machine unattended if servicing requires the engine running. - If the machine is to be raised, place boom and arm at an angle 90 to 110°. Lock machine components which should be raised for maintenance or repair using suitable supporting means. - Never work under a machine kept raised by the boom. - Inspect certain component regularly, repair or replace as necessary. Refer to the Chapter MAINTENANCE in this Manual. - Keep all components in good condition and properly install. Immediately repair any fault. - Immediately repair any damage.Replace worn or failed components. Remove grease, oil, debris build-ups. - Disconnect the negative cable (-) from the battery before carry out any work on he electrical sysem or arc-welding on he machine.
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SAFETY PRECAUTIONS
WARN OTHERS OF SERVICE WORK • Unexpected machine movement serious injury.
can cause
- Before performing any work on the machine, attach a maintenance in progress tag (see also SAFETY PLATES in this Chapter) . This tag can be applied o the left-hand control lever, safety lever or cab door.
SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first. - Always lower the attachment or tool to the ground before working on the machine. - If you must work on a lifted machine or attachment, securely support the machine or attachment. - Do not support the machine on cinder blocks, bollow tires, or props that may crumble under continuous load. - Do not work under a machine that is supported solely by a jack.
STOP THE ENGINE PRIOR TO PERFORMING • DO NOT perform any maintenance operation with the engine running. Trapping by moving parts could cause serious injuries. Stop the engine and wait that it cools-off prior to performing maintenance operations. In case it is indispensable to perform maintenance operations with the engine running, have a person co-operating with you sitting in the operator's seat, to cut-off the engine immediately in case of necessity.
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SAFETY PRECAUTIONS
DISPOSE OF WASTE IN THE APPROPRIATE MANNER • Waste improperly disposed of represents a danger for the envinronment. Potentially dangerous waste used on the excavators includes lubricants, fuel, coolant, brake fluid, filters and batteries. - Used sealed containers when discharging fluids. Do not use containers for food or beverages which may induce drinking. - Do not spill waste over the ground, into drains, or water beds. - Obtain information about the correct methods to recycle or dispose of waste from local Authorities, collection centres or your Dealer.
WORK IN A CLEAN AREA - Before starting an operation, clean the working area. Clear the area from all the objects that can be dangerous for mechanics or people in the working area.
PROPERLY LIGHT THE WORKING AREA • Properly and safely light the working area. - Use safe portable lamps in order to work inside and under the machine. - Make sure that the lamp is shielded by a cage; the incandescent filament of a lamp, accidentally broken, can cause fuel or oil fire.
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SAFETY PRECAUTIONS
KEEP CLEAN THE MACHINE • Keep clean the engine compartment, radiator, batteries, hydraulic pipes, fuel tank and operator's position. - The engine compartment temperature can quickly rise, after stopping the engine. IN THESE CASES, BE CAREFUL TO POSSIBLE FIRES. Open the access doors in order to quicken the engine cooling process and clean the compartment. • Remove all the traces of grease, oil and deposits, in order to avoid people accidents or damages to things. - Do not spray water or steam in the cab.
PREVENT ACID SCALDS • The sulphuric acid, contained in the battery, is poisonous. It is strong enough to scald the skin, corrode clothes and cause blindness, if it is sprayed into the eyes. To avoid dangers: - Fill the batteries in airy areas. - Wear eye protections and rubber gloves. - Avoid breathing the electrolyte vapours when topping up. - Avoid spilling or dripping the electrolyte. - Use proper emergency starting techniques. If you are touched with acid sprays: - Rinse your skin well with water. - Put on your skin sodium bicarbonate or clay to help the acid neutralization. - Rinse your eyes with water for 10-15 minutes. - Immediately see a doctor. If you have swallowed the acid: - Immediately see a doctor.
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SAFETY PRECAUTIONS
STARTING THE ENGINE WITH BOOSTER BATTERIES • If the engine is to be started using booster batteries, ensure to comply with all procedures OPERATING detailed in the chapter INSTRUCTIONS . - The operator should be sitting in the driver’s seat to keep the machine under control when the engine starts. Starting the engine with booster batteries is a two man operation. - Do not use batteries that have been stored in the cold for a long time. - Mistakes in following procedures detailed for starting the engine with slave batteries may cause the batteries to explode or machine to move unexpectedly
PREVENT BATTERY EXPLOSIONS • Battery gas can explode. - Keep sparks, lighted matches, and flames away from the top of battery. - Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. - Do not charge a frozen battery; it may explode. Warm battery to 16 °C. • Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness. - Be sure to wear eye protection when checking electrolyte specific gravity.
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SAFETY PRECAUTIONS
PREVENT BURNS Hot spraying fluids: • After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. - To prevent possible injury from hot spraying water. Do not remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. - The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.
Hot fluids and surfaces: • Engine oil, reduction gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. - Wait for the oil and components to cool down before starting any maintenance or inspection work.
STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic breakers and blades can fall and cause serious injury or death. - Securely store attachments and implements to prevent falling. - Keep bystanders away from storage areas.
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SAFETY PRECAUTIONS
AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. - Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. - Tighten all pressure.
connections
before
applying
- Search for leaks with a piece of cardboard; take care to protect hands and body from highpressure fluids. Wear a face shield or goggles for eye protection. - In an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.
PREVENT PARTS FROM FLYING OFF • Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. - NEVER attempt to remove GREASE FITTING or VALVE ASSEMBLY.
- As pieces may fly off, be sure to keep body and face away from valve.
• Travel reduction gears are under pressure. SP0047
- As pieces may fly off, be sure to keep body and face away from air release plug to avoid injury. Reduction gear oil is hot. Wait for gear oil to cool down, then gradually loosen the air release plug to release pressure.
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SAFETY PRECAUTIONS
PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. - Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. - Keep bystanderds away from the working area before striking any object.
HANDLE FLUIDS SAFELY - AVOID FIRES • Handle fuel with care: it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injuty or death. - Do not refuel the machine while smoking or when near open flame or sparks. - Always stop the engine before refuelling the machine. - Fill the tank outdoors.
• All fuels, most lubrificants, and some antifreeze fluids are flammable. - Store flammable fluids well away from fire hazards. - Do not burn or puncture pressurized containers. - Do not store oily rags; they can ignite and burn spontaneously.
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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 oilcooler flange bolts. - Do not bend or strike high-pressure lines. - Never install bent or damaged lines, pipes, or hoses.
• Check for Shorts: - Short circuits can cause fires. - Clean and tighten all electrical connections. - Check before each shift or after about ten (10) hour operation for loose, kinked, hardened or frayed electrical cables and wires. - Check before each shift or after about ten (10) hour operation for missing or damaged terminal caps. - DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. • Clean up Flammables: - Spilled fuel and lubricans, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. - Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately. • Check Key-start Switch: - If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. - Always check key-start switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key-start switch to the OFF position to confirm that the engine stops. - If any abnormalities are found, be sure to repair them before operating the machine. • Check Heat Shields: - Damaged or missing heat shields may lead to fires. - Damaged or missing heat shields must be repaired or replaced before operating the machine.
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EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: - Stop the engine by turning the key-start switch to the OFF position if there is time. - Use a fire extinguisher if there is time. - Exit the machine.
BEWARE OF EXHAUST FUMES • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. - If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
SP0062
USE APPROPRIATE TOOLS • Use tools appropriate for the job to be performed. - Inappropriate tools, parts and procedures might generate dangerous conditions. - Use tools of correct size to tighten or loosening securing elements, in order to avoid injuries caused by a wrench getting out of control. - Do not use U.S. Standard or British Standard tools on metric fasteners and vice versa. • Use only genuine spare parts (please refer to the Spare Parts Catalogue).
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AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other materials when welding, soldering, etc.
AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS - Do not weld or flame cut pipes or tubes that contain flammable fluids. - Clean them thoroughly with non-flammable solvent before welding or flame cutting them.
REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paints is heated by weiding, soldering, or using a torch. If inhaled, these fumes may cause sickness. - Avoid breathing potentially toxic fumes and dust. - Do all such work outside or in a well-ventilated area. - Dispose of paint and solvents properly. - Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
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SAFETY PRECAUTIONS
WELDING REPAIR INTERVENTIONS • Welding repair interventions must be performed only by a certified welder with sufficient experience. Also, appropriate safety rules must be implemented by all the personnel involved in the operations. The duration through time of the welding depends upon the quality and the accuracy with which the operation is performed. - Identify first all the fracture points and the zones in which welding is required. - Clean accurately the zones involved. - Remove all paint and inspect the parts with penetrating liquid or a magnetic particle tester. - Move the starter switch into position "OFF" and wait for 4 seconds to cut-off electricity from the system. - Disconnect the negative terminal (-) from the battery. - Connect the ground cable of the welder at least 1 m from the component to be welded. - Make sure that the ground cable is NOT connected to a seal or bearing and that there are noo seals or bearings between the ground cable and the part to be welded. - Avoid welding pieces at low temperature i. e. below 16 °C. If necessary, warm-up the part involved prior to welding it. - Remove paints from all surfaces prior to warming-up or welding. Painted surfaces, when warmed-up or when welded, can generate toxic fumes. - Use appropriate masks or protective glasses. - Wear gloves and adequate clothing to protect the skin.
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NOTE:
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SAFETY PLATES
SAFETY PLATES Triple articulation version
Triple articulation version
1. Attachment operating range safety plate. 2. Track adjuster plate. S3 - 1
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SAFETY PLATES
3. Counterweight operating range safety plate.
9. Controls lock/unlock plate (safety lever).
4. Read-your-manual plate.
10. Hydraulic oil pressurised tank warning plate.
5. Boom and arm movement warning plate (Triple articulation version).
11. Burns warning plate. 12. Safety distance plate.
6. Open windscreen warning plate aperta (inside the cab).
13. No-stepping warning plate. 14. Special equipment movement warning plate
7. Tag indicating maintenance in progress. 8. Engine hood warning plate.
S3 - 2
SAFETY PLATES 1 - Attachment operating range safety plate Ensure that any person near the working site is outside the machine operating range before starting the machine or operating the attachments. Sound the horn. Background: yellow Border and icons: black
2 - Track adjuster plate It shows that obligation is made to consult the Operation and Maintenance Instruction Manual prior to acting on the track adjust valve. Danger of severe injuries. Background: yellow Border and icons: black
3 - Counterweight operating range safety plate Ensure that any person near the working site is outside the machine operating range before starting the machine or operating the attachments. Sound the horn. Background: yellow Border and icons: black
S3 - 3
E215B-E245B
E215B-E245B
SAFETY PLATES
4 - Read-your-manual plate It is positioned in the cab to recommend to carefully read the Operation and Maintenance Instruction Manual prior to starting, operating, servicing, refuelling or carrying out any other work on the machine. Background: yellow Border and icons: black
5 - Boom and arm movement warning plate (triple articulation version) It shows the danger represented by the bucket hitting the cab. Pay special attention as no stops are provided to prevent this problem. Background: yellow Border and icons: black
SP0073
6 - Open windscreen warning plate It indicates the risk of injuries deriving from the windscreen not being locked or being improperly locked in the open position. Background: yellow Border and icons: black
S3 - 4
SAFETY PLATES 7 - Tag indicating maintenance in progress Maintenance staff is obliged to apply the tag that indicates that the machine is not fully efficient and warns about maintenance staff being located in not visible positions. This tag should be applied to the left-hand control lever, safety lever or cab door. Background: yellow Border and icons: black
8 - Engine hood warning plate It highlights the obligation to stop the engine before opening engine hood. Danger of severe injuries following the presence of rotating parts such as fan, pulleys, and belts. Background: yellow Border and icons: black
9 - Controls lock/unlock plate It shows the position that the safety lever can assume when the engine is running. When the operator is about to leave the cab with the engine running, even if for a short time, he must move the safety lever to the LOCK position. Controls are disabled and therefore no accidental machine or attachment movement is possible. Background: white Border and icons: black
S3 - 5
E215B-E245B
E215B-E245B
SAFETY PLATES
10 - Hydraulic oil pressurised tank warning plate It indicates that the hydraulic oil is pressurised. Consult the Operation and Maintenance Instruction Manual. Prior to intervening on the hydraulic oil tank, bleed the pressure by actuating the appropriate bleeding button located on the cap. The hydraulic oil, at operating temperature, can cause burns in case of contact with the skin. Background: yellow Border and icons: black
11 - Burns danger plate It indicates that a burns danger exists, since the zone is characterised by high temperature. Background: yellow Border and icons: black
12 - Safety distance plate It instructs to keep at a safe distance from a zone dangerous for personal safety. Background: yellow Border and icons: black
S3 - 6
SAFETY PLATES 13 - No-stepping warning plate It instructs not to step on the zone where this decal is attached. Background: yellow Cross: red Border and icons: black
14 - Special equipment movement warning plate It shows the danger represented by the special equipment hitting the cab. Pay special attention as no stops are provided to prevent this problem. Background: yellow Border and icons: black
S3 - 7
E215B-E245B
E215B-E245B
SAFETY PLATES
NOTE:
S3 - 8
OPERATIONAL PRINCIPLE
M0103
OPERATIONAL PRINCIPLE
E215B-E245B
SECTION AND GROUP CONTENTS Section 1
GENERAL
Group 1
Specifications
Section 2
SYSTEM
Group 1
Group 4
Mechatro Control System Mechatro Controller Hydraulic System Electrical System
Section 3
COMPONENT OPERATION
Group 2 Group 3
Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8
Hydraulic Pump Assy Pilot Valve Control Valve Swing Device Travel Device Swing Joint Cylinders Air Conditioner
SECTION 1
GENERAL
CONTENTS Group 1 - Specifications Main components .............................. T1-1-1 Hydraulic components ....................... T1-1-5 Excavator performance...................... T1-1-8 Digging data E215B (Monoblock Version).......................... T1-1-9 Digging data E215B (Triple Articulation Version) ............... T1-1-10 Transporting dimensions E215B (Monoblock Version) .......................... T1-1-11 Transporting dimensions E215B (Triple Articulation Version) ............... T1-1-12 Bucket applications as a function of the arms E215B ............................. T1-1-13 Digging data E245B (Monoblock Version) .......................... T1-1-14 Digging data E245B (Triple Articulation Version) ............... T1-1-15 Transporting dimensions E245B (Monoblock Version) .......................... T1-1-16 Transporting dimensions E245B (Triple Articulation Version) ............... T1-1-17 Bucket applications as a function of the arms E245B ............................. T1-1-18
E215B-E245B
SPECIFICATIONS
E215B-E245B
MAIN COMPONENTS
1-
Bucket
11 - Swing motor
21 - Track link
2-
Bucket link
12 - Fuel tank
22 - Batteries
3-
Idler link
13 - Hydraulic oil tank
23 - Upper roller
4-
Bucket cylinder
14 - Control valve
24 - Track guide
5-
Arm
15 - Engine muffler
25 - Lower roller
6-
Arm cylinder
16 - Hydraulic pump
26 - Air cleaner
7-
Boom
17 - Engine
27 - Crawler adjuster
8-
Boom cylinder
18 - Counterweight
28 - Front idler
9-
Cab
19 - Engine radiator
29 - Shoe plate
10 - Swivel joint
20 - Travel motor
T1-1-1
SPECIFICATIONS
E215B-E245B Main Components – Upper Structure
1
8
7
2 6
5
3
4 SM0012
1-
Control Cab
5-
Hydraulic Pump
2-
Proportional Solenoid Valve Block
6-
Control Valve
3-
Radiators
7-
Swing Motor Unit
4-
Engine
8-
Center Joint
T1-1-2
SPECIFICATIONS
E215B-E245B
Main Components – Under Carriage
5
4
1
2 3
section A - A SM0013
1-
Right Travel Motor Unit
4-
Swing Gear
2-
Left Travel Motor Unit
5-
Front Idler Assy
3-
Center joint
T1-1-3
SPECIFICATIONS
E215B-E245B Main Components – Front Attachment
2
7
5
1 3
6
4
2
8
7
3 1
SM0014
1-
Boom cylinder
5-
Monoblock Boom
2-
Arm cylinder
6-
Boom (Triple Articulation Version)
3-
Bucket Cylinder
7-
Arm
4-
Positioning Cylinder (Triple Articulation Version)
8-
Positioner (Triple Articulation Version)
T1-1-4
SPECIFICATIONS
E215B-E245B
HYDRAULIC COMPONENTS HYDRAULIC PUMP I te m
Main pump
Gear pump for pilot
P u mp
K3V112DTP1KMR-YTOK-HV
ZX10LPRZ7-07G
Type
Variable displacement plunger pump: regulator attached type
Fixed displacement type gear pump
110 x 2
10
2000
←
Max. displacement capacity
cm3
Revolution
rpm (Clockwise seen from shaft end)
Pressure
Rated Rated ATT boost
34.3
MPa
Max. flow
L/min
Max. input Power (at 2000 rpm) Max. input torque (at 1200 rpm)
220 x 2 at 7.8 MPa
20
kW
118
3.4
Nm
66 5
14.7
M o de l Regulator
Mass
5.0
37.8
KR3G-YTOK-HV
Control function
Electric flow control, positive flow control, total power control at emergency mode and power shift control
Others
With solenoid proportional reducing valve (KDRDE5K-31/ 30C50)
kg
1 43
NOTE: The NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump.
CONTROL VALVE I te m
STD VALVE
Model
KMX15YD / B44041
Max. flow rate Main relief valve set pressure
L/min
22 0 x 2
MPa
34.3 at 70 x 2 L/min
When power boost pressure Over load relief valve set pressure
37.8 at 60 x 2 L/min MPa
Boom H, Bucket H, Arm R
39.7 at 30 L/min
Boom R, Bucket R, Arm H
37.8 at 30 L/min
Mass
kg I te m
OPT VALVE
Model Over load relief valve set pressure
23 2
KADV22Y / 501103A03 MPa
Positioner R
39.7 at 30 L/min
Positioner H
37.7 at 30 L/min
Mass
kg
T1-1-5
2.8
SPECIFICATIONS
E215B-E245B
PILOT VALVE ATTACHMENT
TRAVEL
PV48K2004
6TH6NRZ
5.0 MPa
4.9 MPa
0.6 ~ 3.2 MPa
0.54 ~ 2.35 MPa
20 L/min
25 L/min
Approx. 2 kg
Approx. 8 kg
Model Primary pressure Secondary pressure Rated flow Mass
SWING MOTOR UNIT
r o t o m c i l y a r d y H
Antireaction valve block
Model
M5X130CHB–10A–41C/295
Type
Swash-plate type, fixed-displacement plunger motor
Displacement
cm3
129.2
Working pressure
MPa
32.4
Max. flow
L/min
220
Braking torque
Nm
655
Release pressure
MPa
2.5~5.0
Relief set pressure
MPa
29
Mass
kg
49
Type Mass
Hydraulic motor assy mass
2KAR6P72/240-712 kg
2.5
kg
51.5
Speed reduction type t i n u n o i t c u d e R
Total mass
Planetary 2-stage
Reduction ratio
15.38
Lubicate oil Lubicate oil volume
Gear oil SAE90 (API class GL–4 grade) L
Grease
3.0 Extreme pressure lithium base # 2 grease
Grease volume
kg
Approx. 1.0
Mass
kg
145
kg
Approx. 197
T1-1-6
SPECIFICATIONS
E215B-E245B
TRAVEL DEVICE Item
E215B
Reduction gear unit
E245B
Epicycloidal, three-stage planetary type
Model
710 C3 K
Gearbox ratio
1 : 55.2
Travel motor
Two speed, axial piston swash plate type
Model
MAG 170 VP
MAG 170 VP
high speed
81.2 cm3/rev
112.6 cm3/rev
low speed
129.3 cm3/rev
181.3 cm3/rev
220 L/min
246 L/min
high speed
38949 Nm
42827 Nm
low speed
24469 Nm
25600 Nm
static
32060 Nm
25000 Nm
dynamic
26707 Nm
20900 Nm
Displacement Max. flow Max. gearbox torque
1 : 43.2
output
Parking brake torque Min. pressure parking brake release
11 bar
cracking
311 bar at 1.2 L/min
total flow
353 bar at 40 L/min
Relief valve set pressure Mass
235 kg
262 kg
CYLINDERS Cylinder bore / Rod Dia.
Stroke
(mm)
(mm)
Center distance of pins Full extend B / Full retract A (mm)
Boom
Ø 120 / Ø 85
1345
3200 / 1855
With cushion on rod side
176
Arm
Ø 135 / Ø 95
1558
3637 / 2079
With cushion on both sides
255
Bucket
Ø 120 / Ø 80
1080
2684 / 1604
With cushion on rod side
153
Positioning
Ø 145 / Ø 90
992
2662 / 1670
Without cushion
220
Use
T1-1-7
Cushion
Mass
(kg)
SPECIFICATIONS
E215B-E245B EXCAVATOR PERFORMANCE
GRADEABILITY ......................................................................................................................................... 70% TRAVEL SPEED Excavator
E215B
E245B
First speed
3.6 km/h
3.2 km/h
Second speed
6.0 km/h
5.2 km/h
Speed
ENGINE DATA
MAIN SPECIFICATIONS -
Manufacturer................................................................................................................................. CNH U.K.
-
Model .........................................................................................................................................667TA/MEB
-
Type ..................................................................................... Diesel, 4 stroke, direct injection, turbocharged
-
Number of cylinder ...........................................................................................................................6 in-line
-
Bore ................................................................................................................................................. 104 mm
-
Stroke............................................................................................................................................... 132 mm
-
Total displacement .........................................................................................................................6728 cm 3
-
Compression ratio............................................................................................................................... 17.5:1
-
Net power at flywheel (at 2000 rpm) (ISO 14396).............................................................................118 kW
-
Torque (at 1200 rpm) ........................................................................................................................670 Nm
-
Engine idle at no-load ...................................................................................................................... 800 rpm
INJECTION PUMP -
Type .................................................................................................................................VE6/12 F 1000 LV
-
Injection order ............................................................................................................................. 1-5-3-6-2-4
BATTERY -
Voltage - Capacity............................................................................................................. 2 x 12 V - 100 Ah
STARTER MOTOR -
Manufacturer.................................................................................................................................... BOSCH
-
Voltage - Output.......................................................................................................................... 24V - 4 kW
ALTERNATOR -
Manufacturer.................................................................................................................................... BOSCH
-
Type .................................................................................................................................NCB1 28V 35-70A
-
Voltage - Output............................................................................................................................ 28V - 55A
T1-1-8
SPECIFICATIONS
E215B
DIGGING DATA E215B (Monoblock Version)
(Dimensions in mm) Arm
2080
2400
2940
3500
A
9185
9446
9929
10366
A’
8991
9258
9750
10195
B
5840
6160
6700
7260
B’
5620
5954
6519
7082
C
9440
9519
9733
9749
D
6737
6793
7037
7149
E
3679
3559
3544
3478
F
4268
3955
3503
2942
G
5005
5346
5879
6588
T1-1-9
SPECIFICATIONS
E215B
DIGGING DATA E215B (Triple Articulation Version)
(Dimensions in mm) Arm
2080
2400
2 940
3500
A
9322
9598
10098
10555
A’
9131
9413
9922
10387
B
5590
5891
6417
6932
B’
5467
5775
6310
6832
C
10682
10882
11280
11544
D
7755
7952
8351
8632
E
2929
2742
2524
2695
F
5016
4575
3724
3196
G
2470
2747
3151
3818
T1-1-10
SPECIFICATIONS
E215B
TRANSPORTING DIMENSIONS E215B (Monoblock Version)
VERSIONS
E215BEL
E215BL
E215BLC
A
3656
3656
3656
B
4451
4451
4451
C
D
1035
1035
1035
2800
2800
2800
E
F
(1) 9617
(1) 3133
(2) 9580
(2) 3044
(3) 9493
(3) 2884
(4) 9568
(4) 3044
(1) 9617
(1) 3133
(2) 9580
(2) 3044
(3) 9493
(3) 2884
(4) 9568
(4) 3044
(1) 9617
(1) 3133
(2) 9580
(2) 3044
(3) 9493
(3) 2884
(4) 9568
(4) 3044
G
H
I
L
2503
3027
948
471
2503
3027
948
471
2503
3027
948
471
Arm:
(dimensions in mm)
(1) 2080 mm (2) 2400 mm (3) 2940 mm (4) 3500 mm
E215BEL
E215BL
E215BLC
M Track shoe width
(mm)
500
600
700
600
700
800
900
600
700
800
900
N Gauge
(mm) 2490
2590
2690
2800
2900
3000
3100
2990
3090
3190
3290
(*) Working weight Spec. ground pres.
(kg) 20590 20850 21120 20920 21190 21460 21730 20940 21210 21480 21750 (bar)
0.55
0.47
0.40
0.47
(*) With arm 2940 mm and bucket 1.3 m3
T1-1-11
0.41
0.36
0.32
0.47
0.41
0.36
0.32
SPECIFICATIONS
E215B
TRANSPORTING DIMENSIONS E215B (Triple Articulation Version)
E
G D
H
I
L
F
C
M
A B
N
VERSIONS
E215BEL
E215BL
E215BLC
A
3656
3656
3656
B
4451
4451
4451
C
D
1035
1035
1035
2800
2800
2800
NH0148
E
F
(1) 9683
(1) 3062
(2) 9665
(2) 3014
(3) 9643
(3) 2954
(4) 9631
(4) 3237
(1) 9683
(1) 3062
(2) 9665
(2) 3014
(3) 9643
(3) 2954
(4) 9631
(4) 3237
(1) 9683
(1) 3062
(2) 9665
(2) 3014
(3) 9643
(3) 2954
(4) 9631
(4) 3237
G
H
I
L
2503
3027
948
471
2503
3027
948
471
2503
3027
948
471
Arm:
(dimensions in mm)
(1) 2080 mm (2) 2400 mm (3) 2940 mm (4) 3500 mm
E215BEL
M Track shoe width
(mm)
N Gauge
(mm) 2490
(*) Working weight Spec. ground pres.
500
E215BL
E215BLC
600
700
600
700
800
900
600
700
800
900
2590
2690
2800
2900
3000
3100
2990
3090
3190
3290
(kg) 21220 21490 21760 21560 21830 22100 22360 21580 21850 22120 22390 (bar)
0.57
0.48
0.42
0.48
(*) With arm 2940 mm and bucket 1.3 m 3
T1-1-12
0.42
0.37
0.33
0.48
0.42
0.37
0.33
SPECIFICATIONS
E215B
BUCKET APPLICATIONS AS A FUNCTION OF THE ARMS E215B E215B Monoblock BUCKETS Capacity 3
Width (mm)
(dm ) SAE J296 (ISO 7451)
Mass (kg)
750
525
503
850
625
537
1000
789
634
1200
1000
651
1300
1105
698
1500
1315
760
E215BEL
E215BL
E215BLC
Arm (mm)
Arm (mm)
Arm (mm)
2080 2400 2940 3500 2080 2400 2940 3500 2080 2400 2940 3500
E215B Triple Articulation BUCKETS
E215BEL
E215BL
E215BLC
Capacity
Arm (mm)
Arm (mm)
Arm (mm)
Width (mm)
(dm3) SAE J296 (ISO 7451)
Mass (kg)
750
525
503
850
625
537
1000
789
634
1200
1000
651
1300
1105
698
1500
1315
760
2080 2400 2940 3500 2080 2400 2940 3500 2080 2400 2940 3500
General digging work (specific weight of material < 1.8 t/m3) Slightly heavy digging work (specific weight of material < 1.5 t/m 3) Loading work (specific weight of material < 1.2 t/m3)
T1-1-13
SPECIFICATIONS
E245B
DIGGING DATA E245B (Monoblock Version)
(Dimensions in mm) Arm
2080
2400
2940
3500
A
9185
9446
9929
10366
A’
8991
9258
9750
10195
B
5822
6142
6682
7242
B’
5602
5936
6501
7064
C
9458
9537
9751
9767
D
6755
6811
7055
7167
E
3679
3559
3544
3478
F
4286
3973
3521
2960
G
5005
5346
5879
6588
T1-1-14
SPECIFICATIONS
E245B
DIGGING DATA E245B (Triple Articulation Version)
(Dimensions in mm) Arm
2080
2400
2940
3500
A
9322
9598
10098
10555
A’
9131
9413
9922
10387
B
5572
5873
6399
6914
B’
5449
5757
6292
6814
C
10700
10900
11298
11562
D
7773
7970
8369
8650
E
2929
2742
2524
2695
F
5034
4593
3742
3214
G
2470
2749
3151
3818
T1-1-15
SPECIFICATIONS
E245B
TRANSPORTING DIMENSIONS E245B (Monoblock Version)
VERSIONS
E245B
A
3840
B
4645
C
D
1053
2800
E
F
(1) 9617
(1) 3141
(2) 9577
(2) 3050
(3) 9487
(3) 2886
(4) 9564
(4) 3044
Arm:
G
H
I
L
2503
3045
970
486
(dimensions in mm)
(1) 2080 mm (2) 2400 mm (3) 2940 mm (4) 3500 mm
E245B
M Track shoe width
(mm)
550(*)
700
800(*)
N
(mm)
2490
2690
2890
(**) Working weight
(kg)
22000
22500
22850
Spec. ground pres.
(bar)
0.51
0.41
0.37
Gauge
(**) With arm 2940 mm and bucket 1.3 m 3 (*) Asymmetric type shoes
T1-1-16
SPECIFICATIONS
E245B
TRANSPORTING DIMENSIONS E245B (Triple Articulation Version)
E
G D
H
I
L
F
C
M
A B
N
VERSIONS
E245B
A
3840
B
4645
C
D
1053
2800
NH0148
E
F
(1) 9684
(1) 3067
(2) 9665
(2) 3014
(3) 9641
(3) 2957
(4) 9634
(4) 3235
Arm:
G
H
I
L
2503
3045
970
486
(dimensions in mm)
(1) 2080 mm (2) 2400 mm (3) 2940 mm (4) 3500 mm
E245B
M Track shoe width
(mm)
550(*)
700
800(*)
N
(mm)
2490
2690
2890
(**) Working weight
(kg)
22600
23100
23450
Spec. ground pres.
(bar)
0.53
0.42
0.38
Gauge
(**) With arm 2940 mm and bucket 1.3 m 3 (*) Asymmetric type shoes
T1-1-17
SPECIFICATIONS
E245B
BUCKET APPLICATIONS AS A FUNCTION OF THE ARMS E245B E245B Monoblock BUCKETS Capacity (dm 3) Width (mm) SAE J296 (ISO 7451)
E245B Arm(mm) Mass (kg)
2080
750
525
503
850
625
537
1000
789
634
1200
1000
651
1300
1105
698
1500
1315
760
2400
2940
3500
E245B Triple Articolation BUCKETS
E245B
Capacity (dm3) SAE J296 (ISO 7451)
Mass (kg)
750
525
503
850
625
537
1000
789
634
1200
1000
651
1300
1105
698
1500
1315
760
Width (mm)
Arm (mm)
2080
2400
2940
3500
General digging work (specific weight of material < 1.8 t/m3) Slightly heavy digging work (specific weight of material < 1.5 t/m3)
T1-1-18
MECHATRO CONTROL SYSTEM
1.
E215B-E245B
PREFACE
This chapter explains only those related to the electro hydraulic conversion as mechatro control. This chapter summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the conditions before and after each conversion, refer to the hydraulic system and the electric system.
T2-1-1
E215B-E245B 2
MECHATRO CONTROL SYSTEM
SUMMARY OF MECHATRO CONTROL SYSTEM
2.1
MECHATRO CONTROL SYSTEM IN GENERAL
ELECTRIC CONTROLLER INPUT SIGNAL HYDRAULIC PILOT SECONDARY PRESSURE
VOLTAGE OUTPUT L1
SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT
LH
RH
LH
RH
OPTION PILOT VALVE PILOT VALVE FOR TRAVEL
PILOT VALVE FOR ATT
SE-9 SE-10
SE-11 LOW PRESSURE SENSOR
SE-4
(4)
SE-3 GAUGE CLUSTER LCD DISPLAY FOR SELECTION FUEL GAUGE COOLANT TEMP. GAUGE SWITCH
K C O L B R O S N E S
SE-7
SCREEN CHANGE
(2)
SE-1 SE-8
L2 L3
(3)
SE-2
(1)
(8) (7)
L4
BUZZER STOP
(6)
MODE WASHER
SE-5
WIPER
(5)
E G A T L O V T U P T U O
TRAVEL AUTO-IDLE
N O I T A C I N U M M O C L A I R E S
ACCEL DIAL SE-16
N O I T A C I N U M M O C L A I R E S
PSV-R SHORT-CIRCUIT
PROPORTIONAL
VALVE
VALVE
SE-23 HIGH PRESSURE SENSOR
C-1
SE-22
MECHATRO CONTROLLER
ENGINE GOVERNOR MOTOR
M-2
A1
L5 A2
A3
SPEED SENSOR
SE-13
PSV-P1 P1 PUMP PROPORTIONAL VALVE
: HIGH PRESSURE SENSOR (FOR P1,P2 : 2pcs)
PSV-P2 P2 PUMP PROPORTIONAL VALVE
: GOVERNOR MOTOR : E/G SPEED SENSOR
L6
: LOW PRESSURE SENSOR (ATT : 7pcs, TRAVEL : 2pcs)
L7 VOLTAGE 24V PROPORTIONAL COMMAND CURRENT
SM0116
T2-1-2
MECHATRO CONTROL SYSTEM
L1
E215B-E245B
MAIN CONTROL VALVE SE-29
ARM OUT
DUMP
(8)
(2)
D E E P S 2 M R A
T E K C U B
DOWN FORWARD
(3)
D E E P S W O L M O O B
(1)
(3)
DIGGING
UP
LEFT ARM OUT
FORWARD
(4) D A O L N U 1 P
T H G I R L E V A R T
T S O O B T N E M H C 1 A T L T P A
T L H I E G V A A R R T T S P1 P2
REVERSE
T F E L L E V A R T
REVERSE
L2 L3
(6)
(8)
P X U U L M F O N O O B C D A O L N U 2 P
SV-13
G N I W S
D E E P S 1 M R A
(5)
(7)
N O I T P O
E V L A V R O T C E B L & E N S
SOL
RIGHT ARM IN
SOLENOID SOLENOI D VALVE VALVE
L4 SWING MOTOR PARKING RELEASE
TRAVEL MOTOR 1,2 SPEED SELECT
L5
D E E P S 2 N I M R A
PSV -A
D A O L N U 1 P
T H G I A R T S L E V A R T
PSV PSV -D -C
D A O L N U 2 P
PSV -B
T S O O B T N E M H C A T T A
SV -2
D E E P S 2 , 1 L E V A R T
SV -3
BOOM CYLINDER BOOM DOWN RECIRCULA RECIRCULATION TION BOOM CONFLUX
E K A R B G N I K R A P G N I W S
SV -1
R E V E L K C O L Y T E F A S
SV -4
ARM CYLINDER ARM OUT CONFLUX ARM IN CONFLUX
(7) ARM IN
L6
BUCKET CYLINDER DIGGING / DUMP CONFLUX
L7 PROPORTIONA L VALVE PROPORTIONAL VALVE SOLENOID VAL VALVE VE
) BLOCK SM0117
T2-1-3
E215B-E245B 2.2 2.2
MECHATRO CONTROL SYSTEM
UNLO UNLOAD AD VALVE ALVE CONT CONTRO ROL L
N&B SELECTOR VALVE SOLENOID
N O I T P O
D E E P S 1 M R A
X U L F N O C P U M O O B
G N I W S
T F E L L E V A R T
D A O L N U 2 P
D A O L N U 1 P
T L H E G I V A A R R T T S
P2
(LEFT)
(RIGHT)
OPTIONAL PILOT VALVE
PILOT VALVE
T H G I R L E V A R T
M O O B
T E K C U B
D E E P S 2 M R A
P1
PILOT VALVE
PILOT VALVE FOR TRAVEL
SE-11 SE-10
SE-9
LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4
SE-5,7,8
pi
PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P1 UNLOAD PROPORTIONAL VALVE PSV-D
MECHATRO PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0118
1. On starting any one of operations, operations, the control pilot pilot secondary secondary pressure switches switches spools and enters enters in respective low pressure sensors. 2. The output voltage voltage of low pressure pressure sensor is input to mechatro mechatro controller controller and the mechatro mechatro controller controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve. 3. Each unload unload pressure proportional proportional valves valves output pilot pilot secondary pressure pressure according according to the command output by mechatro controller and switches each unload spools. 4. With this operation, operation, the bleed opening opening according to lever manipulated manipulated movement movement is obtained, obtained, consequently consequently the pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating. T2-1-4
MECHATRO CONTROL SYSTEM 2.3 2.3
E215B-E245B
POSIT POSITIVE IVE CONT CONTRO ROL L & P-Q P-Q CON CONTR TROL OL
N&B SELECTOR VALVE SOLENOID
N O I T P O
X U L F N O C P U M O O B
D E E P S 1 M R A
G N I W S
OPTIONAL PILOT VALVE
D A O L N U 2 P
D A O L N U 1 P
T F E L L E V A R T
T H G I R L E V A R T
T L H G E I V A A R R T T S P2
S E -2 3
M O O B
T E K C U B
D E E P S 2 M R A
P1
S E -2 2
SE-11
(LEFT)
(RIGHT)
PILOT VALVE
PILOT VALVE
PILOT VALVE FOR TRAVEL
SE-10
SE-9
LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4
SE-5,7,8
pi PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE COMMAND
P2 PUMP PROPORTIONAL VALVE PSV-P2
PILOT SECONDARY PRESSURE
pi
pi
PILOT SIGNAL PROCESS PILOT SECONDARY PRESSURE
P1 PUMP PROPORTIONAL VALVE COMMAND
P1 PUMP PROPORTIONAL VALVE PSV-P1
MECHATRO pi : PROPORTIONAL VALVE CONTROLLER
SECONDARY PRESSURE SM0119
T2-1-5
E215B-E245B
MECHATRO CONTROL SYSTEM
1. Posit Positiv ive e contr control ol 1) On starting any one of operations, pilot secondary pressure switches each spool spool and is input to each low pressure sensor. 2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve. 3) Each pump proportional proportional valve valve outputs pilot secondary secondary pressure pressure according according to the command output by mechatro controller and changes the tilting angle of each pump and controls the delivery rate. 4) With this operation, operation, the delivery delivery rate according according to lever manipulated manipulated movement movement is fed to the actuator, and consequently the working speed according to the lever manipulated movement will be obtained. 2. P-Q P-Q cont contro roll 1) The output voltage of high pressure sensor provided on each pump line is input input to mechatro controller and the mechatro controller processes pilot signal and operates the command according to the input voltage (load pressure). 2) The lower value between between command command values calculated calculated by positive positive control and operated operated value found by P-Q control {operated value found in item 1)} is selected and is output to each pump proportional valve as command value. 3) Each pump proportional proportional valve valve outputs pilot secondary secondary pressure pressure according according to the command output by mechatro controller and changes tilting angle of each pump and controls the delivery rate. 4) With this operation, operation, the delivery delivery rate according according to lever manipulated manipulated movement movement is fed to actuator and consequently working speed will be obtained according to lever movement.
POSITIVE CONTROL
E L R U A S N S O I E T R R P O Y P R O A R D P N P O M C U E P S
P-Q CONTROL
PILOT SIGNAL PROCESS
E L R U A S N S O I E T R R P O Y P R O A R D P N P O M C U E P S
PILOT PRESSURE
PILOT SIGNAL PROCESS
PUMP DELIVERY PRESSURE
SM0120
T2-1-6
MECHATRO CONTROL SYSTEM 2.4 2.4
E215B-E245B
BOOM BOOM UP CONF CONFLU LUX X CON CONTR TROL OL
N&B SELECTOR VALVE SOLENOID
N O I T P O
D E E P S 1 M R A
X U L F N O C P U M O O B
G N I W S
D A O L N U 2 P
T F E L L E V A R T
D A O L N U 1 P
T L H E G I V A A R R T T S P2
PILOT VALVE
T H G I R L E V A R T
M O O B
T E K C U B
D E E P S 2 M R A
P1
LOW PRESSURE SENSOR SE-3
pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
BOOM UP PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P1 PUMP PROPORTIONAL VALVE PSV-P1
BOOM UP PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
BOOM UP PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
MECHATRO CONTROLLER BOOM UP PILOT SECONDARY PRESSURE
P2 UNLOAD PROPORTIONAL VALVE PSV-D
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
SM0121
1. On starting boom boom up operation, boom up operating operating pilot pressure pressure switches switches boom spool and boom up conflux conflux spool and is input to low pressure sensor. 2. The output voltage voltage of low pressure pressure sensor is input to mechatro mechatro controller controller and the mechatro mechatro controller controller processes pilot signal and outputs command according to the input voltage t o P1 and P2 proportional valves and P1 and P2 unload proportional valves. 3. Each proportional proportional valve valve outputs pilot pilot secondary secondary pressure according according to the command output output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valve. 4. With original original hydraulic hydraulic pressure command, command, boom main spool spool and boom up conflux spool are switched, switched, and also with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.
T2-1-7
E215B-E245B 2.5
MECHATRO CONTROL SYSTEM
ARM IN RECIRC RECIRCULA ULATIO TION N & CONFLU CONFLUX X CONT CONTROL ROL
N&B SELECTOR VALVE SOLENOID
D E E P S 1 M R A
N O I T P O
X U L F N O C P U M O O B
G N I W S
PILOT VALVE
D A O L N U 2 P
T F E L L E V A R T
D A O L N U 1 P
T L H G E I V A A R R T T S P2
LOW PRESSURE SENSOR SE-1~6
T H G I R L E V A R T
M O O B
T E K C U B
D E E P S 2 M R A
P1
LOW PRESSURE SENSOR SE-7
CONTROL PROCESS FOR 2 SPEED
pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
ARM IN PILOT SECON SECONDARY DARY PRESSU PRESSURE RE P1 PUMP PROPORTIONAL VALVE PSV-P1
PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
ARM IN PILOT SECON SECONDARY DARY PRESSU PRESSURE RE P1 UNLOAD PROPORTIONAL VALVE PSV-D
pi PILOT SECONDARY PRESSURE
pi REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A
ARM PILOT PILOT SECOND SECONDARY ARY PRESSURE
P2 PUMP PRESSURE
MECHATRO CONTROLLER
pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0122
T2-1-8
MECHATRO CONTROL SYSTEM
E215B-E245B
1. Recirculation and conflux (Low loading) 1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool and low pressure sensor. 2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool. In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal according to the combined operation and outputs command, which is different from the armin independent operation, to P1 pump proportional valve, P1 unload proportional valve and reverse proportional valve for arm-in 2 spool. 3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure and it switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls recirculation rate and conflux rate.) The other proportional valves output proportional secondary pressure according to command from mechatro controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload valve. 4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2 unload spools and arm 2 spool are switched according to the command output by mechatro controller, and consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil during arm operation. 2. Recirculation cut The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is raised during arm operation the mechatro controller processes pilot signal processing according to the pressure detected by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for arm-in 2 spool. The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently recirculation passage is blocked.
T2-1-9
E215B-E245B 2.6
MECHATRO CONTROL SYSTEM
ARM-IN ANTI-CAVITATION CONTROL
N&B SELECTOR VALVE SOLENOID
N O I T P O
D E E P S 1 M R A
X U L F N O C P U M O O B
G N I W S
PILOT VALVE
D A O L N U 2 P
D A O L N U 1 P
T F E L L E V A R T
T L H E G I V A A R R T T S P2
LOW PRESSURE SENSOR
T H G I R L E V A R T
M O O B
T E K C U B
D E E P S 2 M R A
P1
ACCEL POTENTIO
SE-7 pi
PILOT SIGNAL PROCESS
pi P2 PUMP PROPORTIONAL VALVE PSV-P2
ARM IN PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL PSV-Bpi
ARM IN PILOT SECONDARY PRESSURE
pi REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL COMMAND
ENGINE SPEED (COMMAND VALUE)
MECHATRO CONTROLLER
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A
pi
pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0123
1. On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low pressure sensor. 2. The engine speed command output by accel potentiometer is input to mechatro controller. 3. Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2 unload proportional valve. 4. And also outputs command according to input pressure output by potentiometer to reverse proportional valve for arm 2 spool. 5. Each proportional valve outputs pilot secondary pressure according to each command output by mechatro controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump delivery rate is low due to low engine speed.
T2-1-10
MECHATRO CONTROL SYSTEM 2.7
E215B-E245B
ARM-OUT CONFLUX CONTROL
N&B SELECTOR VALVE SOLENOID
N O I T P O
D E E P S 1 M R A
X U L F N O C P U M O O B
G N I W S
D A O L N U 2 P
T F E L L E V A R T
PILOT VALVE
D A O L N U 1 P
T H G I R L E V A R T
T L H E G I V A A R R T T S P2
M O O B
T E K C U B
D E E P S 2 M R A
P1
LOW PRESSURE SENSOR
SE-8 pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
ARM OUT PILOT SECONDARY PRESSURE
pi
P1 PUMP PROPORTIONAL VALVE PSV-P1
ARM OUT PILOT SECONDARY PRESSURE
pi P2 UNLOAD PROPORTIONAL VALVE PSV-B
ARM OUT PILOT SECONDARY PRESSURE
pi
MECHATRO CONTROLLER ARM OUT PILOT SECONDARY PRESSURE
P1 UNLOAD PROPORTIONAL VALVE PSV-D
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
SM0124
1. On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is input to low pressure sensor. 2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage t o P1 and P2 proportional valves and P1 and P2 unload proportional valves. 3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valves. 4. With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation.
T2-1-11
E215B-E245B 2.8
MECHATRO CONTROL SYSTEM
BUCKET DIGGING (DUMP) CONFLUX CONTROL
N&B SELECTOR VALVE SOLENOID
N O I T P O
PILOT VALVE
D E E P S 1 M R A
X U L F N O C P U M O O B
G N I W S
D A O L N U 2 P
T F E L L E V A R T
D A O L N U 1 P
T H G I R L E V A R T
T L H E G I V A A R R T T S P2
M O O B
T E K C U B
D E E P S 2 M R A
P1
LOW PRESSURE SENSOR
SE-1(2) pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi PILOT SIGNAL PROCESS
P1 PUMP PROPORTIONAL VALVE PSV-P1
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P1 UNLOAD PROPORTIONAL VALVE PSV-D
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
TRAVELSTRAIGHT PROPORTIONAL VALVE PSV-C
MECHATRO CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE
SM0125
1. On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket spool and is input to low pressure sensor. 2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload proportional valves and travel straight proportional valve. 3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of the control valve. 4. The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched. T2-1-12
MECHATRO CONTROL SYSTEM 2.9
E215B-E245B
BUCKET DIGGING ANTI-CAVITATION CONTROL
N&B SELECTOR VALVE SOLENOID
N O I T P O
D E E P S 1 M R A
X U L F N O C P U M O O B
G N I W S
PILOT VALVE
D A O L N U 2 P
T F E L L E V A R T
D A O L N U 1 P
T H G I R L E V A R T
T L H G E I V A A R R T T S P2
M O O B
T E K C U B
D E E P S 2 M R A
P1
LOW PRESSURE SENSOR SE-1 (2)
pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
BUCKET DIGGING PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P1 PUMP PROPORTIONAL VALVE PSV-P1
BUCKET DIGGING PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
ACCEL POTENTIO
P2 UNLOAD PROPORTIONAL VALVE PSV-B
BUCKET DIGGING PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P1 UNLOAD PROPORTIONAL VALVE PSV-D
BUCKET DIGGING PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C
BUCKET DIGGING PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS BUCKET ANTI-CAVITATION PROCESS
ATT BOOST SOLENOID VALVE SV-2
ENGINE SPEED (COMMAND VALUE)
MECHATRO CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE
P1 PUMP PRESSURE
T2-1-13
SM0126
E215B-E245B
MECHATRO CONTROL SYSTEM
1. On starting bucket digging operation, bucket digging operating pilot pressure switches bucket spool and is input to low pressure sensor. 2. The engine speed command output by accel potentiometer is input to mechatro controller. 3. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload proportional valves and travel straight proportional valve. 4. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of control valve. 5. The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched. 6. ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary pressure, and actuate stroke limiter and then controls the stroke of bucket spool. The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and pump delivery rate is low. 7. When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control the stroke limit of bucket spool.
T2-1-14
MECHATRO CONTROL SYSTEM
E215B-E245B
2.10 SWING PRIORITY CONTROL
PILOT VALVE
N&B SELECTOR VALVE SOLENOID
N O I T P O
D E E P S 1 M R A
X U L F N O C P U M O O B
G N I W S
D A O L N U 2 P
T F E L L E V A R T
D A O L N U 1 P
T H G I R L E V A R T
T L H E G I V A A R R T T S P2
M O O B
T E K C U B
D E E P S 2 M R A
P1
LOW PRESSURE SENSOR SE-5
SE-7
pi
PILOT SIGNAL PROCESS
ARM IN PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2 P1 PUMP PROPORTIONAL VALVE PSV-P1 P2 UNLOAD PROPORTIONAL VALVE PSV-B P1 UNLOAD PROPORTIONAL VALVE PSV-D
ARM IN PILOT SECONDARY PRESSURE
pi
SWING PILOT SECONDARY PRESSURE
pi
SWING PILOT SECONDARY PRESSURE
TRAVEL STRAIGHT PROPORTIONAL VALVE COMMAND
TRAVEL STRAIGHT COMMAND PROPORTIONAL VALVE PSV-C
REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A
MECHATRO CONTROLLER
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
SM0127
1. During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low pressure sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot secondary pressure switches swing spool and is input to low pressure sensor. 2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool. 3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel straight spool, arm 2 spool. 4. With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil on arm cylinder rod side is recirculated into arm cylinder head side. 5. Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum speed drop possible. T2-1-15
E215B-E245B
MECHATRO CONTROL SYSTEM
2.11 TRAVEL STRAIGHT CONTROL
OPTIONAL PILOT VALVE
N&B SELECTOR VALVE SOLENOID
(LEFT)
(RIGHT)
PILOT VALVE
N O I T P O
D E E P S 1 M R A
X U L F N O C P U M O O B
G N I W S
PILOT VALVE
D A O L N U 2 P
D A O L N U 1 P
T F E L L E V A R T
T H G I R L E V A R T
T L H G E I V A A R R T T S P2
M O O B
T E K C U B
D E E P S 2 M R A
P1
PILOT VALVE FOR TRAVEL SOLENOID SHORT CIRCUIT VALVE
SE-10
SE-9
SE-11
LOW PRESSURE SENSOR
VALVE SIGNAL TRAVEL STRAIGHT SIGNAL
pi PILOT SIGNAL PROCESS
PROPORTIONAL VALVE PSV-R IN SHORT-CIRCUIT VALVE
PILOT SECONDARY PRESSURE
pi PILOT SIGNAL PROCESS
TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C
PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P1 PUMP PROPORTIONAL VALVE PSV-P1
PILOT SECONDARY PRESSURE
pi PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
PILOT SECONDARY PRESSURE
T2-1-16
P1 UNLOAD PROPORTIONAL VALVE PSV-D
SM0128
MECHATRO CONTROL SYSTEM
E215B-E245B
1. Judgment travel straight 1) During travel operation (right and left), pilot pressure switches each travel spool and is input to low pressure sensor on carrying out attachment system operation. 2) Mechatro controller decides as travel straight on receiving the input according to the combination shown in the table from the low pressure sensor and turns travel straight signal on. 3) On turning travel straight signal on, the following commands are output to each proportional valve. 2. Operation of each proportional valve (Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump in travel straight condition.) 1) Travel straight proportional valve outputs switching pressure according to the high priority select pressure in the attachment system operating (Boom, arm, bucket, swing, option) pilot pressure during operation. 2) Short-circuit proportional valve outputs pressure according to the high priority select pressure in the both attachment and travel system operating pilot pressure during operation. 3) P1 unload proportional valve outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation. 4) P2 unload proportional valve outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation. 5) P1 pump proportional valve outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation. 6) P2 pump proportional valve outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation. ATT operatio n
Boom
Arm
Right travel operation (P1) Left travel operation (P2)
T2-1-17
Bucket
Swing
Option
E215B-E245B
MECHATRO CONTROL SYSTEM
2.12 PRESSURE RELEASE CONTROL
N&B SELECTOR VALVE SOLENOID
N O I T P O
GAUGE CLUSTER
D E E P S 1 M R A
X U L F N O C P U M O O B
G N I W S
PILOT VALVE
D A O L N U 2 P
T F E L L E V A R T
D A O L N U 1 P
T H G I R L E V A R T
T L H G E I V A A R R T T S P2
M O O B
T E K C U B
D E E P S 2 M R A
P1
SE-23
SE-22
ENGINE (M-2)
PRESSURE RELEASE CONTROL
ENGINE SPEED CONTROL
pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
pi PILOT SIGNAL PROCESS
pi
pi
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS MECHATRO CONTROLLER
P1 PUMP PROPORTIONAL VALVE PSV-P1
P2 UNLOAD PROPORTIONAL VALVE PSV-B
P1 UNLOAD PROPORTIONAL VALVE PSV-D
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
SM0130
1. Change mechatro controller to “PRESSURE DRAING MODE” by operating switch on gauge cluster. For detail of changing mode method, refer to “Pressure draining (releasing) circuit” on GROUP 2 HYDRAULIC CIRCUIT. 2. Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot, accel potentiometer, etc.) the mechatro controller; 1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum tilt angle. 2) Outputs command of pressure release to control step-by step motor (M2) and fixes engine speed to pressure release control speed. 3) Outputs maximum command to P1 and P2 unload proportional valves and each pilot secondary pressure fixes P1 and P2 unload valves to the maximum opening. 3. Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster. 4. Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to be released by operating each control lever and switching spool with the unload valve opened.
T2-1-18
MECHATRO CONTROL SYSTEM
E215B-E245B
2.13 N&B SWITCH CONTROL (OPTION)
PRESSURE SENSOR N&B FOR BREAKER SELECTOR SE-29 VALVE SOLENOID
D E E P S 1 M R A
N O I T P O
X U L F N O C P U M O O B
G N I W S
D A O L N U 2 P
T F E L L E V A R T
D A O L N U 1 P
T H G I R L E V A R T
T L H G E I V A A R R T T S P2
M O O B
T E K C U B
D E E P S 2 M R A
P1
A MODE
B MODE
GAUGE CLUSTER
pi
B MODE SWITCH
MECHATRO CONTROLLER
pi : OUTPUT OF N&B SELECTOR SOLENOID
SM0131
1. Nibbler circuit 1) Select A mode through gauge cluster. 2) Nibbler display appears on gauge cluster. 3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of main control valve. 4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output. It is in normal when there is no output from sensor in A mode, and in cases of other than above, error display is output to gauge cluster. 2. Breaker circuit 1) Select B mode through gauge cluster. 2) Breaker display appears on gauge cluster. 3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank. 4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal. It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display is output to gauge cluster.
T2-1-19
E215B-E245B
MECHATRO CONTROL SYSTEM
2.14 OPTION CONFLUX CONTROL (OPTION)
N&B SELECTOR VALVE PILOT VALVE
SOLENOID
N O I T P O
D E E P S 1 M R A
X U L F N O C P U M O O B
G N I W S
T F E L L E V A R T
D A O L N U 2 P
D A O L N U 1 P
T L H E G I V A A R R T T S P2
LOW PRESSURE SENSOR
T H G I R L E V A R T
M O O B
T E K C U B
D E E P S 2 M R A
P1
SINGLE / CONFLUX SWITCH
SE-11
pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
OPTION PILOT SECONDARY PRESSURE
pi PILOT SIGNAL PROCESS
P1 PUMP PROPORTIONAL VALVE PSV-P1
OPTION PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
OPTION PILOT SECONDARY PRESSURE
pi PILOT SIGNAL PROCESS
P1 UNLOAD PROPORTIONAL VALVE PSV-D
OPTION PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE
TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE CONTROLLER SECONDARY PRESSURE
SM0132
1. Select the Conflux with the aid of Conflux/Single switch. 2. On starting option operation, option operating pilot pressure switches option spool and is input to low pressure sensor. 3. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload pressure proportional valves and travel straight proportional valve. 4. Each proportional valves output pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of the control valve. 5. The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.
T2-1-20
MECHATRO CONTROL SYSTEM 3.
E215B-E245B
MECHATRO CONTROLLER
3.1
SUMMARY OF MULTI DISPLAY
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster. 1. Controls
SWING PARKING BRAKE RELEASE SWITCH
GAUGE CLUSTER SAFETY LOCK LEVER RIGHT CONTROL LEVER WITH ATT BOOST SW.
FUSE & RELAY BOX
STARTER SWITCH ACCEL DIAL
DETAIL A
SM0133
A
2. Gauge cluster
11
22:00 H
1
2 3
10 6 4
9
8
5
7
No.
Name
1
Engine coolant temperature gauge
2
Fuel level gauge
3
Screen change switch
4
Buzzer stop switch
5
Work mode select switch
6
Washer switch
7
Wiper switch
8
Travel high speed, low speed select switch
9
Auto accel switch
10
Select switch
11
Multi display (LCD)
SM0134
T2-1-21
E215B-E245B
MECHATRO CONTROL SYSTEM
3. Screen selection by work mode select switch After starting engine, "S" mode is usually set. The work modes "S","H","B" and "A" are selected in order every time ( ) is pressed. Select efficient work mode according to the working condition and the purpose from the following table. The selected mode is displayed on the left lower corner on multi display. • • • •
S mode: For standard digging work H mode: For heavy duty digging work B mode: For works with breaker A mode: For works with crusher (nibbler)
10:25 H
SM0135
Work mode
Display
10:25
S mode
Contents "S mode"is suitable for standard digging and loading works and is in fuel saving and is maintained well-balanced relations with workload.
10:25
H mode
"H mode"is suitable for heavy duty digging work which gives priority to the workload at the high speed.
10:25
B mode
For the work with breaker, select "B mode" without fail.
10:25
A mode
For the work with crusher (nibbler), select "A mode".
T2-1-22
MECHATRO CONTROL SYSTEM
1) Pump flow rate adjustment (A mode /B mode)
No.
1
2
E215B-E245B
3
4
Switches
1
Screen change switch
2
Buzzer stop switch
3
KPSS work mode select switch
4
Washer switch
5
Wiper switch
6
Travel speed select switch
7
Auto accel switch
8
Select switch
5 8
7
6
SM0140
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate in accordance with the procedure mentioned below. In this machine, last set flow rate has been stored and the initial flow r ate is 210L/min. The adjustment (increase or decrease) of flow rate is changeable by 10L/min step. Main screen
Attachment mode (A mode)
10:25
Flow rate
H
130 L/m
Flow rate
Enter
A
(a)
Flow rate
100 L/m
(b)
(d)
100 L/m
A
Increase/Decrease
In Breaker mode (B mode) Flow rate
130 L/m
Flow rate
Enter
B Screen in Attachment/Breaker mode A mode Flow rate
(c)
(d)
Flow rate
A
100 L/m
B
Increase/Decrease When the conflux switch is tuned on, the double flow rate is displayed.
B mode 130 L/m
Flow rate
100 L/m
130 L/m
B (b)
(c)
SM0141
1) Turn starter key switch on and display main screen (a). 2) The display on the left lower corner of screen is changed in order of "S" → "H" → "B" → "A" each time the "MODE" switch (3) is pressed under the condition where main screen (a) is displayed. 3) Select "A" and A mode screen is displayed, and select " B" and B mode screen is displayed. 4) Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and the screen (d) is displayed. In this condition, press FEED ( 4)/ (5) and the flow rate value increases or decreases. 5) Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.
T2-1-23
E215B-E245B
MECHATRO CONTROL SYSTEM
4. MAINTENANCE SCREEN DISPLAYS This screen displays the remaining time to the end of recommended replacement/change interval specified for filter/oil. For the initial set value of recommenced replacement/change time, see the following table. Replacement interval Item
Default
Engine oil
500 Hr
Fuel filter
500 Hr
Hydraulic oil filter
1,000 Hr
Hydraulic oil
5,000 Hr
This menu is available for confirmation of the following items. The maintenance screen changes each time the screen change switch is pressed.
1) Remaining time display to the engine oil change This display shows the remaining time to the coming engine oil change.
492Hr ENGINE OIL
H 2) Remaining time display to the coming fuel filter replacement This display shows the remaining time to the coming engine fuel filter replacement.
492Hr FUEL FILTER
H 3) Remaining time display to the coming hydraulic oil filter replacement This display shows the remaining time to the coming hydraulic oil filter replacement.
992Hr HYD. FILTER
H 4) Remaining time display to the coming hydraulic oil change This display shows the remaining time to the coming hydraulic oil change.
4992Hr HYD. OIL
H
NOTE: • The display automatically changes to the main screen, if switch is not operated for 30 seconds. • For the setting procedure of maintenance time to be performed to the coming oil change in each type and filter replacement, see the paragraph 3.6 “SET PROCEDURE OF MAINTENANCE SCHEDULE”.
T2-1-24
MECHATRO CONTROL SYSTEM
E215B-E245B
5. Gauge cluster display After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen. The display functions of multi display are explained below.
CLOCK DISPLAY
SELF DIAGNOSIS / WARNING
MACHINE CONDITION
H MULTI DISPLAY INDICATIONS SM0146
1) Display function for operator .........................Screen usually displayed during operation 1.1 Clock display function ............................Current time is displayed. 1.2 Self-diagnosis display ............................When abnormality is detected on mechatro system like sensor, proportional valve, etc., this displays error code. 1.3 Warning display .....................................When machine was thrown into dangerous state, or was failed, displays warning symbol. (For warning contents, see items shown on the next page.) 1.4 Machine condition display ......................Displays machine operating condition. 2) Display function for maintenance...................Displays remaining time up to replacement/change of following items. (1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil 3) Failure history display function.......................Stores abnormality occurred on mechatro system in the past and displays in order of recent occurrence. 4) Mechatro adjustment display .........................Displays procedure for adjustment of mechatro system like output adjustment and unload adjustment, etc. 5) Service diagnosis display...............................Displays informa tion like pressure sensor sensed value, proportional valve command, etc. output by mechatro controller 6) Failure diagnosis mode display function .......Specifie s failed section automatically for failures which are not detected by self diagnosis and displays the results.
T2-1-25
E215B-E245B
MECHATRO CONTROL SYSTEM
• Warning table These descriptions indicate error codes stored as “trouble history code”
W009
CAUTION ATTACHMENT
W005
LOW ENG OIL PRESS.
W011
PREHEAT
W006
POWER BOOST ON
HIGH ENG WATER TEMP.
CPU
CHARGE ERROR
W004
DATA COMMUNICATION ERROR
LOW ENG WATER LEVEL
W001
W010
SWING BRAKE DISENGAGED
DRAIN WATER SEPARATOR
LOW FUEL LEVEL
AUTO WARMING UP
W008
ENG LOW PRESSURE (ENGINE STOP)
NOTE:
CLOGGED AIR FILTER
CHANGE ENG OIL
Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.
T2-1-26
MECHATRO CONTROL SYSTEM
E215B-E245B
Warning Condition Priority
A
Level (*)
Screen
1
DATA COMMUCATION ERROR
1
SWING BRAKE DISENGAGED
1
ENGINE STOP
2
FAIL DRAIN HYD. PRESSURE
2
DRAINING HYD. PRESS.
1
Condition
O O
Auto Stop
O
3
x
O
O
2
O
O
1
O
x
O
1
x
O
Possible to drain hyd. Pressure
O
4
x
O
CAUTION ATTACHMENT
The selector valve (OPT) is malfunction
O
2
x
O
2
POWER BOOST ON
The power boost switchis turn ON
2
FINISH WARM-UP
After finishing warming up control
O
2
O
x
Low engine oil pressure
O
2
x
O
W005
3
LOW ENG OIL PRESS.
O
O
3
x
O
W006
O
O
3
x
O
W010
O
O
3
x
O
W008
O
O
3
x
O
O
O
3
Data from Mechatro controller is not received The swing parking brake switch is turned ON Engine is stopped after engine oil pressare low warning Impossible to drain hyd. Pressure
O O
O
O
W001
W009
-
O
The engine water is more than 105 °C Water in water separator filter is increased
3
HIGH ENG. WATER TEMP.
3
DRAIN WATER SEPA
3
CLOGGED AIR FLTR
3
(SELF DIAGNOS IS SCREE NS )
3
PREHEAT
4
CHARGE ERROR
No signal from the alternator
4
LOW FUEL LEVEL
The fuel level is less than 10 %
O
4
LOW ENG WATER LEVEL
The warter engine coolant reservoir is low
O
5
AUTO WARMING UP
The auto warming up control is activated
5
CHANGE ENG OIL
The remaining time is reached zero Huors
The air filter is clogged According to the self diagnosis control The heater relay contact is faulty
(*) 1: these extremely influence safety and the machine performance 2: these warn the machine control mode is switched 3: fatal failure 4: normal priority warning 5: low priority message
3.2
Engine Run
Type (**)
Disconnection
B
Only Key ON
Trouble History Manual Code Stop
Buzzer sounds
O
O
O
-
O
-
O
-
O
-
W011
W004
(**) 1: Continuation 2: Beep ON 0.2 sec. OFF 0.3 sec. 3: Beep ON 0.5 sec. OFF 0.5 sec. 4: Beep ON 0.5 sec. OFF 1.0 sec.
SELF DIAGNOSIS DISPLAY
1. Outline This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during machine operation through self diagnosis. The failed items are displayed on multi display of gauge cluster. For connector No. and pin No., refer to the section "Mechatro Control Equipment" explained later. Electric circuit diagram or harness is available to identify wire No. and wire color. 2. I/O configuration L O R T N O C
Pressure sensor, Governor motor INPUT
Proportional valve, Battery relay Selector valve (SOL)
SERIAL COMMUNICATION Gauge cluster (Buzzer sound) SM0147
T2-1-27
E215B-E245B
MECHATRO CONTROL SYSTEM
3. Self diagnosis display items As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with the aid of error code. Alphabet: Decide system failure occurred.
10:25
B 01 3
B013
Last 2nd and 3rd digits: Specifies failed section.
Last 1 digit: Specifies failure type. This failure symbol is displayed simultaneously with error code during failure diagnosis.
ERROR CODE
SM0148
ALPHABET A Controller memory
B Low pressure sensor
C High pressure sensor
D Proportional valve for
E Proportional valve for
F
G
H
Solenoid valve
Speed sensor
Potentiometer etc.
Throttle
I
K
R
C om mu ni ca ti on
B at te ry r e la y
R el ay o u tp ut
Battery relay
Wiper ark prevention
2nd AND 3rd DIGIT 01
Engine adjust data
Boom up
P1 pump
P1 unload
P1 pump
ATT boost
Step motor
02
Torqueadjust data
Boom down
P2 pump
P2 unload
P2 pump
Swing parking brake
Step motor
03
Unload adjust data
Boom head
Travel straight
04
Arm out Arm in
05
Bucket digging
06
Bucket dump
07
Swing
09
Travel right
10
Travel left
11
Selector position
Wiper ark forward
Travel 1,2 speed
Wiper ark reverse
Option selector
Washer motor
Arm 2 spool for arm in
Fuel sensor
13 14 PSV-R Short Cricuit valve
15 16
P1 side option
AIS relay2
17
P2 side option
Engine stop relay Safety lock lever relay
18 21
Adjustment data sector 1
22
Adjustment data sector 2
23
Hourmeter sector 1
24
Hourmeter sector 2
25
Proportional valve adjust
Safety relay
Cluster communication
31
LAST DIGIT Larger than normal range
0
Larger than normal range Transistor OFF failure/
1
-
2
-
Wrong output
Wrong output
Transistor ON failure
Transistor ON failure
3
-
Discon nection
Disconnection
Disconne ctio n
Disconn ection
4
-
Power source short circuit
Power source short circuit
5
Over run Transistor ON failure /
Disconnection
Disconnection Power source short circuit
Obnormal data
T2-1-28
Time is over Contact point is melted and adhered
Power source short circuit
MECHATRO CONTROL SYSTEM 3.3
E215B-E245B
SERVICE DIAGNOSIS DISPLAY FUNCTION
The current service diagnosis is displayed on multi display based on the data received from mechatro controller. This section explains the operating procedure and examples of each screen. The values in display changes according to the conditions like engine speed, attachment position, etc. 1. Service diagnosis display screen operating procedure 1)
Turn starter switch ON keeping buzzer stop switch pressed.
2) After logo mark is displayed, the screen changes in service diagnosis mode. The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first. The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in "Screen No.1". The screen number each mode can display differs. The screen number displayed by each mode is as follows. • Mode No.1: Screen No.1~No.30 • Mode No.2: Screen No.1, Screen No.31~No.40 • Mode No.3: Screen No.1, Screen No.41~No.50 3) The screen changes each time each switch is pressed from now on. Washer switch: Screen gains by 1 in order. (No.2 →No.3→No.4→...) Wiper switch: Screen loses by 1 in order. (No.24 →No.23→No.22→...) Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.1. (No.1 →No.2→No.3→No.1→...) Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to No.3. (No.3 →No.2→No.1→No.3→...) 4) Turn key switch OFF and the display of service diagnosis mode is closed.
T2-1-29
E215B-E245B
MECHATRO CONTROL SYSTEM
2. Service diagnosis display screen (Example) The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low speed and lever to neutral position.) 1) Service diagnosis “Mode No.1”
No. 1
Displays
Contents
NO.1 MAIN CONT. P/N YN22E00207F1 PROGRAM VERSION 1-VER 2.00 2-VER 0.00
P/No. indication
NO.2 ENG G-3 SPEED SET MEAS G-5 ENG PRS. WATER TEMP MODE H-1 ACCEL VOLT. POS. G-1 MOTOR STEP POS. COIL A COIL B G-2 LIMIT SW.
3
NO.3 SOL.VALVE F-1 POW ER BOOST COMP. MEAS. SWITCH F-2 SWING-BRAKE COMP. MEAS. RELEASE SW F-3 1/2-TRAVEL COMP. MEAS. SWITCH
Service diagnosis mode
5 1000 1000 LIVE 20 °C OFF H 0.3 V 0% 30 0% 1.5 A 1.5 A OFF
No load setting rpm Actual rpm Engine oil pressure Coolant temperature sensor / Coolant tempreature switch
Work mode Potentiometer voltage Voltage % indication Number of step Step % indication A phase current B phase current Limit switch
6 OFF OFF OFF
Set value in computer Measured value Switch
ON ON OFF
Set value in computer Measured value Switch
OFF OFF OFF
Set value in computer Measured value Switch
Displays
Contents
NO.4 RELAY K-1 AIS RELAY 2 K-2 SAFETY RLY K-3 ENG STOP KEY SWITCH START SWITCH CHARGE K-4 LOCK LEVER SWITCH
Program version indication
SERVICE DIAG 1
2
No. 4
NO.5 PRESS.SENSOR B-1 BOOM RAISE 0.4 V 0.0 M B-2 BOOM LOWER 0.4 V 0.0 M B-3 ARM OUT 0.4 V 0.0 M B-4 ARM IN 0.4 V 0.0 M B-5 BUCKET DIG 0.4 V 0.0 M B-6 BUCKET DUMP 0.4 V 0.0 M
NO.6 PRESS.SENSOR B-7 SWING 0.4 V 0.0 M B-9 TRAVEL (R) 0.4 V 0.0 M B-10 TRAVEL (L) 0.4 V 0.0 M B-16 P1 OPT. 0.4 V 0.0 M B-17 P2 OPT. 0.5 V 0.0 M B-18 DOZER 1 0.0 V 0.0 M B-19 DOZER 2 0.0 V 0.0 M
ON ON OFF ON OFF LIVE OFF ON
Indicated value Indicated value Indicated value Key switch Starter switch Alternator Indicated value Switch
Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
SM0149
T2-1-30
MECHATRO CONTROL SYSTEM
7
8
9
10
11
Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Set value in computer / Converted value from pressure Measured value / Converted value from pressure
Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure
1.0 M 1.0 M 0 mA 30 L
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
1.0 M 1.0 M 0 mA 30 L
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
Power shift Flow rate of pump P1
Power shift Flow rate of pump P2
20 Fuel level Hydraulic oil temperature Glow switch Air filter clogging Water separator clogging Engine oil filter clogging Front window open/close switch Conflux/Single flow select switch Command from grid heater Engine oil level Coolant level
21 OFF OFF
SPOOL POS. NIB SELECT SWITCH NIB F-5 FAN PUMP COMP. --MEAS. --F-6 COMP. --MEAS. ---
15
18
19
NO.10 SENSOR,SWITCH H-9 FUEL LEVEL 1.2 V 77% H-10 HYD.OIL TEMP 0.0 V 0 GLOW --AIR FILTER LIVE WATER SEPA. LIVE ENG OIL FILTER --FRONT WINDOW OFF DOUBLE FLOW ON KPSS SW --HEATER OFF ENG OIL LEVEL OK COOLANT LEVEL OK NO.11 SOL.VALVE F-4 OPT SELECT COMP. MEAS.
NO.15 PROPO-VALVE D-11 P1 I-TRAVEL COMP. 0 mA MEAS. 0 Ma D-12 P2 I-TRAVEL COMP. 0 mA MEAS. 0 mA D-15 P1 BY PASS VALVE COMP. 347 mA MEAS. 347 mA D-16 P2 BY PASS VALVE COMP. 0 mA MEAS. 0 mA
NO.16 PRESS.SENSOR B-11 0.4 V 0.0 M B-12 0.0 V 0.0 M B-13 0.0 V 0.0 M B-14 0.0 V 0.0 M B-15 0.0 V 0.0 M B-20 0.0 V 0.0 M
Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
NO.8 PROPO-VALVE D-1 P1 UN-LOAD(BP-CUT) COMP. 750 mA 3.0 M MEAS. 750 mA 3.0 M D-2 P2 UN-LOAD(BP-CUT) COMP. 750 mA 3.0 M MEAS. 750 mA 3.0 M D-3 S-TRAVEL COMP. 350 mA 0.6 M MEAS. 350 mA 0.6 M D-6 ARM IN-2-SPEED COMP. 750 mA 0.0 M MEAS. 750 mA 0.0 M
NO.9 PROPO-VALVE E-1 P1 PUMP COMP. 417 mA MEAS. 417 mA POWER SHIFT FLOW RATE E-2 P2 PUMP COMP. 417 mA MEAS. 417 mA POWER SHIFT FLOW RATE
16
NO.7 P.SENSOR PROPO-V C-1 P UMP P1 0.4 V 0.3 M C-2 P UMP P2 0.4 V 0.0 M C-3 BOOM-HEAD 0.5 V 0.9 M C-4 BOOM-ROD 0.0 V 0.0 M PROPO-VALVE E-3 OPT RELIEF 1 COMP. 0 mA 2.0 M MEAS. 0 mA 2.0 M E-4 OPT RELIEF 2 COMP. 0 mA 2.0 M MEAS. 0 mA 2.0 M
E215B-E245B
Set value in computer Measured value (Feed back value) Spool position Mode of selector valve Set value in computer Measured value Set value in computer Measured value
22 0.0 M 0.0 M
Set value in computer / Converted value from pressure
0.0 M 0.0 M
Set value in computer / Converted value from pressure
0.6 M 0.6M
Set value in computer / Converted value from pressure
0.0 M 0.0 M
Set value in computer / Converted value from pressure
Measured value / Converted value from pressure
Measured value / Converted value from pressure
Measured value / Converted value from pressure
Measured value / Converted value from pressure
NO.18 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 DI9 DI10 DI11 DI12 DI13 DI14
DIGITAL INPUT OFF ON OFF OFF OFF OFF --OFF OFF OFF ----ON ---
ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication
NO.19 DI15 DI16 DI17 DI18 DI19 DI20 DI21 DI22 DI23 DI24 DI25 DI26 DI27 DI28
DIGITAL INPUT --ON ON OFF --OFF ----ON OFF ON --OFF ---
ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication
NO.20 DI29 DI30 DI31 DI32 DI33 DI34 DI35 DI36 DI37 DI38 DI39 DI40 DI41 DI42
DIGITAL INPUT OFF ------ON ----OFF --OFF --OFF -----
ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication
NO.21 DIGITAL OUTPUT DO1 COMP. OFF MEAS. OFF DO2 COMP. OFF MEAS. OFF DO3 COMP. OFF MEAS. OFF DO4 COMP. OFF MEAS. OFF DO5 COMP. --MEAS. --DO6 COMP. --MEAS. --DO7 COMP. OFF MEAS. OFF
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
NO.22 DIGITAL OUTPUT DO8 COMP. ON MEAS. ON DO9 COMP. OFF MEAS. OFF DO10 COMP. --MEAS. --DO11 COMP. O FF MEAS. OFF DO12 COMP. --MEAS. --DO13 COMP. --MEAS. --DO14 COMP. --MEAS. ---
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
See Mechatro controller connector
SM0150
T2-1-31
E215B-E245B
No. 23
24
25
MECHATRO CONTROL SYSTEM
Displays
Contents
NO.23 DIGITAL OUTPUT DO15 COMP. --MEAS. --DO16 COMP. ON MEAS. ON DO17 COMP. OFF MEAS. OFF DO18 COMP. OFF MEAS. OFF DO19 COMP. OFF MEAS. OFF DO20 COMP. --MEAS. --DO21 COMP. ON MEAS. ON
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
NO.24 DIGITAL OUTPUT DO22 COMP. --MEAS. --DO23 COMP. OFF MEAS. ON DO24 COMP. --MEAS. --DO25 COMP. --MEAS. --DO26 COMP. --MEAS. --DO27 COMP. --MEAS. --DO28 COMP. --MEAS. ---
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
NO.25 WIPER SYSTEM WIPER SW OFF RISEUP SW ON REVERSE SW ON PREVENT ARC OFF CW MOTOR RLY OFF CCW MOTOR RLY OFF WASHER SW OFF MOTOR RELAY OFF
Wiper switch Wiper rise-up switch Wiper reverse rotation switch Wiper motor ark prevention relay Wiper normal rotation relay Wiper reverse rotation relay Washer switch Washer motor relay
SM0151
T2-1-32
MECHATRO CONTROL SYSTEM
E215B-E245B
2) Service diagnosis “Mode No.2”
No. 1
31
32
Displays
Contents
NO.1 MAIN CONT. P/N YN22E00207F1 PROGRAM VERSION 1-VER 2.00 2-VER 0.00
No. 33
P/No. indication Program version indication MERIT controller program version
SERVICE DIAG 2
Service diagnosis mode 2
NO.31 BOOM C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) B-1 BOOM RAISE B-2 BOOM LOWER G-3 ENG SPEED POWER SHIFT
0.2 M 0.0 M 417 mA 417 mA 750 mA 750 mA 0.0 M 0.0M 1000 0 mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Boom up pressure sensor Boom down pressure sensor Engine actual speed Power shift current
NO.32 ARM,SWING C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) D-3 S-TRAVEL D-6 ARM-IN-2 B-3 ARM OUT B-4 ARM IN B-1 BOOM RAISE B-7 SWING G-3 ENG SPEED POWER SHIFT
0.2 M 0.0 M 417 mA 417 mA 750 mA 750 mA 350 mA 750 mA 0.0 M 0.0 M 0.0 M 0.0 M 1000 0 mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current Arm out pressure sensor Arm in pressure sensor Boom up pressure sensor Swing pressure sensor Engine actual speed Power shift current
34
35
Displays
Contents
NO.33 BUCKET C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) D-3 S-TRAVEL B-5 BUCKET DIG B-6 BUCKET DUMP G-3 ENG SPEED POWER SHIFT
0.2 M 0.0 M 417 mA 417 mA 750 mA 750 mA 350 mA 0.0 M 0.0 M 1000 0 mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Bucket digging pressure sensor Bucket dump pressure sensor Engine actual speed Power shift current
NO.34 TRAVEL C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) D-3 S-TRAVEL B-9 TRAVEL(R) B-10 TRAVEL(L) Pi-P1 Pi-P2 G-3 ENG SPEED POWER SHIFT
0.2 M 0.0 M 417 mA 417 mA 750 mA 750 mA 350 mA 0.0 M 0.0 M 0.0 M 0.0 M 1000 0 mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Travel right pressure sensor Travel left pressure sensor Pilot pressure at travel straight (P1 side) Pilot pressure at travel straight (P2 side) Engine actual rpm Power shift current
NO.35 OPT C-1 P1 PUMP 0.2 M C-2 P2 PUMP 0.0 M E-1 P1-PSV 417 mA E-2 P2-PSV 417 mA D-1 P1-UL(BPC) 750 mA D-2 P2-UL(BPC) 750 mA D-3 S-TRAVEL 350 mA E-3 OPT RELIEF 110 mA B-16 P1 OPT 0.0 M B-17 P2 OPT 0.0 M F-4 OPT SELECT NIB DOUBLE FLOW SW OFF G-3 ENG SPEED 1000 POWER SHIFT 0 mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current P1 side option pressure sensor P2 side option pressure sensor Optional selector SOL (Nibbler line) Conflux/ Single selector switch Engine actual rpm Power shift current SM0152
3) Service diagnosis “Mode No.3” No. 1
Displays NO.1 MAIN CONT. P/N YN22E00207F1 PROGRAM VERSION 1-VER 2.00 2-VER 0.00 SERVICE DIAG 3
41
NO.41 ADJUSTMENT 1 ENG HI-IDLE 2230 PUMP ACT I 515 mA 7 mA PUMP P 35.0 M ESS N 930 UN-LOAD P1 565 mA P2 565 mA BOOM 0 0 ARM 0 0 OFFSET 0 0 INTER-B 0 0
Contents
No. 43
P/No. indication Program version indication MERIT controller program version Service diagnosis mode 3
44 Engine speed high idle Current at pump adjustment Current correction at pump adjustment Pressure at pump adjustment Engine speed sensor rpm P1 unload corrective current P2 unload corrective current Angle adjustment Angle adjustment Angle adjustment Angle adjustment
Displays NO.43 MACHINE-INFORM. HOUR METER 3550 TRIP METER 3500 OPERATION 3300 TRAVEL 300 SWING 3000 HAMMER 100 CRANE 100 STARTER 1200
Contents Hour meter of controller Trip meter of controller All accumulated operating time All accumulated traveling time All accumulated swing time All accumulated breaker operating time All accumulated high-reach crane operating time
All accumulated starter operating time
NO.44 MACHINE-INFORM. PUMP PRESS. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%
Pump pressure distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours
WATER TEMP. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%
Coolant temperature distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours
SM0153
T2-1-33
E215B-E245B
MECHATRO CONTROL SYSTEM
3. Service diagnosis data list Preface and precaution The following is the data decided as normal status after service diagnosis for every operation. Use these data to decide normal/abnormal status. • The values in following display are reference values with standard attachment attached machine. • The value of pressure sensor is calculated taking variation into accounts. When compared to performance check reference criteria, measure it with the aid of calibrated measuring instrument. • The current of proportional valve is not the measured value, but command value. The measured value should be confirmed by the value in the displayed value for each proportional valve. • The current value of pump proportional valve is reference value because it varies according to pump pressure and adjusted torque value. • The value in display during operation shows the value in steady state, rather than, at start of operation. • Check on machine after sufficiently warming up machine. • The value in display may differ according to software version. Contact our dealer/distributor.
Operation No.1 : No operation H mode Hi idle
Operation No.2 : No operation S mode Hi idle
No.32 ARM, SWING
No.32 ARM, SWING
C-1 P1-PRES
0.2~1.5 M
C-1 P1-PRES
0.2~1.5 M
C-2 P2-PRES
0.2~1.5 M
C-2 P2-PRES
0.2~1.5 M
E-1 P1-PSV
350 mA
E-1 P1-PSV
350 mA
E-2 P2-PSV
350 mA
E-2 P2-PSV
350 mA
D-1 P1-UL(BPC)
750 mA
D-1 P1-UL(BPC)
750 mA
D-2 P2-UL(BPC)
750 mA
D-2 P2-UL(BPC)
750 mA
D-3 S-TRAVEL
350 mA
D-3 S-TRAVEL
350 mA
D-6 ARM-IN-2
750 mA
D-6 ARM-IN-2
750 mA
B-3 ARM OUT
0.0 M
B-3 ARM OUT
0.0 M
B-4 ARM IN
0.0 M
B-4 ARM IN
0.0 M
B-1 BOOM RAISE
0.0 M
B-1 BOOM RAISE
0.0 M
B-7 SWING
0.0 M
B-7 SWING
0.0 M
G-3 ENG SPEED POWER SHIFT
1970~2030
G-3 ENG SPEED
0 mA
POWER SHIFT
1770~1830 0 mA
Operation No.3 : Boom up in full lever operation & relief H mode Hi idle
Operation No.4 : Boom up in full lever operation & in operation H mode Hi idle
No.31 BOOM
No.31 BOOM
C-1 P1-PRES
33.0~35.8 M
C-1 P1-PRES
11.0~16.0 M
C-2 P2-PRES
33.0~35.8 M
C-2 P2-PRES
11.0~16.0 M
E-1 P1-PSV
415~525 mA
E-1 P1-PSV
560~750 mA
E-2 P2-PSV
415~525 mA
E-2 P2-PSV
560~750 mA
D-1 P1-UL(BPC)
360 mA
D-1 P1-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
B-1 BOOM RAISE
3.0 M
B-1 BOOM RAISE
3.0 M
B-2 BOOM LOWER
0.0 M
B-2 BOOM LOWER
0.0 M
G-3 ENG SPEED POWER SHIFT
1970~2060
G-3 ENG SPEED
0 mA
POWER SHIFT
T2-1-34
1970~2060 0 mA
MECHATRO CONTROL SYSTEM
E215B-E245B
Operation No.5 : Boom down in full lever operation & in operation H mode Hi idle
No.31 BOOM C-1 P1-PRES
12.5~16.0 M
C-2 P2-PRES
0.2~1.5 M
E-1 P1-PSV E-2
P2-PSV
600~617 mA 350 mA
D-1 P1-UL(BPC)
427~477 mA
D-2 P2-UL(BPC)
750 mA
B-1 BOOM RAISE
0.0 M
B-2 BOOM LOWER
3.0 M
G-3 ENG SPEED POWER SHIFT
1970~2060 0 mA
Operation No.6 : Arm-in in full l ever operation & relief H mode Hi idle
Operation No.7 : Arm-in in full lever operation & in operation H mode Hi idle
No.32 ARM, SWING
No.32 ARM, SWING
C-1 P1-PRES
33.0~35.8 M
C-1 P1-PRES
12.5~16.5 M
C-2 P2-PRES
33.0~35.8 M
C-2 P2-PRES
12.5~16.5 M
E-1 P1-PSV
415~525 mA
E-1
P1-PSV
550~750 mA
E-2 P2-PSV
415~525 mA
E-2
P2-PSV
550~750 mA
D-1 P1-UL(BPC)
360 mA
D-1 P1-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-3 S-TRAVEL
350 mA
D-3 S-TRAVEL
350 mA
D-6 ARM-IN-2
200 mA
D-6 ARM-IN-2
400 mA
B-3 ARM OUT
0.0 M
B-3 ARM OUT
0.0 M
B-4 ARM IN
3.0 M
B-4
ARM IN
3.0 M
B-1 BOOM RAISE
0.0 M
B-1 BOOM RAISE
0.0 M
B-7 SWING
0.0 M
B-7 SWING
0.0 M
G-3 ENG SPEED POWER SHIFT
1970~2060
G-3 ENG SPEED
0 mA
POWER SHIFT
T2-1-35
1970~2060 0 mA
E215B-E245B
MECHATRO CONTROL SYSTEM
Operation No.8 : Arm-out in full lever operation & relief H mode Hi idle
Operation No.9 : Arm-out in full lever operation & in operation H mode Hi idle
No.32 ARM, SWING
No.32 ARM, SWING
C-1 P1-PRES
33.0~35.8 M
C-1 P1-PRES
15.0~22.0 M
C-2 P2-PRES
33.0~35.8 M
C-2 P2-PRES
15.0~22.0 M
E-1 P1-PSV
415~525 mA
E-1 P1-PSV
488~677 mA
E-2 P2-PSV
415~525 mA
E-2 P2-PSV
488~677 mA
D-1 P1-UL(BPC)
360 mA
D-1 P1-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-3 S-TRAVEL
350 mA
D-3 S-TRAVEL
350 mA
D-6 ARM-IN-2
750 mA
D-6 ARM-IN-2
750 mA
B-3 ARM OUT
3.0 M
B-3 ARM OUT
3.0 M
B-4 ARM IN
0.0 M
B-4 ARM IN
0.0 M
B-1 BOOM RAISE
0.0 M
B-1 BOOM RAISE
0.0 M
B-7 SWING
0.0 M
B-7 SWING
0.0 M
G-3 ENG SPEED
1970~2060
POWER SHIFT
G-3 ENG SPEED
0 mA
1970~2060
POWER SHIFT
0 mA
* Measure the values after a lapse of 5 minutes or * Measure the values after a lapse of 5 minutes or after release of low temperature mode after release of low temperature mode Operation No.10 : Swing in full lever operation & relief H mode Hi idle
Operation No.11 : Swing in full lever operation & in operation H mode Hi idle
No.32 ARM, SWING
No.32 ARM, SWING
C-1 P1-PRES
0.2~1.5 M
C-1 P1-PRES
0.2~1.5 M
C-2 P2-PRES
28.0~35.8 M
C-2 P2-PRES
10.0~15.0 M
E-1 P1-PSV
350 mA
E-1 P1-PSV
350 mA
E-2 P2-PSV
528~750 mA
E-2 P2-PSV
750 mA
D-1 P1-UL(BPC)
750 mA
D-1 P1-UL(BPC)
750 mA
D-2 P2-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-3 S-TRAVEL
350 mA
D-3 S-TRAVEL
350 mA
D-6 ARM-IN-2
750 mA
D-6 ARM-IN-2
750 mA
B-3 ARM OUT
0.0 M
B-3 ARM OUT
0.0 M
B-4 ARM IN
0.0 M
B-4 ARM IN
0.0 M
B-1 BOOM RAISE
0.0 M
B-1 BOOM RAISE
0.0 M
B-7 SWING
3.0 M
B-7 SWING
3.0 M
G-3 ENG SPEED POWER SHIFT
1970~2060
G-3 ENG SPEED
0 mA
POWER SHIFT
T2-1-36
1970~2060 0 mA
MECHATRO CONTROL SYSTEM
E215B-E245B
Operation No.12 : Bucket digging in full lever operation & relief H mode Hi idle
Operation No.13 : Bucket digging in full lever operation & in operation H mode Hi idle
No.33 BUCKET
No.33 BUCKET
C-1 P1-PRES
33.0~35.8 M
C-1 P1-PRES
4.0~8.0 M
C-2 P2-PRES
33.0~35.8 M
C-2 P2-PRES
4.0~8.0 M
E-1 P1-PSV
415~525 mA
E-1 P1-PSV
650~750 mA
E-2 P2-PSV
415~525 mA
E-2 P2-PSV
540~563 mA
D-1 P1-UL(BPC)
360 mA
D-1 P1-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-3 S-TRAVEL
720 mA
D-3 S-TRAVEL
720 mA
B-5 BUCKET DIG
3.0 M
B-5 BUCKET DIG
3.0 M
B-6 BUCKET DUMP
0.0 M
B-6
0.0 M
G-3 ENG SPEED
1970~2060
POWER SHIFT
BUCKET DUMP
G-3 ENG SPEED
0 mA
POWER SHIFT
1970~2060 0 mA
Operation No.14 : Bucket dump in full lever operation & relief H mode Hi idle
Operation No.15 : Bucket dump in full lever operation & in operation H mode Hi idle
No.33 BUCKET
No.33 BUCKET
C-1 P1-PRES
33.0~35.8 M
C-1 P1-PRES
6.0~15.0 M
C-2 P2-PRES
33.0~35.8 M
C-2 P2-PRES
6.0~15.0 M
E-1 P1-PSV
415~525 mA
E-1
P1-PSV
577~750 mA
E-2 P2-PSV
415~435 mA
E-2
P2-PSV
415~435 mA
D-1 P1-UL(BPC)
360 mA
D-1 P1-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-3 S-TRAVEL
720 mA
D-3 S-TRAVEL
720 mA
B-5 BUCKET DIG
0.0 M
B-5 BUCKET DIG
0.0 M
B-6 BUCKET DUMP
3.0 M
B-6
3.0 M
G-3 ENG SPEED POWER SHIFT
1970~2060
BUCKET DUMP
G-3 ENG SPEED
0 mA
POWER SHIFT
T2-1-37
1970~2060 0 mA
E215B-E245B
MECHATRO CONTROL SYSTEM
Operation No.16 : P2 side option in full lever operation & relief A mode Hi idle
Operation No.17 : P2 side option in full lever operation & relief B mode Hi idle
No.35 OPT
No.35 OPT
C-1 P1-PRES
22.5~26.0 M
C-1 P1-PRES
0.2~1.5 M
C-2 P2-PRES
22.5~26.0 M
C-2 P2-PRES
22.5~26.0 M
E-1 P1-PSV
459~584 mA
E-1 P1-PSV
500 mA
E-2 P2-PSV
459~584 mA
E-2 P2-PSV
665~750 mA
D-1 P1-UL(BPC)
360 mA
D-1 P1-UL(BPC)
750 mA
D-2 P2-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-3 S-TRAVEL
720 mA
D-3 S-TRAVEL
350 mA
E-3 OPT RELIEF
0 mA
E-3 OPT RELIEF
0 mA
B-16 P1 OPT
0.0 M
B-16 P1 OPT
0.0 M
B-17 P2 OPT
2.0~2.6 M
B-17 P2 OPT
2.0~2.6 M
F-4
OPT SELECT
NIB
DOUBLE FLOW SW.
ON
G-3 ENG SPEED POWER SHIFT
F-4
1970~2060
OPT SELECT
BRK
DOUBLE FLOW SW.
OFF
G-3 ENG SPEED
0 mA
POWER SHIFT
1970~2060 0 mA
* Conflux switch is ON. Relief set pressure is value of shipping.
* Conflux switch is OFF. Relief set pressure is value of shipping.
Operation No.18 : Travel right in full lever operation & travel idling H mode Hi idle
Operation No.19 : Travel left in full lever operation & travel idling H mode Hi idle
No.34 TRAVEL
No.34 TRAVEL
C-1 P1-PRES
5.0~12.0 M
C-1 P1-PRES
0.2~1.5 M
C-2 P2-PRES
0.2~1.5 M
C-2 P2-PRES
5.0~12.0 M
E-1 P1-PSV
750 mA
E-1 P1-PSV
350 mA
E-2 P2-PSV
350 mA
E-2 P2-PSV
750 mA
D-1 P1-UL(BPC)
360 mA
D-1 P1-UL(BPC)
750 mA
D-2 P2-UL(BPC)
750 mA
D-2 P2-UL(BPC)
360 mA
D-3 S-TRAVEL
350 mA
D-3 S-TRAVEL
350 mA
B-9 TRAVEL (R)
2.0~2.5 M
B-9 TRAVEL (R)
0.0 M
B-10 TRAVEL (L)
0.0 M
B-10 TRAVEL (L)
2.0~2.5 M
Pi-P1
0.0 M
Pi-P1
0.0 M
Pi-P2
0.0 M
Pi-P2
0.0 M
G-3 ENG SPEED POWER SHIFT
1970~2060
G-3 ENG SPEED
0 mA
POWER SHIFT
T2-1-38
1970~2060 0 mA
E215B-E245B
MECHATRO CONTROL SYSTEM 3. 3.4 4
TROU TROUBL BLE E HIST HISTOR ORY Y DIAG DIAGNO NOSIS SIS
The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as one of history. And the errors are able to be indicated on the multi display. • •
A part of warning warning contents contents is stored stored (the (the stored stored items items are listed in warning warning table). The error error code code for for self self diagnos diagnosis is is stor stored. ed.
1. How How to to dis displ play ay 1) Turn Turn starte starterr switch switch on. 2) Press buzzer buzzer stop switch continuou continuously sly 5 times and the trouble history history screen is displayed displayed..
(Example) No errors
NO ERROR
Error detected in the past
SM0154
3) Transmit Transmit trouble history history data (One (One or many) and hour hour meter to gauge cluster. cluster. • Hour meter meter and 4 failure failure data are are displayed displayed on screen. screen. • In case of more than than 4 failure data, data, 4 data is displayed displayed at a time for 10 seconds seconds by turns. 4) Paging Paging (Up and down) down) • Press washer washer switch switch ( ) A, and the item moves upward. upward. • Press wiper switch ( ), and the item moves downward. downward. 5) Turn starter starter switch switch off, and and the display display is disappeare disappeared. d. 2. How to to delete delete contents contents of trouble history history 1) 2) 3) 4)
NOTE:
Display Display trouble trouble history history screen. screen. Press work mode mode change switch and buzzer buzzer stop switch simultane simultaneously ously for 10 seconds seconds or more. When "NO ERROR" ERROR" is displaye displayed, d, the deletion deletion is complete completed. d. Turn Turn starte starterr switch switch off. off.
all the stored items are erased. It is impossible to erase data partially.
T2-1-39
E215B-E245B 3.5 3.5
MECHATRO CONTROL SYSTEM
TROU TROUBL BLE E DIA DIAGN GNOS OSIS IS MODE MODE
The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be detected through the use of self diagnosis function (the failure can be specified through the use of error code) like disconnection and abnormal output. This is useful to save the time for troubleshooting. 1. Funct unctio ion n There are two types of trouble diagnosis mode. 1) Trouble Trouble diagnosis mode mode 1: Used to diagnose unload unload system, pump system, system, travel straight straight system. system. 2) Trouble Trouble diagnosis diagnosis mode 2: Used Used to diagnose diagnose pilot pilot system. system. In any mode, with the attachment not moved, both directional valve and proportional valve are automatically actuated, the sensor detects the machine status and the mechatro controller identifies the normal condition or failed condition of the system. For details of how to use, refer to Chapter: “TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".
T2-1-40
MECHATRO CONTROL SYSTEM 3.6 3.6
E215B-E245B
SET SET PROCE PROCEDU DURE RE OF MAI MAINT NTEN ENAN ANCE CE SCHE SCHEDU DULE LE
This machine is equipped with multi-display which allows confirmation of remaining time to the coming replacement/change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the remaining time reaches to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc. and perform the initial setting by the following order. Screen change switch
NOTE: interval NOTE: interval of replacement of parts is mentioned below. • • •
Engi Engine ne oil oil : 500 500 Hr Fuel Fuel filt filter er : 500 500 Hr Hydr Hydrau auli lic c filt filter er : 1,0 1,000 00 Hr Hr
•
Hydraulic oil : 5,000 Hr
Buzzer stop switch
KPSS work mode select switch Washer switch
Select switch
Auto accel switch
Travel speed spee d select switch
Wiper switch
SM0155
Procedure
1
Operating Procedure
Display on Multidisplay
NEW HOLLAND
Turn starter key switch on.
KOBELCO
After several several seconds, display is changed to clock autmatically.
10:25 H
2
3
Press " " switch press once display change switch on the switch panel once. And the clock display changes to the display of remaining time for coming engine oil change. Press " " switch press once select switch once and the display for the engine oil change reverses.
10:25
Press screen change switch once more.
H
250 Hr ENGINE OIL
H
250 Hr ENGINE OIL
Press select switch once more.
250 Hr 250 Hr ENGINE OIL
H
4
5
When required to adjust the interval to the coming change time by 10 hours, press " " switch and the time to the coming engine oil change is added. Press " " switch and the time to the coming engine oil change is reduced. When desired to return to the initial set time, press " " buzzer stop switch once. Press " " select switch once and the set time is stored.
250 Hr 250 Hr ENGINE OIL
500 Hr 500 Hr ENGINE OIL
Replacing interval is changed with each pressing of switch.
To set the desired interval, press the select switch
500 Hr 500 Hr ENGINE OIL
500 Hr ENGINE OIL
H
SM0156
NOTE: 1. After displaying displaying the display display for setting setting by pressing the display display change switch, switch, set the respective respective maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5. 2. The engine oil oil change time time is displayed displayed on the multi-display multi-display by 500 hours hours as a warning, warning, but the buzzer does not sound.
T2-1-41
E215B-E245B 3.7 3.7
MECHATRO CONTROL SYSTEM
ADJU ADJUSTI STING NG PRO PROCE CEDU DURE RE OF OF DISPL DISPLA AY
1. For For ope opera rato tor r 1) Clock Adjustment Switches No.
1
2
3
4
Switches
1
Screen Change nge Sw Switch
2
Buzze zzer Stop top Switch
3
Work ork Mode Mode Sele Select ct Swit Switch ch
4
Washer Switch
5
Wiper Switch
6
Trave ravell Speed peed Sele Select ct Swit Switch ch
7
Auto Ac Accel Switch
8
Select Sw Switch
5 8
7
6
(a)
Main screen
10:25
SWITCH STATUS CLOCK/CONTRAST
13:15
H (a)
SM0140
H (b)
(c) SWITCH STATUS CLOCK/CONTRAST
(d)
(e)
ADJUST CLOCK CLOCK ADJ CONTRAST CONTRAST
Y M D H M 06 04 01 13 15
Select Year/Month/Day/Hour/Minute
Enter
Increase/Decrese SM0157
1) Turn starter starter key switch switch on and display display main main screen screen (a (a) for operator, and then press select switch ( 8) and display "SWITCH STATUS CLOCK/CONTRAST" select screen ( b). 2) In operat operation ions s of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c ( c) and then press select switch (8 ( 8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d ( d) is displayed. 3) In operat operation ions s of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then pr ess select switch (8 ( 8) and the "ADJUST CLOCK" screen (e ( e) is displayed. 4) Select any of "Y•M•D•H•M" "Y•M•D•H•M" in operation operation of FEED operations of FEED (6) and FEED (7).
(4) and FEED
(5) and vary the values in
5) After adjustm adjustment, ent, press press select select switch switch (8 (8) and the adjusted values are stored as memory and time setting is completed, and then the screen returns to main screen ( a).
T2-1-42
MECHATRO CONTROL SYSTEM
2) Contrast Adjustment Switches No.
1
2
E215B-E245B
3
4
Switches
1
Screen een Ch Change Sw Switch
2
Buzzer St Stop Sw Switch
3
Work ork Mode Mode Sele Select ct Swit Switch ch
4
Washer Sw Switch
5
Wiper Switch
6
Trave ravell Speed peed Sele Select ct Swit Switch ch
7
Auto Accel Switch
8
Select Switch
5 8
7
6
SM0140
Main screen
10:25
SWITCH STATUS CLOCK/CONTRAST
H (a)
(b)
(c)
(d)
SWITCH STATUS
ADJUST CLOCK CLOCK
CLOCK/CONTRAST
ADJ CONTRAST CONTRAST
(a)
10:25 H
(e)
(f)
ADJUST CLOCK CLOCK
ADJ CONTRAST CONTRAST
ADJ CONTRAST CONTRAST
55555
Adjustable range range 11111~99999 (Default 55555)
Enter
Increase/Decrease SM0158
1) Turn starter starter key switch on and display display main main screen screen ( a), and press select switch ( 8) and display "SWITCH STATUS CLOCK CONTRAST" select screen ( b). 2) In operati operations ons of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST" screen (c) and then press select switch ( 8) and the "ADJUST CLOCK ADJ CONTRAST" screen ( d) is displayed. 3) In operati operations ons of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and then press select switch ( 8) and the "ADJUST CLOCK ADJ CONTRAST" screen ( e) is displayed. 4) Press Press selec selectt switc switch h (8) and the "ADJ CONTRAST 55555" screen ( f ) is displayed. 5) Vary the values values by pressing pressing the desired desired figure in operatio operations ns of FEED ( 4) and FEED The available setting range is in 9 steps from "11111" to "99999". [Example] 11111 (faint) → 99999 (clear) * The initial set value is 55555.
(5).
6) Press Press sele select ct swit switch ch (8) and the adjusted values are stored as a memory and the contrast adjustment is completed, and then the screen returns to main screen ( a).
T2-1-43
E215B-E245B
MECHATRO CONTROL SYSTEM
2. Functio Function n for servic service e Following items are provided for adjustment of service function. •
LANG ANGUAGE AGE/LOG LOGO Function
Explanation
LANGUAGE
To change la language
LOGO
To change Company Logo
•
Note
Range
All language data is stored in 15 one gauge cluster languages 5 Logos
Default
ISO NHK
ADJU ADJUST STIN ING G MOD MODE 1 Function
Explanation
RISE-UP WIPER
Note
To change wiper control, when special CAB is installed on demolition OFF is for special CAB machine
Range
ON/OFF
Default
ON
P1 OPT SENSOR To activate the self-diagnosis when P1 Switch to ON when 2PB is ON/OFF ACTIVE OPT pressure sensor is failed installed
OFF (*)
P2 OPT SENSOR To activate the self-diagnosis when P2 Switch to ON when N&B ON/OFF ACTIVE OPT pressure sensor is failed option is installed
OFF (*)
PRIORITY MODE
Only for EU, to activate the priority valve
ON/OFF
OFF
LEFT ACTIVE
To use P1 option pedal for P4-rotation circuit, releasing auto accel. And not activating unload valve
ON/OFF
OFF
PEDAL
SELECT SYSTEM
OPT
1:No selector valve Switch to ON when N&B 2:Selector Valve + Mechanical relief 1 or 3 option is installed 3:Selector Valve + Electrical relief
1 or 3 (*)
ADJ OVERLOAD To change the pressure for overload PRESS alarm in EU
10 - 27
18
ENG DISPLAY
ON/OFF
OFF
SPEED To activate the engine information for customer
speed
AUTO ACCEL ACCEL
To change auto accel control control type
START MODE
To change (S,H,B,A)
the
starting
6, 8, 10, 12, 18 14, 16, 18
MODE X: return to default MODE S, H, B, B, A, A, X S when key sw is ON
To cancel the low temp. mode to CANCEL LOW OFF = Low Temp. Mode prevent hydraulic hunching at low ON/OFF TEMP MODE ACTIVE temp.
OFF
DRAIN PRESS
OFF
HYD. To activate the pressure function
drain
hydraulic When switch is ON, this ON/OFF function starts.
To adjust Pressure and Flow for ADJ OPT HAMMER Follow setting procedure Hammer (9set)
20 35 15 Mpa (at Pressure 220 L/min) 30 - 220 220 L/min Flow rate
To adjust Pressure and Flow for Follow setting procedure Nibbler (9set)
20 35 15 Mpa (at Pressure 220 L/min) 30 - 220 220 L/min Flow rate
ADJ OPT NIBBLER
(*) Autodetect
T2-1-44
MECHATRO CONTROL SYSTEM
E215B-E245B
2.1 Setting the language To modify the language, proceed as follows: 1. Keep BUZZER CUT-OFF button (1) pressed and, at the same time, move the STARTER SWITCH onto “ON”; the screen shows display (A).
10:25
2. Keep BUZZER CUT-OFF button (1) pressed, then press SELECT button (2) three times; the screen shows display (B). 3. Press SELECT button (2); the screen shows display (C) indicating the symbol of the language previously set, for example: ENG (English). 4. Press WIPER button (3) or WINDSHIELD WASHER button (4), once or more until the symbol of the desired language is displayed, for example FRA (French); the screen shows display (D).
S
1 4 5 3
2
5. Press SELECT button (2) to memorize the language selected, the screen shows display (E). At this stage, the language is selected and after about three seconds returns automatically to display (B). To exit the program, move the STARTER SWITCH onto “OFF”.
SM0069
NO. 1
(A) List of the languages available:
MAIN CONT. P/N YN 22E 00207 F1 PROGRAM VERSION 1 VER 2.00 2 VER 0.00 SERVICE DIAG 1
1
EU (ISO icons only)
2
ITA
(B)
USA
LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY
CHN IDN THA
SELECT LANGUAGE
ESP
ENG
(C)
FRA
FEED
DEU VNM
4
MYS
3
MMR TAM
SELECT LANGUAGE
POR
(D)
ENG
FRA FEED
JPN
SELECT LANGUAGE
(E)
FRA FEED SM0070
T2-1-45
E215B-E245B
MECHATRO CONTROL SYSTEM
2.2 Setting Adjusting Mode 1 NO. 1
To enter the displays Adjusting Mode 1 proceed as follows: 1. Keep BUZZER CUT-OFF button (1) pressed and, at the same time, move the STARTER SWITCH onto “ON”; the screen shows display (A) 2. Keep BUZZER CUT-OFF button (1) pressed, then press SELECT button (2) three times; the screen shows display (B). 3. Press WINDSHIELD WASHER button (3) to get ADJUSTING MODE 1, the screen shows display (C).
(A)
MAIN CONT. P/N YN 22E 00207 F1 PROGRAM VERSION 1 VER 1.00 2 VER 0.00 SERVICE DIAG 1
x3
1
(B)
2
LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY
3
(C)
4. By pressing SELECT button (2) you enter the Adjusting Mode 1 functions; the first function is shown on the screen, display (D). To enter the other functions, actuate WIPER button (3), to move forward or WINDSHIELD WASHER button (4), to return back.
LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY
11 RISE-UP WIPER ON
(D)
FEED
3
4
2.3Adj. Overload Press (tip-over momentum device)
SM0071
To modify the value of the pressure at which the pressure sensor goes ON to operate the tip-over momentum device, proceed as follows: 1. In function Adjusting Mode 1, display (C), press SELECT button (2) to enter the functions and use WIPER button (3), to select function 63 ADJ OVERLOAD PRESS on display (E).
(C) 2
3
2. Press SELECT button (2) to choose the number relative to the setting pressure, display (F). 18 = 180 bar
63 A DJ OVERLOAD PRESS
(E)
3. Press WINDSHIELD WASHER button (4), to increase the pressure, or WIPER button (3), to decrease it. 4. Set the desired pressure value (for example: 11), display (G), press SELECT button (2) to memorise it. By pressing SCREEN CHANGE button (5) you return to display (C). To exit the program, move the STARTER SWITCH onto “OFF”.
LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY
18
FEED
63
(F)
ADJ OVERLOAD PRESS 18
FEED
3
4 63
(G)
ADJ OVERLOAD PRESS 11
FEED
63 ADJ OVERLOAD PRESS 11
FEED
5 SM0073
T2-1-46
MECHATRO CONTROL SYSTEM
E215B-E245B
2.4 Drain Hyd. Press To drain the hydraulic pressure from the system, proceed as follows: 1. In function Adjusting Mode 1, display (C), press SELECT button (2) to enter the functions and using WIPER button (3), select on the display function DRAIN HYD. PRESS, display (H).
LANGUAGE/LOGO ADJUSTING MODE 1
(C)
PRESET BY FACTORY
3
2
2. Press SELECT button (2) to show the writing OFF, display (I).
(H)
3. Press WINDSHIELD WASHER button (4) to activate function ON, display (L).
DRAIN HYD PRESS OFF
FEED
4. Press SELECT button (2) and start the engine. The screen shows display (M). At this point, with the engine in operation, actuate the pilot valves performing all the movements so that the pressure is drained from all the actuators. The function is automatically deactivated by returning the STARTER SWITCH onto “OFF”.
(I)
DRAIN HYD PRESS OFF
FEED
4 NOTE: if the monitor displays “FAIL DRAIN HYD PRES.” this means that the pressure draining operation has not been performed correctly. In this case, repeat the operation.
DRAIN HYD PRESS
(L)
ON
FEED
10:25
(M)
PR
S SM0072
T2-1-47
E215B-E245B 3.8
MECHATRO CONTROL SYSTEM
MECHATRO CONTROL EQUIPMENT
1. C-1 Mechatro controller 1) Outside view
10
2 1
6
2 1
4 2 1 8
27
22
18
16 12
2
1
16 26 34
CN101
CN105
CN102
CN106 21 7
9
CN103
28
22
CN104
CN107 CN108 CN109 2 16 21 9 21 7 21
21
10
31
12
8
16 22
24
17
7 17
28 10 22 13 19 20 15 16
8
SM0159
2) List of connectors Connector No.
Pin No.
Port name
CN101
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
GA A1 +5VA +5VA A2 GA GA A3 +5VA +5VA A4 GA GA A5 +5VA +5VA A6 GA TXD1 RXD1 GP SHG1 TXD3 RXD3 DL GP CANH1 CANL1 DO 20 DO 21 DO 22 DO 23 DO 24 DI 36
Function
Input/putput
Boom up
Input
Boom down
Input
Arm in
Input
Arm out
Input
Bucket digging
Input
Bucket dump
Input
Gauge cluster
Transmission
Reception
Down load
Transmission
Reception
Spare Spare Safety relay Spare Extra pressure release Spare Heavy lift
Output Output Output Output Output Input
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V RS232C communication RS232C communication 0V Shield GND RS232C communication RS232C communication EARTH / OPEN(5V 0V CAN communication CAN communication EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN SM0160
T2-1-48
MECHATRO CONTROL SYSTEM
Connector No. CN102
Connector No. CN103
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Port name GA A8 +5VA +5VA A9 GA GA A10 +5VA +5VA A13 GA GA A14 +5VA +5VA A27 GA GA A28 +5VA D1 37
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Port name GA A +5VA +5VA A11 GA GA A12 +5VA +5VA A15 GA GA A16 +5VA
Function
E215B-E245B
Input/putput
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V
Travel right
Input
Travel left
Input
Accelation
Input
P1 option
Input
P2 option
Input
Spare
Input
Spare
Input
Spare
Input
GND / OPEN
Input/putput
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V
Function Swing
Input
P1 pump
Input
P2 pump
Input
Boom angle
Input
Arm angle
Input
Reserved SM0161
T2-1-49
E215B-E245B
Connector No. CN104
Connector No. CN105
MECHATRO CONTROL SYSTEM
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Port name GA A17 +5VA +5VA A18 GA GA A19 +5VA +5VA A20 GA A21 GA A22 GP A23 GA GA A24 +5VA +5VA A25 GA GA A26 +5VA DI 1
Pin No. 1 2
Port name +24V +24V
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
+24V DO 7 DO 8 DO 9 DO 11 GND GND D10+ D1+ D1D2+ D2D3+ D3D4+ D4D5+ D5GND D10D6+ D6D7+ D7D8+ D8D9+ D9+24V
Function
Input/putput
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.54.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V
Boom head (Over load)
Input
Spare
Input
Extra pressure source
Input
Spare
Input
Engine coolant temperature
Input
Resistor
Fuel level
Input
Resistor
Spare
Input
Resistor
Selector detection
Input
Extra pressure source
Input
Spare
Input
Starting point of accel motor
Input
Function
Input/putput
Battery relay output side Battery relay output side
Travel 1,2 speed select valve Attachment boost selec t valve
Output Output Output Output
Battery (-) Battery (-) OPT changeable relief 1 P1 unload
Output Output
P2 unload
Output
Travel straight
Output
Arm in
Output
P1 pump
Output
Battery (-) OPT changeable relief 1 P2 pump
Output Output
Spare
Output
Spare
Output
Spare
Output
Travel 1,2 speed select valve
Swing P/B select valve
Battery direct connection
0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V GND / OPEN Signal level 20~32V 20~32V 20~32V 24V/OPEN 24V/OPEN 24V/OPEN 24V/OPEN 0V 0V +0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA -0~800mA +0~800mA 20~32V SM0162
T2-1-50
MECHATRO CONTROL SYSTEM
Connector No. CN106
Connector No. CN107
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Port name +24V SHGF F1+ F1F2+ F2OIL OILG D11+ D11D12+ D12D13+ D13D14+ D14GND D12+ D12E1+ E1SHG3 CANH2 CANL2
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Port name DI 3 DI 8 DI 9 DI 10 DI 11 DI 12 DI 13 DI 14 DI 15 DI 20 DI 28 DI 32 DI 38 DI 39 DI 40 DI 41
Function Battery relay secondary side
E215B-E245B
Input/putput
0
Oil level (spare)
Output Output Output Output 0
OPT changeable relief 2
Output
Spare
Output
Bypass valve
Output
Spare
Output
Battery (-) Spare
Output
Accel motor A phase Accel motor A phase Accel motor B phase Accel motor B phase
E/G speed sensor
Input
Proportional vlave expand unit
Input/putput Function Grid heater feedback Input Engine coolant temperature Input E/G oil pressure Input Air filter Input Spare Input Spare Input E/G coolant level Input Spare Input Spare Input Heater temperature of fuel filter Input Spare Input Hand control nibbler Input Quick coupler Input Spare Input Heater temperature Input Spare Input Reserved
Signal level 20~32V Shield GND 1.5A 1.5A 1.5A 1.5A
+0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V +0~800mA -0~800mA XX~XXVp-p 0V Shiled GND CAN communication CAN communication Signal level +24V/OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN SM0163
T2-1-51
E215B-E245B
Connector No. CN108
MECHATRO CONTROL SYSTEM
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Connector No. CN109
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
DI 2 DI 4 DI 5 DI 6 DI 7 DI 16 DI 17 DI 18 DI 19 DI 21 DI 22 DI 23 DI 24
Key switch (ON) Water separator Swing P/B release E/G start Spare Wiper rise up Wiper reverse ATT boost Spare Spare Spare Lever lock Hand control rotation
Input Input Input Input Input Input Input Input Input Input Input Input Input
Signal level +24V / OPEN +24V / OPEN GND / OPEN +24V / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN +24V / OPEN +24V / OPEN +24V / OPEN GND / OPEN
DI DI DI DI DI
Front window open or close Spare Conflux/single select Overload select Spare Reserved
Input Input Input Input Input
GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN
Charge Spare Spare Reserved Spare
Input Input Input
~12V / 12V~ +24V / OPEN +24V / OPEN
Port name
25 26 27 29 30
GP DI 33 DI 34 DI 35 H1+ H2H2+ H2Port name
DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 12 DO 13 DO 14 DO 15 DO 16 DO 17 DO 18 DO 19 GP TXD2 RXD2 RTS CTS SHG2 DO 10
Function
Input/putput
0~5V 0V 0~5V 0V
Spare
Function Wiper arc prevention Wiper normal moving Wiper reserve moving Washer motor Spare Reserved Spare Swing flasher (RH) Swing flasher (LH) Travel alarm Auto idle stop relay Engine stop Lever lock Grid heater Reserved
Spare
Spare
Input/putput
Output Output Output Output Output Output Output Output Output Output Output Output Output Output
Signal level GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN
0V Tranmission RS232C communication Reception RS232C communication RS232C communication RS232C communication Shiled GND 24V/OPEN SV SM0164
T2-1-52
MECHATRO CONTROL SYSTEM
E215B-E245B
2. Gauge cluster (symbol C-2) 1) General view
4. BUZZER 1. MULTI DISPLAY LCD
2. COOLANT TEMPERATURE
GAUGE FUEL LEVEL GAUGE
MATED SIDE AMP 040 HOUSING : 174044-2 TERMINAL : 173681-2
5. SCREEN CHANGE SWITCH ETC. 6. BUZZER STOP SWITCH
7. WORK MODE SWIHCH SM0165
2) Connector CN-600 (Harness side) No.
Item name
Wire color
No.
Item name
Wire color
1
Gauge cluster → Mechatro controller (RS232C communication)
White
5
GND source (+24V Battery direct connection)
2
Mechatro controller → Gauge cluster (RS232C communication)
Red
6
GND
Black
3
—
—
7
Source (+24V starter switch ON)
White
4
—
—
8
GND communication)
Black
(RS232C
Yellow / Black
3) Function a. It processes signals by communication between the gauge cluster and the mechatro controller, displays them in lamps, displays them in LCDs and actuates the buzzer. b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro controller through the communication port. 4) Summary of display and drive item No.
Item
Remarks
1
Monitor display
LCD dot 120×168
2
Gauge display (Coolant temp., Fuel level)
Stepping motor
3
—
4
Buzzer
5
Screen change switch
6
Buzzer stop switch
7
Work mode select switch
Piezo-electricity type
T2-1-53
E215B-E245B
MECHATRO CONTROL SYSTEM
3. Relay & fuse box (symbol E-1) 1) General view
(Overhead view of box)
LABEL
INSIDE
Note) These circles indicate the parts which are used in standard specification 14
1
1
14
1
12
1
10 1
3
CN2-1
20
CN2-2
20
13
26
13
26
1
13
17
11
22
1 9
1 17
CN3-1
CN4-1
12
CN3-2
CN5
15
9
20
6
7
12
1
2
6
1
3
CN8
2
1 CN9
2
1 CN2-3 3
2
6
1
3
2
6
2
6
1
3
1
3
3 CN12 2
16
8
24
12 1
3
CN15
CN14
CN4-2
1 CN17
CN16
CN13 6
2
6
CN1 1
2 2
4
2
CN10
LOCATION OF CONNECTORS (Seen from backside)
LOCATION OF RELAY & FUSE
LABEL OF RELAY & FUSE BOX No. CODE IN CIRCUIT
PARTS NAM E
SM0166
T2-1-54
MECHATRO CONTROL SYSTEM
E215B-E245B
2) Circuit diagram
SM0167
T2-1-55
E215B-E245B
MECHATRO CONTROL SYSTEM
SM0168
T2-1-56
MECHATRO CONTROL SYSTEM
E215B-E245B
SM0169
T2-1-57
E215B-E245B
MECHATRO CONTROL SYSTEM
4) High pressure sensor : YN52S00048P1
ECONOSEAL SERIES MARK 3POLES CAP MATING HOUSING174357-2
SPECIFICATION :
(+)>
PRESSURE RANGE : 0
50 MPa
POWER SOURCE VOLTAGE : 5.0+0.5V DC OUTPUT : 1/10Vs-9/10Vs
COMMON
(Vs=5V DC 0.5
OUTPUT (+)
4.5V DC)
INSURANCE RESISTANCE : 100M
POWER SOURCE (+) HOUSING TERMINAL PLASTIC POTTING
OR MORE
(BETWEEN CASING AND ALL IN/OUT TERMINALS AT 50V DC MEGGER)
CONDENSER COVER
ELECTRIC CONNECTING DIAGRAM
DIE CASING
FLEXIBLE BOARD CIRCUIT
DIAPHRAGM
O-RING P14 JIS B2401 CLASS1B PF 3/8 Tightening torgue 73.5N.m (54.2lbf .ft)
(Ex. Construction of internal controller)
PIPE THREAD
STRUCTURE
SM0170
5) Low pressure sensor : YX52S00013P1
Tightening torgue
Vout
29.4 34.3N.m (21.7 25.3lbf .ft) PF1/4
Vcc
GND
ELECTRIC CONNECTING DIAGRAM (Ex. Construction of internal controller)
SPECIFICATION : PRESSURE RANGE : 0
3.0 MPa
RATED VOLTAGE : 5.0+0.5V DC OUTPUT CHARACTERISTIC
INSURANCE RESISTANCE : 50M
OR MORE
(BETWEEN BODY AND EACH TERMINAL AT 50V DC MEGGER)
SM0171
T2-1-58
E215B-E245B
HYDRAULIC SYSTEM
2. HYDRAULIC CIRCUITS AND COMPONENTS
HYDRAULIC DIAGRAM READING KEY Item
T2-2-2
Component name
1
Hyd. pump assy
2
Control valve (main)
3
Swing motor unit
4
Travel motor unit
5
Boom cylinder (RH & LH)
6
Arm cylider
7
Bucket cylinder
8
Swivel joint
9
Pilot valve (ATT)
10
Pi lot v al ve ( tr av el)
11
Inline filter
12
Suction strainer
13
So len oi d v al ve a ss y
14
Return filter
15
Air breather
16
Restrictor
17
Shuttle valve
18
Sh or t- ci rc uit v al ve
19
Low pressure sensor block
HYDRAULIC SYSTEM
E215B-E245B
HYDRAULIC CIRCUIT (MONOBLOCK VERSION)
SM0077
T2-2-3
E215B-E245B
HYDRAULIC SYSTEM
3. N&B HYDRAULIC CIRCUIT (OPTION) N&B HYDRAULIC CIRCUIT READING KEY
Item
Component name
50
Selector valve
51
Stop valve
52
Pilot valve
53
Overload relief valve
The hydraulic circuit for N&B is used to add to standard circuit Selection condition and proportional valve command when any of nibbler single & conflux flow or breaker in service.
SELECTION
Conflux/single flow changeover switch
Electromagnetic command signal of selector valve (50) (W:O, W/O: -)
Conflux flow of nibbler
Conflux “ON”
Single flow of nibbler Breaker
P1 Pump
P2 Pump
Travel Straight
P1 Unload
P2 Unload
-
O
O
O
O
O
Conflux “OFF”
-
-
O
-
-
O
Conflux “OFF”
O
-
O
-
-
O
When using nibbler, according to specification of nibbler installed. Adjust overload relief valve (53) of optional port to customize specification ordinary set pressure.
T2-2-4
Command signal of solenoid proportional valve (W:O, W/O: -)
HYDRAULIC SYSTEM
E215B-E245B
N&B HYDRAULIC CIRCUIT
51
53
52
53
50
SM0078
T2-2-5
E215B-E245B
HYDRAULIC SYSTEM 4. HOLDING VALVE FOR BOOM & ARM (OPTION) HOLDING VALVE FOR BOOM The holding valve for boom prevents the boom falling in case of head side cylinder piping breaks. HOLDING VALVE FOR ARM The holding valve for arm prevents the arm falling in case of rod side cylinder piping breaks.
HYDRAULIC CIRCUIT READING KEY Item
T2-2-6
Component name
54
Holding valve for boom cylinders
55
Holding valve for arm cylinder
HYDRAULIC SYSTEM
E215B-E245B
HOLDING VALVE FOR BOOM & ARM HYDRAULIC CIRCUIT
54
54
55
SM0079
T2-2-7
E215B-E245B
HYDRAULIC SYSTEM
5. POSITIONING CIRCUIT (TRIPLE ARTICULATION VERSION) HYDRAULIC POSITIONING CIRCUIT READING KEY Item
Component name
56
P1 OPT valve
57
Holding valve for positioner cylinder
58
Positioner cylinder
59
Positioning pilot valve
OPERATION When the operation for positioning is performed, the pilot proportional secondary pressure is delivered through port A of the positioning pilot valve (59) and flows to PAo1 port of the P1 OPT valve (56) then, the spool of P1 OPT valve (56) is switched. The pressure oil by P1 pump is supplied to (R) side of positioner cylinder (58) through Ao1 port of P1 OPT valve (56). On the other hand, the return oil from (H) side of positioner cylinder returns to the tank circuit thorough Bo1 port of P1 OPT valve (56). The holding valve (57) prevents the positioning falling in case of rod side cylinder piping breaks.
T2-2-8
HYDRAULIC SYSTEM
E215B-E245B
POSITIONING CIRCUIT (TRIPLE ARTICULATION VERSION)
57
R POSITIONING CYLINDER
H
58
59
56
SM0080
T2-2-9
HYDRAULIC SYSTEM
E215B-E245B
NEUTRAL CIRCUIT: Positive control function at safety lock lever down (unloked position)
651 652 611 643
646 532
SM0081
T2-2-11
HYDRAULIC SYSTEM
E215B-E245B
TRAVEL CIRCUIT: Travel 2nd speed, RH & LH simultaneous operation.
SM0082
T2-2-13
HYDRAULIC SYSTEM
E215B-E245B
BUCKET CIRCUIT: Bucket digging (Travel priority conflux), Auto-accelation and Standby flow rate constant control
SM0083
T2-2-15
E215B-E245B
HYDRAULIC SYSTEM
10. BOOM CIRCUIT This section describes the boom raise conflux operation. 10.1 Boom up pilot circuit 10.2 Boom up 2 pumps conflux main circuit in C/V 10.1 BOOM RAISE PILOT CIRCUIT (1) Operation: 1) If boom up operation is performed, the secondary pilot proportional pressure from the right pilot valve (9) gets out of port 4 and acts upon the low pressure sensor (SE3). At the same time, the pressure acts upon the PAb and PB1 ports. 2) The secondary pressure which enters the PAb port of C/V (2) shifts the boom spool. The secondary pressure which enters the PB1 port shifts the boom conflux spool. 10.2 BOOM UP 2 PUMPS CONFLUX MAIN CIRCUIT IN C/V (1) Purpose: Boom up speed up (2) Principle: Confluxing oil from 2 pumps (3) Operation: 1) The oil delivered through A1 port of P1 pump flows into C/V (2) P1 port, and branches into bypass circuit and parallel circuit. Since P1 unloading valve is closed, the boom spool is moved and bypass circuit is closed, the oil opens load check valve LCb through parallel circuit and flows into boom spool. 2) Then the oil passes through boom spool, opens lock valve of boom lock valve CRb, and is led into (H) side of boom cylinder through C/V (2) Ab port. 3) Meanwhile, the oil delivered from the A2 port of the P2 pump enters the P2 port of C/ V (2) and due to shut off the P2 unloading valve, the oil then passes through the parallel circuit and via the restrictor on the circumference of the boom conflux spool, pushes the load check valve CCb open from the boom conflux circuit, and combines the oil delivered by the P1 pump internally. 4) The return oil from boom cylinder (R) side flows into tank circuit through boom spool from C/V (2) Bb port.
T2-2-16
HYDRAULIC SYSTEM
E215B-E245B
BOOM CIRCUIT : Boom up operation, Confluence function.
SM0084
T2-2-17
HYDRAULIC SYSTEM
E215B-E245B
BOOM CIRCUIT: Boom down operation & Prevention of natural boom falling.
SM0085
T2-2-19
E215B-E245B
HYDRAULIC SYSTEM
11. SWING CIRCUIT This section describes the following operations. 11.1 Swing left pilot circuit 11.2 Swing auto parking brake 11.3 Swing main circuit 11.4 Swing motor circuit 11.1 PILOT CIRCUIT FOR LEFT SWING (1) Operation: 1) When the left swing operation is performed, the pilot proportional secondary pressure is delivered through port (1) of left pilot V (9), and the secondary pressure acts on PBs port of C/V (2), and simultaneously flows out from Pss port of C/V and acts on low pressure sensor (SE-5). 2) The voltage output by the low pressure sensor is input in the mechatro controller, and is signal-processed. 3) Then, the secondary pressure led into PBs port of C/V (2) switches the swing spool. 11.2 SWING AUTO PARKING BRAKE (1) Purpose: Swing lock in neutral position and parking (2) Principle: Release mechanical brake only when required to operate swing and arm in. (3) Operation: 1) The swing parking system excites the swing parking SOL (SV-1) usually if the key switch is turned on and works by the action of the mechanical brake. 2) The mechanical brake is released if the swing parking solenoid is de-excited only when the secondary operating pressure in the swing and arm in actions acts upon any of the low pressure sensors (SE-5, 7). 3) The swing parking solenoid (SV-1) is excited five seconds after the pressure of the swing low pressure sensors (SE-5) is reduced to zero. In the case of arm in operation, the swing parking solenoid (SV-1) is excited the moment the pressure of the arm in low pressure sensor (SE-7) is reduced to zero. This causes the mechanical brake to operate. 11.3 SWING MAIN CIRCUIT (1) Operation: The oil delivered from the A2 port of the P2 pump enters the P2 port of C/V (2) and is branched off into the bypass line and the parallel circuit. However, since the bypass line is closed T2-2-20
as the swing spool is shifted, the oil pushes the load check valve LCs open through the parallel circuit, enters the B port of the swing motor via the Bs port of C/V (2), and rotates the swing motor counterclockwise. 11.4 SWING MOTOR CIRCUIT (1) Anti cavitation circuit at swing deceleration (2) Shockless relief valve that prevents the swing motor from being reversed.
HYDRAULIC SYSTEM
E215B-E245B
SWING CIRCUIT: Swing operation (LH)
SM0086
T2-2-21
HYDRAULIC SYSTEM
E215B-E245B
ARM CIRCUIT: Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function
SM0087
T2-2-23
E215B-E245B
HYDRAULIC SYSTEM This section describes the following operations. 12.3 Arm in, heavy load operating pilot circuit (recirculation cut) 12.4 Arm in, heavy load operating sequence confluxed main circuit
4) The return oil returns directly into tank circuit because arm 2 spool is switched to recirculation cut position. Position of arm 2 spool Neutral positio n
12.3 ARM IN, HEAVY LOAD OPERATING PILOT CIRCUIT (1) Operation: 1) 1)In arm-in operation, when the heavy loading is applied to arm and the P2 pump pressure increases to the set pressure, the voltage output by P2 pump pressure sensor (SE-23) is converted to signal (signal processing) by mechatro controller, consequently the current of arm 2 solenoid proportional valve is controlled according to the load pressure and the arm variable recirculation is cut. When the recirculation is cut, internal confluence is held similarly to that in light load operation. 2) Left pilot valve actuation due to arm-in operation is equivalent to that at light load operation.
12.4 ARM IN, HEAVY LOAD OPERATING RECIRCULATION CUT MAIN CIRCUIT (1) Purpose: Speed up for arm in operation (2) Principle: Cut the recirculation and reduce rod pressure. (3) Operation: 1) P2 pump delivery oil flows in the travel left section through P2 port of C/V (2) and branched off in by-pass circuit and parallel circuit. Consequently the arm spool is switched and pushes and opens load check valve LCa through parallel circuit, and flows in the arm spool. 2) On the other hand, P1 pump delivery oil flows in P1 port of C/V (2), and flow in travel right tandem passage through travel straight section. Then because arm 2 spool was switched, the delivery oil opens load check valve LCAT2, and confluences with P2 pump delivery oil in the valve section, and is flowed into arm cylinder head (H) side through Aa port of C/V(2). 3) The return oil from arm cylinder (R) side flows in Ba port of C/V(2) and is flowed to arm lock valve CRar, but because the arm lock valve CRar is open, the return oil goes through arm lock valve CRar and flows in arm 2 spool. T2-2-24
Recirculation cut position
From arm out P/V From arm 2 inverse proportional valve SM0197
HYDRAULIC SYSTEM
E215B-E245B
ARM CIRCUIT: Arm in (Heavy load) operation, Arm confluence & recirculation cut function
SM0088
T2-2-25
E215B-E245B
HYDRAULIC SYSTEM This section describes the following operations. 12.5 Arm out pilot circuit 12.6 Arm out 2 pumps conflux main circuit 12.7 Natural fall protection with arm lock valve 12.5 ARM OUT PILOT CIRCUIT (1) Operation: 1) When the arm out operation is performed, the secondary pilot proportional pressure gets out of port 8 of the left pilot valve (9), and acts upon the low pressure sensor (SE8). At the same time, the oil is branched off in two flows and act upon the PBa1 and PBa2 ports of C/V (2). 2) The operating proportional secondary pressure flowed in PBa1 port of C/V (2) switches the arm 1 spool. 3) Then, the operating secondary pressure flowed in PBa2 port of C/V (2) switches the arm 2 spool valve. 12.6 ARM OUT 2 PUMPS CONFLUX MAIN CIRCUIT (1) Purpose: Arm out operation speed up. (2) Principle: The oil delivered by the P1 pump is confluxed with that delivered by the P2 pump in C/V (2). (3) Operation: 1) P1 pump delivery oil opens load check valve (LCAT2) by switching arm 2 spool and confluxes with P2 pump delivery oil just short of the arm lock valve. 2) And, P2 pump delivery oil flows through arm 1 spool and confluences with P1 delivery oil, opens lock valve of arm lock valve CRar with free flow and is flowed into arm cylinder rod (R) side through Ba port of C/V(2). 3) On the other hand, the return oil from arm cylinder (H) side flows in Aa port, and returns into tank circuit through arm 1 spool and arm 2 spool. The return line which does not pass through boost check valve is used for this return circuit to reduce the pressure loss.
T2-2-26
12.7 NATURAL FALL PROTECTION WITH ARM LOCK VALVE (1) Purpose: To prevent the arm from falling naturally by the weight of the arm and bucket. (2) Principle: Complete seat of the return circuit against the arm spool of the arm cylinder (R) side circuit. (3) Operation: 1) When the secondary pressure for arm operation disappears and the arm cylinder stops, the pressure on the rod (R) side passes through the selector of the lock valve from the Ba port of C/V, acts the back pressure on the lock valve CRar and seats the lock valve. 2) Since the oil flow into the arm spool from the lock valve is shut off completely, natural fall of the arm due to oil leaks through the arm spool is prevented.
HYDRAULIC SYSTEM
E215B-E245B
ARM CIRCUIT: Arm out operation, Confluence function
SM0089
T2-2-27
E215B-E245B
HYDRAULIC SYSTEM
13. COMBINED CIRCUIT This section describes only the difference in combined operation. 13.1 Boom up / travel, pilot circuit 13.2 Boom up / travel, main circit 13.1 BOOM UP / TRAVEL, PILOT CIRCUIT (1) Operation: 1) The mechatro controller outputs command current to travel priority solenoid proportional valve (PSV-C) and to shortcircuit solenoid proportional valve (PSV-R) after signal processing. And the solenoid proportional valve outputs secondary pressure and acts on PTb port and short-circuit valve. 2) Then the pressure of PTb port switches the travel priority valve. And the secondary pressure of solenoid valve in short-circuit valve switches spool of short-circuit valve 1 step. 13.2 BOOM UP / TRAVEL, MAIN CIRCUIT (1) Purpose: To insure straight travel movement during travel operation even if the attachment is operated. (2) Principle: The travel action and the attachment action are actuated by separate pumps. (3) Operation: 1) P1 pump delivery oil flows through P1 port of C/V(2) and branches off in P1 parallel circuit and spool of short-circuit valve. P2 pump delivery oil flows through P2 port of C/V(2) and branches off in P2 tandem circuit and spool of short-circuit valve. 2) The delivery oil flowed into P1 parallel circuit of P1 pump opens check valve CT1 and LCb and flows in boom spool, which exerts on boom up operation. The delivery oil flowed into travel priority spool of P1 pump opens check valve CT2 because the travel priority spool is shifted, and flows in boom conflux spool and exerts on boom up operation with the internal oil conflux. (In travel straight operation, P1 pump delivery oil exerts on operation of attachment.) 3) The delivery oil flowed into P2 tandem circuit of P2 pump flows in left travel spool to travel leftward. The delivery oil flowed into travel priority spool of P2 pump flows in right travel spool T2-2-28
because the travel straight spool is shifted and exerts on the right travel operation. (In travel straight operation, P2 pump delivery oil exerts on travel operation.) 4) However, a portion of the flow is led to the spool of short-circuit valve notch restriction. The speed of attachments like travel, boom, etc. is adjusted by the circuit of restriction.
HYDRAULIC SYSTEM
E215B-E245B
COMBINED CIRCUIT: Boom up & Travel forward 1st speed operation, Travel priority function.
SM0090
T2-2-29
E215B-E245B
HYDRAULIC SYSTEM In this section, the independent operation is omitted and describes difference in combined operation. 13.3 Swing / Arm in light load, pilot circuit 13.4 Swing / Arm in, swing priority main circuit
Position of arm 2 spool
Position of forced recirculation Neutral position
13.3 SWING / ARM IN LIGHT LOAD, PILOT CIRCUIT (1) Operation: 1) On operating swing (left) and arm in motions simultaneously, mechatro controller outputs command current to travel priority solenoid proportional valve (PSV-C) and arm 2 solenoid inverse proportional valve according to signal processing, and this proportional valve outputs secondary pressure, which acts on PTb port and PAa2 port of C/V(2). 2) PTb port pressure switches the travel priority spool, and the PAa2 port pressure switches the arm 2 spool to the forced recirculation position. 13.4 SWING / ARM IN, SWING PRIORITY MAIN CIRCUIT (1) Purpose: Stable swing speed. (2) Principle: Raise the oil pressure flowing to arm cylinder, and give a priority of the delivery of P2 pump to swing operation. (3) Operation: 1) The swing main circuit operates with P2 pump flow. But on P2 pump circuit side, the flow goes to the swing circuit and arm circuit simultaneously because the swing circuit and arm circuit are parallel. Then since the return oil from arm cylinder rod (R) side is restricted in the arm 2 spool because the arm 2 spool is switched to forced recirculation position, the pressure of return oil is raised, causing the rise of circuit pressure on the arm cylinder head (H) side. 2) At the same time meter-in of arm 2 spool closes and arm in conflux is therefore cancelled, and delivery oil from P2 pump and P1 pump are combined in the parallel circuit on P2 pump side because the travel straight spool was switched. The conflux oil of P1 and P2 delivery oil in high pressure flows in swing side taking priority over all others. This operation is called "Swing Priority Circuit".
T2-2-30
From arm out P/V
Meter-in passage (Close) From arm 2 inverse proportional valve Normal recirculation position
Arm 2 spool
SM0198
HYDRAULIC SYSTEM
E215B-E245B
COMBINED CIRCUIT: Swing / Arm in operation, swing priority function
SM0091
T2-2-31
HYDRAULIC SYSTEM
E215B-E245B
PRESSURE DRAINING (RELEASING) CIRCUIT: at pressure release mode
651 652 611 643
646 532
SM0092
T2-2-33
E215B-E245B
T2-2-34
HYDRAULIC SYSTEM
AIR CONDITIONER SYSTEM
E215B-E245B
BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and an inside /outside air switching unit. And this unit changes hot air to cool air. AIR CYCLE
•
Heater Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from grille through duct.
•
Cooler Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air blows off from grille through duct.
•
Heater system The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows in the heater core of air-con unit and then heat exchange is performed. The intake air is heated and the heated air blows off from the grille provided on the inside of cab. The blow off air temperature is controlled by the temperature control switch on the control panel, and the operation is controlled by air mixing damper on the air-con unit.
T3-8-1
AIR CONDITIONER SYSTEM
E215B-E245B
AUTO AIR CONDITIONER SYSTEM OUTLINE
AIR CONDITIONER CONTROL PANEL
COMPRESSOR
COMPRESSOR DRIVE SOURCE
SOLAR RADIATION SENSOR
REFRIGERANT PRESSURE SWITCH
AIR MIXED DAMPER SIGNAL
AIR-CON AIR OUTLET SWITCHING SIGNAL
BLOWER REVOLUTION SIGNAL
CONTROLLER INNER AIR SENSOR
EVAPORATION SENSOR INNER AIR AND OUTER AIR SWITCHING SIGNAL
OUTER AIR
MOTOR ACTUATOR
VENT
INTAKE
INNER AIR MOTOR ACTUATOR
AIR CONDITIONER UNIT
FACE
FOOT
BLOWER MOTOR ACTUATOR CONTROLLER
SM0024
T3-8-2
AIR CONDITIONER SYSTEM
E215B-E245B
COMPONENT AND CONSTRUCTION COMPONENT
27
30
33
27-1 40
32 39
27-6 27-3
27-5
27-2 35
35-6
35-7
35-1
35-5
35-2
35-8
34
35-9
35-10
SM0025
Air conditioner group
No.
Parts
Q.ty
No.
Parts
Q.ty
No.
Parts
Q.ty
27
Air conditioner assy
1
32
Compressor
1
35-6
D hose
1
27-1
Air conditioner unit
1
33
Pulley
1
35-7
L hose
1
27-2
Hose
2
34
Condenser
1
35-8
L hose: Ø 15.5
1
27-3
Clamp
2
35
Air dryer assy
1
35-9
S tube: Ø 16
1
27-5
Filter
1
35-1
Receiver dryer
1
35-10
L tube: Ø 8.5
1
27-6
Tube assy
1
35-2
Bracket
1
39
Filter
1
30
Panel assy
1
35-5
S hose: Ø 24.5
1
40
Solar radiation sensor
1
T3-8-3
AIR CONDITIONER SYSTEM
E215B-E245B
CONSTRUCTION
(1) Air conditioner unit
49
48
6 47
46 44 42
31
31
41
50
3
45
F 1
1 43
1
G
32
1
28
1
39
37 38 B
36 27 H
9 40
A
I 2
33
SM0022
Air conditioner unit (1/2)
T3-8-4
AIR CONDITIONER SYSTEM
1
1 1
31
E215B-E245B
14
16
5
15
31
1
3
1
61 1
F C
1
D
4
7 G
1
1 1
26
20
13
59
29
11
21
22
H
23
1
24
B
1 8
60
D
17
18 A
I C
10 31 19
12 1 3 31
25 52
SM0021
Air conditioner unit (2/2)
T3-8-5
AIR CONDITIONER SYSTEM
E215B-E245B
No.
Parts
Q.ty
No.
Parts
Q.ty
No.
Parts
Q.ty
1
Screw M5×16
23
19
Relay
2
40
KK-box lower packing
1
2
Main harness
1
20
Evaporator
1
41
Vent lever
1
3
MA air mix
3
21
Expansion valve
1
42
Face lever
1
4
Blower controller
1
22
O-ring
1
43
Foot joint lever
1
5
Upper casing
1
23
O-ring
1
44
MA mode lever
1
6
Air mix door
1
24
Screw M5×40
2
45
Foot lever
1
7
Air mix lever
1
25
Thermistor
1
46
Face lever cam
1
8
Lower casing
1
26
Thermistor holder
1
47
Vent lever cam
1
9
Air mix door sub
1
27
Heater core
1
48
Face rod
1
10
Air mix lever sub
1
28
Pipe holder
1
49
Vent rod
1
11
Blower
1
29
Thermistor
1
50
Foot rod
1
12
Lever MA air mix
1
31
Screw M4×30
9
52
Inner air filter
1
13
Intake door
1
32
Upper casing
1
55
Screw M6×25
10
14
MA intake lever
1
33
Lower casing
1
56
Screw M8×25
10
15
Intake lever
1
36
Foot door
1
59
Evaporator packing
1
16
Intake rod
1
37
Vent door
1
60
Casing packing A
1
17
Air mix rod
1
38
Face door
1
61
Casing packing B
1
18
Air mix rod sub
1
39
KK box upper packing
1
Receiver dryer 1 - Pressure switch 2 - Sight glass 3 - Desiccant 4 - Suction pipe 5 - Filter 6 - Receiver tank A - Refrigerant INLET B - Refrigerant OUTLET
A
2
B
2 -M6 1
3 4 5
6
SM0037
T3-8-6
AIR CONDITIONER SYSTEM
E215B-E245B
FUNCTION Mechanism of cooling circuit MECHANISM OF COOLING
In the cooling process, the refrigerant that flows through the cooling circuit changes its phases from liquid to gas and vice versa during which process heat is transferred from the low temperature part (compartment) to the high temperature part (outside of the vehicle).
HFC-134a (R134a)
Chemical formula
CH2FCF3
Molecular weight
102.03
Boiling point
–26.19 °C
Critical temperature
101.14 °C
Critical pressure
4.065 MPa
Kind of Refrigerant
Critical density
511 kg/m3
Many kinds of refrigerants that change in that way are available, but the following requirements are needed for use in such applications: • Latent heat of vaporization (heat of vaporization) is large. • It is easy to liquefy (condense). (It does not require very high pressure for condensation.) • It is easy to gasify (evaporate). (It evaporates sufficiently at not too low pressure, i.e. cools down an object.) • It has small specific heat. (Since the refrigerant itself is cooled by the expansion valve, the loss resulting from it must be held down to a minimum.) • It has a high critical temperature and a low solidification point. • It is stable chemically and does not corrode and permeate into the circuit parts. • It is free from toxicity, objectionable odor, flammability 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, sufficient refrigeration will not be performed or the equipment 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 R134a refrigerant that is used in this machine.
Density of saturated liquid (25 °C)
CHARACTERISTICS OF REFRIGERANT
In general, the fluid (general term of gas and liquid) has the following qualities: 1.
As a gas under certain pressure is cooled down, it begins to condensate at a certain temperature to take a liquid state. The temperature at which condensation begins is unique to each substance (fluid) at a given pressure. The temperature determined by a given pressure is called saturation temperature.
T3-8-7
Specific volume vapor (25 °C)
of
saturated
Latent heat of vaporization (0 °C) Flammability
1206 kg/m3 0.0310 m3/kg 197.5 kJ/kg Non flammable
Ozone destruction coefficient
0
P (MPa)
R134a
4
3
LIQUID
2
GAS 1
0
15 18
35
50
T (°C) SM0038
E215B-E245B
2.
AIR CONDITIONER SYSTEM
Inversely to 1. above, the pressure at which a gas condenses for a temperature is determined. This pressure is called saturation pressure. Figure beside illustrates the relationships between the saturation temperature and the saturation pressure in the case of refrigerant R134a used in the air-conditioner. At the temperature and the pressure on the lower righthand side of the curve in figure, the refrigerant take a gaseous state, while at the temperature and the pressure on the upper lefthand side of the curve, the refrigerant takes a liquid state. Let us think of a case where an air-conditioner is operated in the midst of summer. As the refrigerant evaporates, it absorbs evaporation heat from the air of the compartment. In order to cool the inside of the compartment down to 25 °C, the refrigerant must transform (evaporate) from a liquid to a gaseous state at a lower temperature. It can be seen from the figure that R134a under a pressure above the atmospheric pressure is capable of cooling the inside of the compartment sufficiently. (If a refrigerant that requires a pressure below the atmospheric pressure to cool it to a required temperature is used, air is mixed into the circuits, thereby deteriorating the performance of the cooling unit.) In the process in which gaseous refrigerant is brought back to a liquid state, the refrigerant is cooled and condensed by the outer air exceeding 35 °C. Accordingly the refrigerant is capable of condensing at a pressure exceeding 1 Mpa, as seen from the figure.
1 2
3
9
6 4
5
7
8
SM0039
1 - Inside of the compartment (cab) 2 - Evaporator 3 - Blower 4 - Compressor 5 - Cooling fan 6 - Inside of engine room 7 - Condenser 8 - Receiver dryer 9 - Expansion valve
Cooling circuit
The figure illustrates the cooling circuit of the car airconditioner. In this circuit diagram, the portion that cools the air of the compartment is the evaporator. The object air is cooled off by utilizing the fact that the refrigerant takes heat off the surrounding area as evaporation heat as it evaporates in the cooling circuit. Since the part at which vaporization of the refrigerant takes place is the evaporator, cooled air is constantly delivered to the circumference of the evaporator by the blower fan. In the meantime, liquid refrigerant (slightly wet vaporized refrigerant) is fed into the evaporator, when "cooling" effect is attained. For instance, in order to cool the air to 15 °C, the refrigerant can not absorb evaporation heat from the air unless it evaporates at a temperature lower that 15 °C. For that purpose, it can be seen from the figure that the pressure of the refrigerant in the evaporator must be less than 0.51 MPa.
Furthermore, the cooling effect deteriorates unless the feed rate of the refrigerant is controlled so that all of the refrigerant supplied to the evaporator vaporizes and turns into dry vapor.
T3-8-8
AIR CONDITIONER SYSTEM
E215B-E245B
Consequently, the cooling circuit is so constructed that the evaporator can cool down an object (air in this case) sufficiently (i.e. so as to decrease the pressure in the evaporator) and that an adequate amount of refrigerant can be fed to the evaporator. The feed rate of the refrigerant is controlled by the expansion valve, but the pressure in the evaporator is held low by the throttling action of the expansion valve and the suction action of the compressor. The compressor acts as a pump that allows the refrigerant to circulate. The compressive action of the compressor and the heat exchange (heat radiation) action of the condenser transform the refrigerant in a dry vapor state back to a liquid state. Component parts EVAPORATOR
The evaporator is an important heat exchanger that absorbs the heat of the compartment air (object) by the utilization of the latent vaporization heat of the low-temperature, low-pressure liquid-state refrigerant. Therefore, it is necessary that satisfactory heat transfer between the object and the refrigerant take place in the evaporator. To that end, the evaporator is equipped with fins on the air side in order to increase the heat transfer area of the air side and thereby perform excellent thermal transfer between the refrigerant and the air. The humidity in the air condenses as the air cools down and adheres to the outside of the evaporator as water drops. The cooling effect deteriorates if the water drops freeze. Therefore, how to discharge water is an important point. The amount of refrigerant supplied to the evaporator is controlled by the expansion valve which is described in the following. In order to attain proper control, it is necessary to reduce the pressure drop of the refrigerant of the evaporator. Accordingly, reducing the pressure drop is one element that makes the evaporator attain its full performances. EXPANSION VALVE
1
2
3
4 SM0026
1 - Evaporator 2 - O-ring 3 - Expansion valve 4 - Socket bolt M5 x 40
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.
T3-8-9
E215B-E245B
AIR CONDITIONER SYSTEM
The expansion valve feeds the flowing highpressure high-temperature liquid refrigerant to the evaporator as low-pressure low-temperature liquid refrigerant (damp vapor of low dryness). The expansion valve controls the feed rate of the refrigerant at the same time. The figure beside shows how the block type expansion valve is constructed. The temperature sensing part is provided in the shaft of the expansion valve to directly detect the refrigerant temperature at the outlet of the evaporator. The diaphragm contains R134a in saturated state. The pressure in the diaphragm changes according to the temperature detected by the sensor. The change in the pressure causes the force acting upon the diaphragm to vary accordingly. The high-pressure high-temperature liquid refrigerant that is fed from the receiver side reduces the pressure abruptly as it passes through the valve (throttling action). On that occasion, part of the refrigerant evaporates by the very heat of the refrigerant and cooled off. The result is that lowpressure low-temperature damp refrigerant vapor is fed to the evaporator. The opening of the valve is determined by the equilibrium between the pressure (low) of the evaporator side, the action of the adjust spring and the pressing force of the diaphragm (the temperature of the refrigerant at the outlet of the evaporator to be sensed by the thermowell). The feed rate is controlled automatically so that under the pressure in the evaporator, the refrigerant is properly overheated (3 ~ 8 degrees) and goes out of the evaporator. This action is carried out by sensing the refrigerant temperature at the outlet of the evaporator as against the inlet pressure of the evaporator and consequently controlling the feed rate of the refrigerant. This means that if the refrigerant pressure drop in the evaporator is excessive, it is difficult to control the overheating or the feed rate of the refrigerant. For this reason, the smaller the pressure drop of the evaporator, the better. The expansion valve senses the pressure and the temperature at the outlet of the evaporator and controls the overheating of the refrigerant and the refrigerant supply to the evaporator more securely. The air-conditioner of this machine adopts a block type expansion valve.
1
2 3 4
5 6 7 SM0040
1 - Diaphragm 2 - Evaporator side 3 - Refrigerant outlet 4 - Shaft 5 - Refrigerant inlet 6 - Ball valve 7 - Spring
T3-8-10
SM0041
AIR CONDITIONER SYSTEM
E215B-E245B
COMPRESSOR
The compressor performs the following three functions in the cooling circuit: 1. Suction action 2. Pumping action 3. Compressive action 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 refrigerant 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 hereunder, transforms vaporized refrigerant back to a liquid state again. The saturation temperature gets higher as the pressure increases. For instance, it becomes possible 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 pressure 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 refrigerant discharged by the compressor turns into high-temperature high-pressure vapor and is delivered to the condenser.
1
2
3
SM0042
1 - D Hose 2 - S Hose 3 - Compressor
CONDENSER
This is a heat exchanger that cools the vaporized refrigerant at high temperature and high pressure by the use of outer air and condenses the refrigerant. The direction in which heat moves is from the refrigerant 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 purpose, it is necessary to secure ventilation required for the cooling of the refrigerant. SM0023
T3-8-11
E215B-E245B
AIR CONDITIONER SYSTEM
RECEIVER DRYER
1.
2.
3.
Receiver Tank On the air-conditioner, the revolution of the compressor varies greatly which causes the proper flow of refrigerant in the cooling circuit to vary. It is the receiver tank that receives the variations. When the cooling circuit does not need much refrigerant, the receiver tank stores extra refrigerant 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 penetration into rubber hoses.
1
2 3
4
Dryer If water is mixed in the cooling circuit, it deteriorates the compressor valves and oil, corrodes the metallic parts of the circuit or clogs the circuit as the water 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.
6
Sight Glass This is a inspection window with which the refrigerant level in the circuit is determined, the only means of confirming the inside of the circuit visually.
8
4.
Filter
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 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 compressor when the pressure of the circuit falls below 0.196 MPa.
5
7
SM0043
1 - Refrigerant inlet 2 - Sight glass 3 - Refrigerant outlet 4 - Pressure switch 5 - Desiccant 6 - Suction pipe 7 - Filter 8 - Receiver tank
T3-8-12
AIR CONDITIONER SYSTEM
E215B-E245B
DISASSEMBLY AND ASSEMBLY PRECAUTIONS TO BE EXERCISED IN OPERATION
1.
Special Refrigerator Oil This air-conditioner uses special refrigerator oil SP20 for use with new refrigerant R134a. Oils other than SP20 may not be used. Since SP20 tends to absorb moisture and may corrode paint and resin, the following points must be noted: 1) Do not keep open all pipe connections on a new compressor and the component parts of the installed refrigeration circuit (Remove valves and caps at the pipe openings of the compressor, just before connecting pipes. If you have removed a pipe joint for repair, put a cap to both ports immediately.) 2) Use care so SP20 does not adhere to the painted surface and resin parts. In case SP20 has adhered to such surfaces, wipe it off immediately.
2.
3.
The receiver dryer is filled with desiccant to absorb moisture in the circuit. Therefore, remove the valve at the pipe port immediately before connecting pipes. Tightening Torque 1) Pipe Joints When connecting pipe joints, coat the O-ring with special oil (SP20) and fasten to the tightening torque indicated in the table, using a double spanner. 2) Screws and Bolts Fasten to the tightening torque indicated in the table
4.
5.
6.
Amount of Oil for Compressor The compressor SD7H (HD type) is filled with 135cc (8.2cu•in) of oil. If the oil volume is small, seizure at high revolution and shortening of service life will occur. If the oil volume is large, the cooling ability will be deteriorated. Once the air-conditioner is operated, part of the oil is dispersed in the refrigeration circuit. Therefore, when replacing the parts in right Table, adjust the oil level to that of table. Before performing operation, stop the engine and turn off all power supplies to the equipment related to the air-conditioner. After the operation is over, confirm that all faults have been repaired completely, by operating the air-conditioner.
Unit: N·m (lbf ·ft) TIGHTENING TORQUE
PIPE FASTENING PART D hose and compressor (M8 bolt)
19.6~24.5 (14~18)
D hose and condenser
19.6~24.5 (14~18)
L hose and condenser
11.8~14.7 (8.7~11)
L hose and receiver dyer (M6 bolt)
7.8~11.8 (5.8~8.7)
L hose and air-conditioner unit
11.8~14.7 (8.7~11)
S hose and air-conditioner unit
29.4~34.3 (22~25)
Expansion valve
1.96~2.45 (1.4~1.8)
Unit: N·m (lbf ·ft) TIGHTENING TORQUE
SCREW SIZE N4, T4 machine screw, M4
0.78~1.18 (0.58~0.87
N5, T5 machine screw, M5
1.96~2.45 (1.4~1.8)
M6 (mounting part of L hose joint)
7.85~11.8 (5.8~8.7)
M6 (except mounting part of L hose joint)
9.8~11.8 (7.2~8.7)
M8 (mounting part of S,D hose joints)
19.6~24.5 (14~18)
M8 (mounting part of A/C unit)
9.8~11.8 (7.2~8.7)
M8 (other than those mentioned above)
11.8~15.7 (8.7~12)
M10
39.2~53.9 (29~40)
REPLACED PARTS
AMOUNT TO BE FILLED IN
EVAPORATOR
40 cc (2.4cu ·in)
CONDENSER
40 cc (2.4cu ·in)
COMPRESSOR
Drain out the volume of oil left in the compressor to be replaced, from the new compressor.
RECEIVER DRYER
20 cc (1.2cu ·in)
HOSES
20 cc (1.2cu ·in)
T3-8-13
E215B-E245B
AIR CONDITIONER SYSTEM
DISASSEMBLY AND ASSEMBLY OF UNIT
1.
Removing inner air filter Slide the inner air filter ( 1) leftward and remove it from the unit (2).
2
7
1 SM0027
2.
3.
Removing selector box Remove 6 plus screws ( 3), remove connector (4) connected to the mode actuator ( 5) on mode selector box ( 6), and separate the mode selector box from the unit ( 2).
3
5
Removing main harness Pull out 3 harness clamps ( 7) from the unit ( 2), and disconnect all connected connectors and remove harness (8) on the body from the unit (2).
8
4 6
2
SM0028
4.
Removing upper unit case 1) Remove air MIX rod (9) and air MIX rod sub (10) from air MIX lever (11). 2) Remove 12 plus screws (12) which are used to install the upper and lower unit casings (2a). Pull out the upper unit casing ( 2b) upward giving attention to the thermistor harness so as not to be caught by the casing.
11
12
2b 10 9
2a
T3-8-14
SM0029
AIR CONDITIONER SYSTEM
E215B-E245B
5. Replacing blower controller 1) Remove 2 plus screws (14) and remove the blower controller ( 15) from the upper unit casing (2b). 2) Install new blower controller by the reverse procedure of removal.
2b
* Do not disassemble the blower controller.
14
15 SM0030
6.
Removing heater core 1) After draining the coolant, remove heater hos e from the heater core ( 16). 2) Remove 1 plus screw (17), and remove pipe clam (18) which is used to secure the heater core and then remove the heater core ( 16) from the lower unit casing ( 2a). 3) Install it by the reverse procedure of removal.
7.
16
17 18 20
19
Replacing blower motor 1) Disconnect connector which is connected to the blower motor and remove the blower motor (19) from the lower unit casing ( 2a). * Do not remove the fan from the blower motor.
2a
SM0031
2) Install it by the reverse procedure of removal.
8.
Replacing evaporator and expansion valve 1) Take the evaporator (20) with expansion valve off from the lower casing. 2) Remove evaporator sensor (21) with sensor holder (22) from the removed evaporator (20). 3) Insert the sensor holder into the new evaporator at the position shown in Fig. SM0032 and install the evaporator sensor (21) again. A - 11th rows of fin
20
22 105mm (4.1 inch)
21
A
SM0032
T3-8-15
E215B-E245B
AIR CONDITIONER SYSTEM
4) Remove 2 socket bolts M5×40 ( 23) with Allen wrench (4 mm) and remove the expansion valve from the evaporator ( 20). 5) Fit O-ring (24) (NF O-ring 5/8 and 1/2 one each) to new evaporator.
20 A
* When assembling again, fit O-ring paying attention so as not to be caught with others. (Socket bolt M5×40 (2 pcs.) Tightening torque: 6.9N•m (5.1lbf•ft)
24
* Do not apply undue force to pipe of evaporator outlet. This undue stress causes the leak of refrigerant from "A" part of evaporator. Moreover, when tube assembly (27-6) (see Pag. T3-8-3 Fig. SM0025) connected with expansion valve (25) is disconnected from expansion valve, similar careful work is necessary. 9.
25
23
Replacing motor actuator
SM0033
1) Replacing mode actuator a) Remove connector ( 26) connected to the motor actuator ( 27). b) Remove FACE rod (28) and VENT rod (29) which is used to connect MA mode lever (30) and mode cam from the holder. c) Remove 3 plus screws ( 31) and remove the motor actuator ( 27) with lever MA mode from the unit. d) Remove the lever MA mode from the removed motor actuator, and install it on new motor actuator by the reverse procedure of removal. 2) Replacing air mixing actuator a) Remove connector ( 32) connected to the motor actuator. b) Remove rod air MIX (33) which is used to connect the motor actuator ( 27) and the lever MA air MIX. c) Remove 3 plus screws ( 34) and remove the motor actuator (35) with MA lever air MIX (36) from the unit. d) Remove the MA lever air MIX from the removed motor actuator, and install it on new motor actuator by the reverse procedure of removal.
29 28 30 31 27
SM0034
33 36
32
34
T3-8-16
26
35
SM0035
AIR CONDITIONER SYSTEM
3) Replacing inner and outer air switching actuator a) Disconnect connector (37) connected to the motor actuator ( 38). b) Remove intake rod ( 39) from MA intake lever (40). c) Remove 3 plus screws and remove the motor actuator (38) with MA intake lever (40) from the unit. d) Remove the MA intake lever (40) from the removed motor actuator, and install it on new motor actuator by the reverse procedure of removal.
E215B-E245B
40
39
41
37
38
T3-8-17
SM0036
E215B-E245B
AIR CONDITIONER SYSTEM
CHARGING REFRIGERANT PRECAUTIONS TO BE EXERCISED IN OPERATION
1.
Always assign a person in charge of handling refrigerant. Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person familiar with how work is done for handling refrigerant. WARNING • •
2.
Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.) The refrigerant in liquid state is at very low temperature [approx. -26°C (-15°F)]. Therefore, handle it with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
Storage and Transportation 1) Keep the service can (hereinafter called can) less than 40°C (104°F). Since high pressure gas of R134a is filled in the can in a saturated liguefied state, the pressure in the can increases sharply as temperature rises. The can may blast as the result. It is for this reason why the can temperature must be kept below 40 °C (104°F). 2) For storage, choose a cold dark place not exposed to direct sunlight. 3) If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes the inside pressure to rise and may cause the can to blow out. Do not bring the can close to a fire. 4) The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the compartment. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous temperature level. Do not bring the can into the compartment. Also, the inside of the trunk room may rise to a dangerous temperature level even in the summer time. Use sufficient care, therefore, taking the above into account. 5) Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate. - Do not drop or knock on the can. - When transporting, loading or unloading cans and packages containing cans, do not throw or drop them. 6) Store cans beyond the reach of children.
3.
Charging 1) When warming the can in which refrigerant is charged, do not fail to open the service can valve and the low pressure valve of the gauge manifold and warm the can in warm water of 40 °C (104°F or below (to an extent that you do not feel hot when you put your hand in the water.) If the can is put in hot water or heated by a direct fire, the pressure of the can may rise sharply, thereby blowing off the can. 2) When charging refrigerant while running the engine, do not open the high pressure valve (HI) of the gauge manifold in any case.
4.
Others Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to enter the air-conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the components of the air-conditioner correctly and speedily. Pay full attention to the entry of water and dust.
CAUTION
• •
Be careful about overcharge of gas Fasten pipes to a specified torque
T3-8-18
AIR CONDITIONER SYSTEM
E215B-E245B
OPERATING PROCEDURE
The change of refrigerant in the air conditioner requires a "vacuum generation procedure" and a "gas charging procedure". - The "vacuum generation procedure" consists in removing moisture from the air conditioner circuit. In the event even a small quantity of moisture remains in the system, it would freeze in the small orifices of the expansion valve when in operation. This causes a clogging of the circuit or the formation of rust, with a series of operational troubles. prior to filling the circuit with refrigerant, apply the vacuum and cause the boiling and vaporisation of the moisture. In this manner, moisture is eliminated from the system.
- The "gas charging procedure" consists in the filing the circuit with refrigerant, after applying a vacuum. the filling of the gas is not only depending upon the cooling performance of the air conditioner, but it influences also the useful working life of the circuit components. An excessive overloading increases considerably the pressure of the system and damages the cooling performance. On the contrary, a too low charging, results in an insufficient circulation of lubricant oil in the compressor, causing the wear of the moving parts of the compressor. WARNING The gas filling operation involves the handling of highly compressed gases; it is dangerous to handle the gas without complying strictly with the relevant procedures. The procedures and the protections described in this manual for the filling of refrigerant gas must be strictly adhered to.
Vacuum making operatio
More than 30 min. Begin vacuum making Lower than -750m mHg
Refrigerant filling operation
Leave it as it is, for five minutes.
Stop vacuum making
Check air-tightness
Fill in refrigerant
Check for gas leak
Fill in refrigerant
Gauge indicates abnormality Charge refrigerant gas to a gauge pressure of 0.1 MPa
Check and correct joints
SM0194
T3-8-19
AIR CONDITIONER SYSTEM
E215B-E245B
PROCEDURE FOR THE GENERATION OF VACUUM
1.
Close high pressure valve (3) and low pressure valve (1) on gauge manifold (2).
2.
Connect the red charging pipe (5) and the blue one (6) to compressor service valves ( 8) "D" and "S" as described in the figure.
2
WARNING Never exchange by mistake the high pressure pipe 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 with the service valve of the compressor. If the charging pipe is connected in the opposite direction, mini-valve ( 9 ) of the compressor fails to open.
1
3
6
5 4
D
S 8
3.
7
Connect the central valve of the gauge manifold with charging pipe (4) of the vacuum pump ( 7).
SM0016
IMPORTANT: some types of manifold are not equipped with an open/close valve in the central part.
4.
Open high pressure valve (3) and low pressure valve (1) of gauge manifold ( 2).
5.
Start the vacuum pump and let it operate 30 minutes to generate the vacuum.
6.
At the end of the vacuum phase for the prescribed time (vacuum value: lower than 750 mm Hg) close the high pressure valve ( 3) and the low pressure valve ( 1) of the gauge manifold (2).
7.
Cut-off the vacuum pump.
8.
With the high pressure valve (3) and the low pressure valve (1) closed, check, after five minutes, that the pressure gauge dial does not return to zero.
NOTE: in the event the pressure gauge moves toward zero, this indicates the presence of a leakage. Tighten again the connecting joints and apply the vacuum again, verifying that there are no further leakages.
T3-8-20
D
S
8
9 SM0017
AIR CONDITIONER SYSTEM
E215B-E245B
PROCEDURE FOR THE CHARGING OF THE GAS
1.
2.
After applying the vacuum repeatedly, exchange charging pipe ( 4) of the gauge manifold (2), from the vacuum pump to the service can ( 9).
2 11
Open the valve of service can ( 10). Close the high and low pressure valves of the gauge manifold. Press central bleeding valve ( 11) of the side service opening on the low pressure side of the gauge manifold using a screwdriver in order to let out the air in the charging pipe by the pressure of the refrigerant. Proceed with this operation until a whistle is heard coming from the bleeder.
4
10 9 SM0018
3.
Open high pressure valve (3) of the gauge manifold and charge the refrigerant to a pressure of 0.1 MPa. Once the charge is completed, close high pressure valve ( 3) of the gauge manifold and service valve (10).
3
1
D
WARNING Never start operating the compressor during this work. The starting of the compressor causes the blowing of the service can.
4.
Check that there are no leakages of gas in the cycle, using a gas leakage tester. Retighten and eliminate all points of leakage.
IMPORTANT: to check for gas leakages, always use a tester for R134a. Do not use one for flon gas service as it provides poor sensitivity.
5.
Make sure that high pressure valve (3) and low pressure valve ( 1) of the manifold and service valve can (10) are closed.
6.
Start the engine running it at 1500 ± 100 rpm and open fully the door and windows of the cab.
7.
Activate the air conditioner, setting it at maximum ventilation speed and at lowest temperature.
8.
During the charging of the gas, set the discharge pressure of the compressor to 1.4 ~ 1.6 MPa.
T3-8-21
10 S
SM0019
AIR CONDITIONER SYSTEM
E215B-E245B
9.
Open low pressure valve ( 1) of the gauge manifold and service valve can ( 10) and fill with refrigerant until all air bubbles in sight window (12) of the dryer disappear. Total quantity of gas to be charged: 900 ± 50 g.
01
10. Once the refrigerant change operation is terminated, close low pressure valve ( 1) of the gauge manifold and the service valve can ( 10).
CAUTION Do not open the high pressure valve of the manifold under any circumstance nor place the service can upside down. R0115
11. The level of refrigerant is correct only once the air conditioner is activated and through the inspection sight window, just a few air bubbles are seen and, afterward, a white colour slightly milky is seen.
IMPORTANT: when the air conditioner operates with an insufficient quantity of refrigerant, this has a negative effect on the compressor; on the contrary, when the refrigerant is charged with an excessive quantity, the cooling performance is lost. Also, the pressure of the system increases abnormally.
12. Disassemble the manifold disconnecting the charging pipes from the compressor, as indicated here below. a. Press the quick release coupling of the charging pipe on the low pressure side against the service valve of the compressor so that the refrigerant doers not escape leaking when loosening the connection. As soon as the nut has been removed, disconnect the charging pipe from the service valve. b. Wait for the pressure in the high pressure site to decrease, indicated on the pressure gauge, to a value of 1.0 MPa. c. Disconnect the red charging pipe from the high pressure side, in the same manner as described for the low pressure.
A: Appropriate quantity of refrigerant B: The system is overloaded C: Insufficient quantity of refrigerant
T3-8-22
AIR CONDITIONER SYSTEM
E215B-E245B
ELECTRIC CIRCUIT WIRING DIAGRAM AND CONNECTORS
Wiring Diagram
1
(A)(B)
2 (C) 12
3
(N)
(R)
(D)
155(BR)
150(BP) FUSE 20A
15
4
85E(WB)
(E)
18(RG) 25(WG)
FUSE 5A
13
26(RL) FUSE 15A
5
E24(B)
FUSE 5A
(Q)
(M) FUSE BOX
(F)
(L)
6
(P)
11 (K) 14
(G)
10
7 9 (J)
(H)
8 SM0044
(I) 1 - CCU(Operation Panel + Controller) 2 - Evaporator Sensor 3 - Air Inlet Sensor 4 - Solar radiation Sensor 5 - Motor Actuator (for air mix) 6 - Motor Actuator (for Mode) 7 - Motor Actuator (Rec/Fresh) 8 - Compressor Relay
9 - Blower AMP 10 - Blower Motor 11 - Blower Off Relay 12 - Pressure Switch 13 - Main Key Switch 14 - Compressor 15 - Light Switch
T3-8-23
AIR CONDITIONER SYSTEM
E215B-E245B
Connectors
(B)
(A)
JAE HOUSING : IL-AG5-22D-S3C1 TERMINAL : IL-AG5-C1-5000
(C)
MAKER : YAZAKI CORP. HOUSING No. : 7123-2228 TERMINAL : 17111
(F)
JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000
(G)
(I)
MAKER : YAZAKI CORP. HOUSING No. : 7123-2249 TERMINAL : 17111
(J)
(L)
MAKER : YAZAKI CORP. HOUSING No. : 7123-2249 TERMINAL : 17111
(D)
MAKER : YAZAKI CORP. HOUSING No. : 7123-2228 TERMINAL : 17111
JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000
MAKER : YAZAKI CORP. HOUSING No. : 7123-2237 TERMINAL : 17111
(M) MAKER : YAZAKI CORP.
HOUSING No. : 7122-6060 REAR HOLDER : 7157-6260-30 TERMINAL : 7114-2871
JAE HOUSING : IL-AG5-14D-S3C1 TERMINAL : IL-AG5-C1-5000
(E)
NIPPON AMP KK 174056-2 TERMINAL : 175062-1
(H)
JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000
(K)
MAKER : YAZAKI CORP. HOUSING No. : 7123-6020 TERMINAL : 7116-2871
(N) MAKER : YAZAKI CORP.
HOUSING No. : 7123-6060-40 TERMINAL : 7116-2871 26
25 85E
150 E24 18
(P)
(Q)
MAKER : YAZAKI CORP. 7120-8019 CP3.96MA
NIPPON AMP KK 170889-1 170003-5
(R)
MAKER : SUMITOMO HOUSING No. : 6189-0094 HARNESS SEAL : 7160-8234 TERMINAL : 1500-0110
150 155
SM0045
JAE : JAPAN AVIATION ELECTRONICS INDUSTRY, LTD.
P
W
B
R
Y
G
L
PINK WHITE BLACK RED YELLOW GREEN BLUE
Br
Lg LIGHT
O
BROWN GREEN ORANGE
T3-8-24
AIR CONDITIONER SYSTEM
E215B-E245B
STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
1.
Control panel and control unit The control unit is integrated into control panel, and processes the signal input by each sensor, etc. and the signal input by each switch through control panel with the function of the built-in micro computer, and comprehensively controls each actuator (Inner and outer air flow select, air mix), fan motor and compressor on the output side. And the self-diagnosis performance is provided to facilitate the trouble shooting.
2.
Blower controller (TKS-B215A1) The power transistor shifts the fan motor into variable speed with base current from the control unit. TERMINAL NO. 1
2
+ -
CONTINUITY
B
3 -
CONTINUED (4.7 k
±5%)
+
NOT CONTINUED
-
CONTINUED (DIODE PARALLEL AND FORWARD DIRECTION FLOW)
TESTER +
SM0047
Lg
L
In normal operation
1) Disconnect the connector of blower amplifier. 2) Check continuity between terminals on the blower amplifier side. * The installing position is provided on the left side of air-con unit. SM0048
T3-8-25
E215B-E245B
3.
AIR CONDITIONER SYSTEM
Relay Four-electrode relay is used for the blower OFF relay and compressor relay. 1) Blower OFF relay The blower OFF relay turns on after receiving the signal from the control amplifier. When the blower OFF relay turns on, the source voltage is supplied to the blower motor and the blower motor starts running.
A A
2) Compressor relay The relay ON—OFF is tripped by the control amplifier and electronic thermostat control. SM0049
3) Relay inspecting items 1. Relay (24-4PE) 2. Coil resistance: 320 3. Specified voltage: DC20V~30V 4. Be careful about the coil side of relay because this relay has polarity. 5. Inspection: Inspect the continuity between 3 and 4 according to the conditions mentioned below. 20~30V applied between terminals 1-2: Continued 20~30V not applied between terminals 12: Not continued 4.
Air mix actuator Air mix actuator is installed at the center of aircon unit, and opens and closes air mix damper through the link. The air mix actuator contains potentiometer which is switched by being coupled to the shaft of actuator. When the target air mix door position is determined through the temperature control switch, the control unit reads the level of potentiometer of the actuator, and determines the rotating direction of motor in either normal rotation or reverse rotation. Then as the motor rotates, the contact point is moved, and when the contact point is detached or the output signal of control unit turns OFF, the motor stops rotating.
T3-8-26
CONTROL AMPLIFIER
MOTOR ACTUATOR
LIMITER COOL POTENTIO 5V POTENTIO POTENTIO GND
HOT
SM0050
AIR CONDITIONER SYSTEM
5.
6.
The actuator for inner and outer The actuator for inner and outer air flow select is installed on the blower intake unit, and opens and closes inner and outer air damper through the link. The actuator for inner and outer air flow select contains position detection switch which is switched with the movement of shaft of the actuator. When the inner and outer damper position is set by the inner and outer switch on the control panel, the control unit reads the signal of the position detection switch in the actuator and determines the rotation direction of motor in either normal rotation or reverse rotation. Then as the motor rotates, the position detection switch also rotates and makes it stop at the set position of the inner and outer air damper. Evaporator sensor This sensor is used to control the evaporator outlet temperature with the compressor ONOFF to protect the evaporator from freezing, and this evaporator sensor functions as a sensor of this control. •
7.
AMPLIFIER
E215B-E245B
MOTOR ACTUATOR
INNER AIR SIDE
OUTER AIR SIDE
LIMITER
SM0051
Evaporator sensor inspecting items (Specification) Terminal resistance: at 0 degree C: 7.2 k at 25 degree C: 2.2k
Dual pressure switch This dual pressure switch is attached on L-hose and is used to turn OFF the compressor, and employs dual type (for high and low pressure control) to protect the cooler cycle from possible failure at the time when abnormal pressure was generated on the high pressure side.
SM0052
SPECIFICATION OF DUAL PRESSURE SWITCH 0.02MPa(2.9psi)
0.59MPa(86psi) SM0053
ON OFF
3.14MPa 0.20MPa (LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
8.
Solar radiation sensor This solar radiation sensor, which is used to correct the solar radiation to the auto air conditioner detects the strength and solar orientation of sunbeam after transforming them into current by means of photo diode. Inspection: Check for the continuity between terminals. SM0054
T3-8-27
AIR CONDITIONER SYSTEM
E215B-E245B
TROUBLESHOOTING Note : M/A is motor actuator * is any of the numbers 0 ~ 9
Air temperature does not fall.
If AUTO switch or A/C switch is pushed, "HL.E" is indicated on the set temp. display of the panel. NO
YES • Connector for air mix M/A is disconnected or in poor contact. • Air mix M/A is failed. • Main harness shows poor continuity.
"HL.*" is shown on the set temp. display of the panel NO
YES
A snow mark ( ) on the panel is flashing.
A snow mark ( panel is flashing. NO
) on Inspect and correct or replace parts.
YES
• Inner air sensor or harness is disconnected or shorted • Inner air sensor connector is disconnected or in poor contact. See section monitor mode.
• Both inner air sensor and evaporation sensor are disconnected or shorted. • Controller failed. See section monitor mode.
Inspect and correct or replace parts. A NO Blowout temp. falls if temp. is set at 18.0 °C (64.4 °F) (COOLMAX) and the blowout mode is changed to vent mode. NO Air mix damper is in COOLMAX.
NO
YES • Evaporation sensor connector is disconnected or in poor contact. • Evaporation sensor is disconnected or shorted.
YES
Inspect and correct or replace parts.
Cool air flowing into inner air sensor
Inspect and correct or replace parts.
YES
If M/A is at stop halfway, eliminate cause, correct and measure operating force. (less than 14.7N: OK)
NO Turn compressor clutch on and off. Inspect and correct electric circuits.
Controller is faulty or inner air sensor is faulty.
Refer to Troubleshooting for refrigeration cycle. Inspect and replace. NO
YES
• Inspect, correct or replace M/A lever link. • After cleaning lever link, apply grease.
M/A failed or controller is out of order. Replace.
T3-8-28
YES
Inspect duct or eliminate cause for cool air intrusion.
AIR CONDITIONER SYSTEM
E215B-E245B
Air temperature does not rise.
Note : * is any of the numbers 0 ~ 9
HL.E is shown on the set temp. display of the panel. NO
YES • Connector for air mix M/A is disconnected or in poor contact. • Air mix M/A is failed. • Main harness shows poor continuity.
"HL.*" is shown on the set temp. display of the panel. NO
YES
• Inner air sensor or harness is disconnected or shorted • Inner air sensor connector is disconnected or in poor contact.
Inspect and correct or replace parts.
See section monitor mode. NO YES Inspect and correct or replace parts.
NO
YES
Blowout temp. rises at blowout mode if temp. is set at HOT MAX 32.0 °C (64.4 °F) NO Air mix damper is in HOT MAX
NO
YES Warm air is flowing into inner air sensor.
YES
If M/A action is at stop, eliminate cause, correct and measure operating force. (less than 14.7N: OK)
NO
YES
Inspect warm water piping. Controller or inner air sensor is out of order.
Inspect and replace. NO • Inspect, correct or replace M/A lever link. • Clean lever link and apply grease.
YES M/A failed or controller is out of order. Replace.
T3-8-29
Inspect duct or eliminate causes for warm air entry.
AIR CONDITIONER SYSTEM
E215B-E245B
Blower motor does not run.
Note 1)
At air flow HI, battery voltage acts across both terminals (+) and (-) of blower motor. NO
YES Blower motor fails.
Battery voltage acts across red (+) and body of blower motor. NO Note 2)
YES
Inspect blower motor relay. Blower motor rotates if white / red wire and red wire of blower motor relay are direct connected.
Replace. Approx. 10V acts across light green wire and grounding of blower amplifier.
NO NO
YES
YES
Controller is out of order. Replace.
Wire harness is faulty. Inspect and correct or replace.
NO Eliminate cause and replace blower amplifier.
Battery voltage acts across white / red wire and body of blower motor relay.
NO Inspect and repair harness or replace.
Remove blower amplifier and check for continuity across light green wire and black wires; you get continuity. YES Inspect and repair harness.
YES Blower turns if orange wire of blower motor relay is connected with ground.
NO Replace relay.
YES Inspect and correct harness or replace controller.
Note 1) Measure with connector set. Note 2) Always turn off air-conditioner, starter key switch and light sw itch before work.
T3-8-30
AIR CONDITIONER SYSTEM
E215B-E245B
Blower motor speed does not change.
CASE (1) "HL.*" is shown on the set temp. display of the panel. NO Replace blower controller.
amplifier
Note) * is any of the numbers 0 ~ 9.
YES • Inner air sensor or harness is disconnected or shorted. • Inner air sensor connector is disconnected or in poor contact. See section monitor mode.
Inspect and correct or replace parts.
CASE (2) Does not blower motor speed change because the setting mode is other face
NO Is door or front window open? NO The limiting or control operation is actuated by door switch or front window switch
YES See CASE (1).
T3-8-31
YES See CASE (1).
AIR CONDITIONER SYSTEM
E215B-E245B
Magnet clutch does not engage.
Snow mark ( ) lights if A/C switch is pressed. NO
YES Voltage acts upon clutch.
Snow mark ( ) flickers and E is shown on panel display.
NO
To A On page T8-3-28.
Voltage is applied to pressure switch harness. NO
Pressure switch is faulty or refrigerant gas is under charged or overcharged. Refer to troubleshooting for refrigeration cycle.
YES
Inspect clutch fuses.
Clutch faulty.
YES
Voltage acts across white / green wire and Ground (Black) connector connected to excavator. NO
YES
Inspect air-conditioner harness. No fault. NO
YES
Replace harness.
Replace controller.
Inner air and outer air do not change
Inner / outer air mode display on operation panel is flickering. NO
YES
M/A lever includes foreign matter or is broken. NO M/A failed
Connector of inner/outer air M/A is disconnected or in poor contact. Or M/A failed or main harness failed.
YES Remove foreign matter and replace parts.
Replace
T3-8-32
Inspect or replace.
AIR CONDITIONER SYSTEM
E215B-E245B
Modes do not change.
Mode display (Mark of person) on operating panel is flickering. NO
YES
M/A rod does not disengage. NO
Mode M/A connector is disconnected or in poor contact or M/A failed or main harness is faulty.
YES
Repair.
Each damper lever does not disengage. NO Repair.
Inspect or replace.
YES When rod is removed and cam is operated by hand, it is heavy. (more than 19.6N.). NO
M/A or controller is out of order. Replace.
YES • Cam or damper shaft includes foreign matter or is broken • Erroneous motion occurs due to dirty grease.
• Remove foreign matter or replace parts. • Clean cam and apply new grease.
T3-8-33
AIR CONDITIONER SYSTEM
E215B-E245B
Trouble with refrigeration cycle.
Both high and low pressures are lower. Air bubbles are seen in sight glass. NO
YES
Cooling does not work if run at high speed. NO
Oil comes out from piping and parts.
YES
NO
YES
Expansion valve is clogged or maladjusted.
Expansion valve is frozen or intruded by water.
Natural leak from hose.
Adjust or replace expansion valve.
After making vacuum, refill refrigerant and replace receiver.
Charge gas.
Gas leaks from pipe joints and parts. Retighten parts.
or
replace
Low pressure is higher. NO
YES
Air bubbles are seen in sight glass.
High pressure is lower.
Compressor cylinder does not get hot.
Compressor cylinder gets very hot.
Expansion valve is maladjusted. (too much open)
Compressor does not discharge well.
Replace expansion valve.
Replace compressor
High pressure is lower.
Air bubbles are seen in sight glass. NO High pressure gets lower slowly.
YES Condenser is fouled or clogged. YES
High pressure circuit before receiver is clogged up.
Remove clogging replace parts.
Clean condenser.
or
NO Air bubbles are hard to go out even if water is poured on condenser.
Air is mixed. Make vacuum and refill refrigerant.
T3-8-34
AIR CONDITIONER SYSTEM
E215B-E245B
SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL The failure of motor actuator and each sensor can be identified on the display of panel. POSITION OF INDICATION FOR FAILURE.
SM0055
The error is indicated on 3 digits segment. EXPLANATION OF INDICATION FOR FAILURE. Failure of Motor Actuator
1.
HL.E is indicated on 3 digits segment.
Check harness or connector to motor actuator for the air mix damper for disconnection.
SM0056
2.
MODE
is flickering.
Check harness or connector to motor actuator for the air outlet damper for disconnection.
SM0057
3.
R/F
is flickering.
SM0058
Check harness or connector to motor actuator for the inner and outer air damper for disconnection. Note: The above indication and flickering does not function if the harness and connector were disconnected under the condition the panel ON/ OFF switch is ON. After the failure was occured, if the panel ON/ OFF switch is turned ON, it functions. After correction of failure, if the starter switch is not switched from OFF to ON the error indication and flickering are not released.
T3-8-35
AIR CONDITIONER SYSTEM
E215B-E245B
Failures of sensors
1.
HL.* is indicated on 3 digits segment.
Check the inner air sensor or the harness for disconnection and short circuit, and also connectors for disconnection.
SM0059
(* is any of the numbers 0 to 9.) 2.
**E and
mark are flickering. (** is displayed leaving the present set temperature value.)
Check evaporator sensor or the harness for disconnection and short circuit, and also connectors for disconnection.
SM0060
Note: The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the condition the panel ON/OFF switch is ON. And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is released.
Communication error of control amplifier and panel
1.
E is indicated on the only use segment of display.
Check the harness of control amplifier and panel for disconnection, and connectors for poor connection.
SM0061
T3-8-36
AIR CONDITIONER SYSTEM
E215B-E245B
EXPLANATION OF MONITOR MODE
When error “failure of sensors” is displayed, the monitor mode is available to identify the sensor condition (disconnection, short circuit). 1.
Position of monitor mode indication
SM0062
3 DIGITS SEGMENT
2.
SEGMENT FOR ONLY MONITOR INDICATION
Operation of monitor mode
A
B
E
SM0063
C
D
1. Press inner and outer air flow select switch ( A) and ON/OFF switch ( D) simultaneously for 1 second. 2. Press AUTO switch (E). (After all segments are lit on for 1 second, the mode is switched into monitor mode.) 3. Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit and 2nd digit of segment in three digits. The 1st digit is indicated by "H". 4. Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing UP or DOWN of blower switch ( B) or (C), and the required sensor is selected from the list below. SEGMENT ASSIGNMENT LIST 0
INNER AIR SENSOR
1
EVAPORATOR SENSOR
2
SOLAR RADIATION SENSOR
SM0064
(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)
5.
The monitor display is terminated by pressing the inner and outer air flow select switch ( A) and ON/OFF switch (D) for 1 second again, or turning off the main switch of excavator.
Notes: - The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for operation and setting until the monitor mode is cancelled. - Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized. Therefore turn on ON/OFF switch ( D) again, and the error display is disappeared.
T3-8-37
AIR CONDITIONER SYSTEM
E215B-E245B
3.
Contents of monitor mode display
Refer to the list of segment display exclusively used for monitor and the list of segments in three digits. 1. Example 1 When the segment exclusively used for monitor indicates 0 (displays the inner air sensor condition), since the segment indicates 3F, the sensor is in normal operating condition according to the list of 3 segments. --> The inner air sensor is in normal operating condition. SM0065
2. Example 2 When the segment exclusively used for monitor indicates 1 (displays the evaporator sensor condition), since the segment indicates 00, the sensor is in disconnection condition according to the list of 3 segments. --> The evaporator sensor is in disconnection condition. SM0066
3. Example 3
SM0067
4.
When the segment exclusively used for monitor indicates 2 (displays the solar radiation sensor condition), since the segment indicates FF,the sensor is in short-circuiting condition according to the list of 3 segments. -->The solar radiation sensor is in short-circuiting condition.
List of 3 segments SECOND SEGMENT INNER AIR SENSOR DISCONNECTION EVAPORATOR SENSOR DISCONNECTION SOLAR RADIATION SENSOR SHORT-CIRCUITING
T N E M G E S D R I H T
EACH SENSOR IS NORMAL
SOLAR RADIATION SENSOR 5V SIDE SHORT-CIRCUITING
INNER AIR SENSOR SHORT-CIRCUITING EVAPORATOR SENSOR SHORT-CIRCUITING SM0068
T3-8-38
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
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 equipment.
1. JUDGMENT OF ACTUAL THING AT SITE
SM0100
GET TO THE SITE AS QUICKLY AS POSSIBLE
Attending the field to verify actual thing
Verify model, serial number, situation of trouble and field, and notify person of arrival time. VERIFY BACKGROUND OF TROUBLE OCCURRED 1. Model name and serial number 2. Kind of attachment Check that the combination of attachment is proper or that the operating method is not unreasonable. 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.
SM0101
Verifying background of trouble occurred
HOW TO DIAGNOSE TROUBLE 1. Verify defective part 2. Make the condition of trouble again 3. Where defective parts can not be verified, surmise causes systematically. 4. Verify reasons for surmise 5. Report methods, procedure, and period for repairing to user. SM0102
EXPLANATION OF THE CAUSE OF TROUBLE 1. Explain the cause of trouble to clients. For example, oil leak through piston is caused by flaws on the piston rod. And the method of using the machines should be explained so that the same kind of trouble does not reoccur.
Confirm the symptoms of the trouble
2. Treatment of damaged parts The damaged parts to be claimed and returned are evidence so they should be handled with care. Protect them from entry of water, soils, etc. into port of hydraulic unit, etc. and return them. And also use care not to flaw and damage those surfaces.
SM0103
Diagnosing fail by means troubleshooting
T5-1-1
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
2. CLASSIFICATION OF FAILURE AND TROUBLESHOOTING Classify failures into the following 3 types and carry out the troubleshooting. No.
Classes of failure
Troubleshooting
A
When error code after self-diagnosis is displayed Carry out troubleshooting according to the error on gauge cluster code.
B
When no failure is detected currently but error When it is hard to recreate the failure situation, code after self diagnosis is remained in trouble cancel the data in the history and reproduce the history failed situation or suppose the cause according to the troubleshooting by error code, and then repair it.
C
When error code after self diagnosis is not • Carry out displayed or is not remained in the history instructions
troubleshooting according to in Chapter T5-2
"TROUBLESHOOTING BY TROUBLE". • Carry out troubleshooting according to instructions in Chapter T5-3 "TROUBLE DIAGNOSIS MODE".
3. THE BLOWN FUSE OF MECHATRO CONTROLLER If the fuse of mechatro controller has blown, the following display appears on the gauge cluster. (1)
The blown fuse of mechatro controller a. Blown fuse 5A of mechatro controller : "DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the controller program is not executed. b. Blown fuse 20A of mechatro controller The controller functions normally but the power supply applied when the controller drives the solenoid, etc. stops. Many error codes are displayed on the gauge cluster. D013, D023, D033, D063, E013, E023, F021
4. TROUBLESHOOTING BY ERROR CODE When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out the troubleshooting referring to applicable page in the contents of error codes.
Error Code
Trouble
Described page
A015
Engine adjustment (A adjustment) is not adjusted yet or is failed.
T5-1-5
A025
Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed.
T5-1-5
A035
Unload valve adjustment (C adjustment) is not adjusted yet or is failed.
T5-1-6
A215
Written data of ROM adjustment data is incorrect.
T5-1-6
A225
Writing of ROM adjustment data is incorrect.
T5-1-7
A235
Written data of ROM hour meter data is incorrect.
T5-1-7
A245
Writing of ROM hour meter data is incorrect.
T5-1-8
A255
Writing of proportional valve adjustment data is incorrect.
T5-1-8
B012
Incorrect output of boom up pressure sensor
T5-1-9
B013
Disconnection of boom up pressure sensor
T5-1-9
B014
Short-circuit of boom up pressure sensor
T5-1-10
B022
Incorrect output of boom down pressure sensor
T5-1-10
T5-1-2
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Described
Error Code
Trouble
B023
Disconnection of boom down pressure sensor
T5-1-11
B024
Short-circuit of boom down pressure sensor
T5-1-11
B032
Incorrect output of arm out pressure sensor
T5-1-12
B033
Disconnection of arm out pressure sensor
T5-1-12
B034
Short-circuit of arm out pressure sensor
T5-1-13
B042
Incorrect output of arm in pressure sensor
T5-1-13
B043
Disconnection of arm in pressure sensor
T5-1-14
B044
Short-circuit of arm in pressure sensor
T5-1-15
B052
Incorrect output of bucket digging pressure sensor
T5-1-16
B053
Disconnection of bucket digging pressure sensor
T5-1-16
B054
Short-circuit of bucket digging pressure sensor
T5-1-17
B062
Incorrect output of bucket dump pressure sensor
T5-1-17
B063
Disconnection of bucket dump pressure sensor
T5-1-18
B064
Short-circuit of bucket dump pressure sensor
T5-1-18
B072
Incorrect output of swing pressure sensor
T5-1-19
B073
Disconnection of swing pressure sensor
T5-1-19
B074
Short-circuit of swing pressure sensor
T5-1-20
B092
Incorrect output of travel right pressure sensor
T5-1-20
B093
Disconnection of travel right pressure sensor
T5-1-21
B094
Short-circuit of travel right pressure sensor
T5-1-22
B102
Incorrect output of travel left pressure sensor
T5-1-23
B103
Disconnection of travel left pressure sensor
T5-1-23
B104
Short-circuit of travel left pressure sensor
T5-1-24
B113
Disconnection of pressure sensor of optional selector positioning
T5-1-25
B114
Short-circuit of pressure sensor of optional selector positioning
T5-1-26
B162
Incorrect output of P1 optional side pressure sensor
T5-1-26
B163
Disconnection of P1 side optional pressure sensor
T5-1-27
B164
Short-circuit of P1 side optional pressure sensor
T5-1-28
B172
Incorrect output of P2 optional side pressure sensor
T5-1-28
B173
Disconnection of P2 side optional pressure sensor
T5-1-29
B174
Short-circuit of P2 side optional pressure sensor
T5-1-29
C012
Incorrect output of P1 pump pressure sensor
T5-1-30
C013
Disconnection of P1 pump pressure sensor
T5-1-30
C014
Short-circuit of P1 pump pressure sensor
T5-1-31
C022
Incorrect output of P2 pump pressure sensor
T5-1-31
C023
Disconnection of P2 pump pressure sensor
T5-1-32
C024
Short-circuit of P2 pump pressure sensor
T5-1-32
C033
Disconnection of boom head pressure sensor
T5-1-33
C034
Short-circuit of boom head pressure sensor
T5-1-33
D012
Failure of output transistor ON at P1 unload proportional valve
T5-1-34
D013
Disconnection of P1 unload proportional valve
T5-1-34
D022
Failure of output transistor ON at P2 unload proportional valve
T5-1-35
D023
Disconnection of P2 unload proportional valve
T5-1-36
D032
Failure of output transistor ON at travel straight proportional valve
T5-1-36
D033
Disconnection of travel straight proportional valve
T5-1-37
D062
Failure of output transistor ON at arm in high speed proportional valve
T5-1-38
page
T5-1-3
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Error Code
Trouble
Described page
D063
Disconnection of arm in high speed proportional valve
T5-1-39
D152
Failure of output transistor ON at short-circuit valve
T5-1-39
D153
Disconnection of short-circuit valve
T5-1-40
E012
Failure of output transistor ON at P1 pump proportional valve
T5-1-40
E013
Disconnection of P1pump proportional valve
T5-1-41
E022
Failure of output transistor ON at P2 pump proportional valve
T5-1-42
E023
Disconnection of P2 pump proportional valve
T5-1-42
F011
Failure of output transistor OFF and GND short of attachment boost SOL valve
T5-1-43
F013
Failure of output transistor ON and disconnection of attachment boost SOL valve
T5-1-4
F021
Failure of output transistor OFF and GND short of swing parking SOL valve
T5-1-45
F023
Failure of output transistor ON and disconnection of swing parking SOL valve
T5-1-45
F031
Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve
T5-1-46
F033
Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve
T5-1-47
F041
Failure of output transistor OFF and GND short of optional selector SOL valve
T5-1-47
F043
Failure of output transistor ON and disconnection of optional selector SOL valve
T5-1-48
G011
Failure of output transistor ON at governor motor
T5-1-48
G013
Disconnection of governor motor
T5-1-49
G023
Starting point indexing is impossible
T5-1-49
G032
Overrun of speed sensor of direct input Mechatro-controller
T5-1-50
G033
Disconnection of speed sensor of direct input Mechatro-controller
T5-1-50
H013
Disconnection of acceleration potentio
T5-1-51
H014
Power short-circuit of acceleration potentio
T5-1-51
H023
Disconnection of boom angle potentio
T5-1-52
H024
Power short-circuit of boom angle potentio
T5-1-53
H033
Disconnection of arm angle potentio
T5-1-54
H034
Power short-circuit of arm angle potentio
T5-1-55
H091
Failure of GND short-circuit of fuel sensor
T5-1-56
H093
Disconnection of fuel sensor
T5-1-56
I313
Received error of cluster communication (time-out error)
T5-1-57
K014
Adhesion of battery relay terminal
T5-1-58
R014
Failure of arc prevention relay of wiper motor
T5-1-59
R024
Failure of normal rotation relay of wiper motor
T5-1-60
R034
Failure of reverse rotation relay of wiper motor
T5-1-61
R044
Failure of washer motor relay
T5-1-62
R134
Failure of swing flasher relay
T5-1-63
R144
Failure of swing flasher relay
T5-1-64
R154
Failure of travel alarm relay
T5-1-65
R164
Failure of auto idling stop relay 2
T5-1-66
R174
Failure of engine forcible stop relay
T5-1-67
R184
Failure of lever lock relay
T5-1-68
R214
Failure of safety relay
T5-1-69
T5-1-4
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 1 Error code
A015
Trouble
Not yet adjusted engine or failed adjustment of engine (A adjustment)
Judging condition
Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting range.
Symptom
Deviated from the reqired value, but no problem in normal operations.
Control in the Rotate with the default engine. event of failure Returned in The engine adjustment is completed normally. normal condition Screen No.
Service diagnosis Screen No. checking screen
2
G-3 SPEED SET
Screen No.
Checking object
Checking contents and remedy
1
• Checking
Carry out engine adjustment (A adjustment). When "ERROR ENG" was displayed during adjustment, refer to the section "Adjustment procedure Measures to be taken with the adjustment failed"
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
Table 2 Error code
A025
Trouble
Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging condition
Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within the adjusting range.
Symptom
Deviated from the rated output, but no problem in normal operation.
Control in the Workable with the default proportional valve output. event of failure Returned in The pump proportional valve adjustment is completed normally. normal condition Screen No.
Service diagnosis Screen No. checking screen
9
E-1 P1 PUMP
9
E-2 P2 PUMP
Screen No.
Checking object
Checking contents and remedy
1
• Checking
Carry out pump adjustment (B adjustment). When"ERROR PUMP" was displayed during adjustment, refer to the section "Adjustment procedure - Measures to be taken with the adjustment failed"
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
T5-1-5
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 3 Error code
A035
Trouble
Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
Judging condition
The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting range.
Symptom
It is not normal output, but no problem in normal operation.
Control in the Work with the aid of output by default proportional valve. event of failure Returned in The adjustment of unload valve is completed normally. normal condition Screen No.
8
D-1 P1 UN-LOAD (BP-CUT)
Service diagnosis Screen checking screen No.
8
D-2 P2 UN-LOAD (BP-CUT)
Screen No. Checking object
Checking contents and remedy
1
• Checking
Carry out adjustment of unload valve (C adjustment). When"ERROR PUMP" was displayed during adjustment, refer to the section "Adjustment procedure - Measures to be taken with the adjustment failed"
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
Table 4 Error code
A215
Trouble
The data of ROM adjustment is written incorrectly.
Judging condition
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
Symptom
No affect.
Control in the Control at side of correct memory data. event of failure Returned in It does not regain. Replace controller. normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object 1
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
2 3
T5-1-6
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 5 Error code
A225
Trouble
The data of ROM adjustment is written incorrectly.
Judging condition
Check adjustment data, and judge the data is correct or not.
Symptom
It is not normal output, but no problem in normal operation.
Control in the Control can be done by default value. event of failure Returned in It does not regain. Replace controller. normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object 1
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
2 3
Table 6 Error code
A235
Trouble
The data of ROM adjustment is written incorrectly.
Judging condition
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
Symptom
No affect.
Control in the Control at side of correct memory data. event of failure Returned in It does not regain. Replace controller. normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object 1
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
2 3
T5-1-7
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 7 Error code
A245
Trouble
The data of ROM hourmeter is written incorrectly.
Judging condition
Check hourmeter memory, and judge the data is incorrect.
Symptom
The hourmeter data which was judged as error is taken as 0 Hr. No problem in normal operation.
Control in the Normal control is available. event of failure Returned in It does not regain. Replace controller. normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object 1
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
2 3
Table 8 Error code
A255
Trouble
The data of proportional valve adjustment is written incorrectly.
Judging condition
Check proportional valve adjustment data, and judge the data is incorrect.
Symptom
It is not normal output, but no problem in normal operation.
Control in the Using fixed value of proportional valve correction data, usual control is done. event of failure Returned in It does not regain. Replace controller. normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object 1
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
2 3
T5-1-8
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 9 Error code
B012
Trouble
Boom up pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom
The boom up operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
5
B-1 BOOM RAISE
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Boom up pressure sensor SE-3 When B012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom up pressure sensor and controller CN-126F CN-101F
When B012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 10 Error code
B013
Trouble
Boom up pressure sensor’s wiring disconnects.
Judging condition
The input voltage from boom up pressure sensor is less than 0.1 V.
Symptom
The boom up speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode) event of failure Set output of P1 unl oad proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.
5
B-1 BOOM RAISE
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Boom up pressure sensor SE-3 When B013 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom up When B013 is displayed after the connector is exchanged with other sensor. pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-126F and repair it if necessary. CN-101F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-9
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 11 Error code
B014
Trouble
Boom up pressure sensor ’s power source is shortcut.
Judging condition
The input voltage from boom up pressure sensor is 4.7 V or more.
Symptom
The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.
5
B-1 BOOM RAISE
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Boom up pressure sensor SE-3 When B014 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom up When B014 is displayed after the connector is exchanged with other sensor. pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-126F and repair it if necessary. CN-101F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 12 Error code
B022
Trouble
Boom down pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4 V or more to l ess than 4.7 V.
Symptom
The boom down operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
5
B-2 BOOM LOWER
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-4 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom down pressure sensor and controller CN-127F CN-101F
When B022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-10
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 13 Error code
B023
Trouble
Boom down pressure sensor ’s wiring is disconnecting.
Judging condition
The input voltage from boom down pressure sensor is 0.1 V or less.
Symptom
The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
5
B-2 BOOM LOWER
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the connector with other sensor. SE-4 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor. pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-127F and repair it if necessary. CN-101F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 14 Error code
B024
Trouble
Boom down pressure sensor ’s power source is shortcut.
Judging condition
The input voltage from boom down pressure sensor is 4.7 V or more.
Symptom
The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
5
B-2 BOOM LOWER
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-4 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom down pressure sensor and controller CN-127F CN-101F
When B024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-11
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 15 Error code
B032
Trouble
Arm-in pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4 V or more to l ess than 4.7 V.
Symptom
The arm-out operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
5
B-3 ARM OUT
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Arm-out pressure sensor SE-8
When B032 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between arm-out pressure sensor and controller CN-131F CN-101F
When B032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 16 Error code
B033
Trouble
Arm-out pressure sensor ’s wiring is disconnecting.
Judging condition
The input voltage from arm-out pressure sensor is 0.1 V or less.
Symptom
Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.
5
B-3 ARM OUT
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Arm-out pressure sensor SE-8
When B033 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between arm-out pressure When B033 is displayed after the connector is exchanged with other sensor. sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-131F and repair it if necessary. CN-101F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-12
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 17 Error code
B034
Trouble
Arm-out pressure sensor ’s power source is shortcut.
Judging condition
The input voltage from arm-out pressure sensor is 4.7 V or more.
Symptom
Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1, P2 unload proportional valves to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
5
B-3 ARM OUT
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Arm-out pressure sensor SE-8
When B034 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between arm-out pressure sensor and controller CN-131F CN-101F
When B034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 18 Error code
B042
Trouble
Arm-in pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the arm-in pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The arm-in operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
5
B-4 ARM IN
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Arm-in pressure sensor SE-7
Checking contents and remedy When B042 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between arm-in pressure sensor and controller CN-130F CN-101F
When B042 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-13
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 19 Error code
B043
Trouble
Arm-in pressure sensor ’s wiring is disconnecting.
Judging condition
The input voltage from arm-in pressure sensor is 0.1 V or less.
Symptom
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode) Control in the Set output of P1 and P2 unload proportional valve to 0 mA. (Valve emergency mode) event of failure Set output of arm 2 arm-in proportional valve to 200 mA. Returned in It returns automatically in normal condition. normal condition Screen No.
5
B-4 ARM IN
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Arm-in pressure sensor SE-7
When B043 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between arm-in pressure When B043 is displayed after the connector is exchanged with other sensor. sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-130F and repair it if necessary.. CN-101F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-14
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 20 Error code
B044
Trouble
Arm-in pressure sensor ’s power source is shortcut.
Judging condition
The input voltage from arm-in pressure sensor is 4.7 V or more.
Symptom
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode) Control in the Set output of P1, P2 unload proportional valves to 0 mA. (Valve emergency mode) event of failure Set output of arm 2 arm-in proportional valve to 200 mA. Returned in It returns automatically in normal condition. normal condition Screen No. Service diagnosis Screen No. checking screen Screen No.
5
B-4 ARM IN
Checking object
Checking contents and remedy
1
• Arm-in pressure sensor SE-7
When B044 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between arm-in pressure When B044 is displayed after turning the starter switch on after the connector sensor and controller is exchanged with other sensor. CN-130F Check wiring for possible failure according to the wiring checking procedure CN-101F and repair it if necessary..
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-15
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 21 Error code
B052
Trouble
Bucket digging pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the bucket digging pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom
The bucket digging operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
5
B-5 BUCKET DIG
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-1 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F
When B052 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 22 Error code
B053
Trouble
Bucket digging pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from bucket digging pressure sensor is 0.1 V or less.
Symptom
The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.
5
B-5 BUCKET DIG
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-1 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F
When B053 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-16
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 23 Error code
B054
Trouble
Bucket digging pressure sensor’s power source is shortcut.
Judging condition
The input voltage from bucket digging pressure sensor is 4.7 V or more.
Symptom
The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
5
B-5 BUCKET DIG
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-1 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F
When B054 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 24 Error code
B062
Trouble
Bucket dump pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the bucket dump pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom
The bucket dump operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
5
B-6 BUCKET DUMP
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Bucket digging pressure sensor When B062 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-2 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F
When B062 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-17
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 25 Error code
B063
Trouble
Bucket dump pressure sensor ’s wiring is disconnected.
Judging condition
The input voltage from bucket dump pressure sensor is 0.1 V or less.
Symptom
The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.
5
B-6 BUCKET DUMP
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Bucket digging pressure sensor When B063 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-2 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F
When B063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 26 Error code
B064
Trouble
Bucket dump pressure sensor ’s power source is shortcut.
Judging condition
The input voltage from bucket dump pressure sensor is 4.7 V or more.
Symptom
The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
5
B-6 BUCKET DUMP
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Bucket digging pressure sensor When B064 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-2 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F
When B064 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-18
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 27 Error code
B072
Trouble
Swing pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the swing pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom
The swing operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
6
B-7 SWING
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• Swing pressure sensor
When B072 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
SE-5 2
• Wiring between swing pressure When B072 is displayed after turning the starter switch on after the connector sensor and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-169F and repair it if necessary. CN-103F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 28 Error code
B073
Trouble
Swing pressure sensor ’s wiring is disconnected.
Judging condition
The input voltage from swing pressure sensor is 0.1 V or less.
Symptom
The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
6
B-7 SWING
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Swing pressure sensor SE-5
Checking contents and remedy When B073 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between swing pressure When B073 is displayed after turning the starter switch on after the connector sensor and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-169F and repair it if necessary. CN-103F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-19
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 29 Error code
B074
Trouble
Swing pressure sensor ’s power source is shortcut.
Judging condition
The input voltage from swing pressure sensor is 4.7 V or more.
Symptom
The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
6
B-7 SWING
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• Swing pressure sensor
When B074 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
SE-5 2
• Wiring between swing pressure When B074 is displayed after turning the starter switch on after the connector sensor and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-169F and repair it if necessary. CN-103F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 30 Error code
B092
Trouble
Travel right pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the travel right pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4 .7 V.
Symptom
The travel right operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
6
B-9 TRAVEL (R)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Travel right pressure sensor SE-9
Checking contents and remedy When B092 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between travel right pressure sensor and controller CN-301F CN-102F
When B092 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-20
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 31 Error code
B093
Trouble
Travel right pressure sensor ’s wiring is disconnected.
Judging condition
The input voltage from Travel right pressure sensor is 0.1 V or less.
Symptom
The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.
6
B-9 TRAVEL (R)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Travel right pressure sensor SE-9
Checking contents and remedy When B093 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between travel right pressure sensor and controller CN-301F CN-102F
When B093 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-21
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 32 Error code
B094
Trouble
Travel right pressure sensor’s power source is shortcut.
Judging condition
The input voltage from Travel right pressure sensor is 4.7 V or more.
Symptom
The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.
6
B-9 TRAVEL (R)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Travel right pressure sensor SE-9
Checking contents and remedy When B094 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between travel right pressure sensor and controller CN-301F CN-102F
When B094 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-22
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 33 Error code
B102
Trouble
Travel left pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the travel left pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom
The travel left operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
6
B-10 TRAVEL (L)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• Travel left pressure sensor SE-10
When B102 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between travel left pressure sensor and controller CN-302F CN-102F
When B102 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 34 Error code
B103
Trouble
Travel left pressure sensor ’s wiring is disconnected.
Judging condition
The input voltage from Travel left pressure sensor is 0.1 V or less.
Symptom
The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
6
B-10 TRAVEL (L)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Travel left pressure sensor SE-10
Checking contents and remedy When B103 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between travel left pressure sensor and controller CN-302F CN-102F
When B103 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-23
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 35 Error code
B104
Trouble
Travel left pressure sensor’s power source is shortcut.
Judging condition
The input voltage from Travel left pressure sensor is 4.7 V or more.
Symptom
The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
6
B-10 TRAVEL (L)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Travel left pressure sensor SE-10
Checking contents and remedy When B104 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between travel left pressure sensor and controller CN-302F CN-102F
When B104 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-24
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 36 Error code
B113
Trouble
Option selector position detect pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from option selector position detect pressure sensor is 0.1 V or less.
Symptom
When B mode is selected, option selector valve error is indicated.
Control in the Normal control. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
16
B-11
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Option selector position detect When B113 is cancelled and other error occurs by turning starter switch on after pressure sensor exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. SE-29
2
• Wiring between option selector When B113 is displayed after turning the starter switch on after the connector position detect pressure sensor is exchanged with other sensor. and controller Check wiring for possible failure according to the wiring checking procedure CN-162F and repair it if necessary. CN-104F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-25
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 37 Error code
B114
Trouble
Option selector position detect pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from selector position detect pressure sensor is 4.7 V or more.
Symptom
When B mode is selected, option selector valve error is indicated.
Control in the Normal control. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
16
B-11
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Option selector position detect When B114 is cancelled and other error occurs by turning starter switch on after pressure sensor exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. SE-29
2
• Wiring between option selector When B114 is displayed after turning the starter switch on after the connector position detect pressure sensor is exchanged with other sensor. and controller Check wiring for possible failure according to the wiring checking procedure CN-162F and repair it if necessary. CN-104F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 38 Error code
B162
Trouble
P1 side option pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P1 side option pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4 .7 V.
Symptom
The P1 side option operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
6
B-16 P1 OPT.
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-20 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P1 side option pressure sensor and controller CN-304F CN-102F
When B162 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-26
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 39 Error code
B163
Trouble
P1 side option pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from P1 side option pressure sensor is 0.1 V or less.
Symptom
The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) But normal control is done when the left control pedal selection is ON. Returned in It returns automatically in normal condition. normal condition Screen No.
6
B-16 P1 OPT.
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• P1 side option pressure sensor When B163 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-20 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P1 side option pressure sensor and controller CN-304F CN-102F
When B163 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-27
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 40 Error code
B164
Trouble
P1 side option pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from P1 side option pressure sensor is 4.7 or more.
Symptom
The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) But normal control is done when the left control pedal selection is ON. Returned in It returns automatically in normal condition. normal condition Screen No.
6
B-16 P1 OPT.
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• P1 side option pressure sensor When B164 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-20 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P1 side option pressure sensor and controller CN-304F CN-102F
When B164 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 41 Error code
B172
Trouble
P2 side option pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P2 side option pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4 .7 V.
Symptom
The P2 side option operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
6
B-17 P2 OPT.
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• P2 side option pressure sensor When B172 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-11 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 side option pressure sensor and controller CN-304F CN-102F
When B172 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-28
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 42 Error code
B173
Trouble
P2 side option pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from P2 side option pressure sensor is 0.1 V or less.
Symptom
The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.
6
B-17 P2 OPT.
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• P2 side option pressure sensor When B173 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-11 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 side option pressure sensor and controller CN-303F CN-102F
When B173 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 43 Error code
B174
Trouble
P2 side option pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from P2 side option pressure sensor is 4.7 V or more.
Symptom
The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) event of failure Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.
6
B-17 P2 OPT.
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• P2 side option pressure sensor When B174 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-11 Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 side option pressure sensor and controller CN-303F CN-102F
When B174 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-29
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 44 Error code
C012
Trouble
P1 pump pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P1 pump pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4 .7 V.
Symptom
The P1 pump operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
7
C-1 PUMP P1
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P1 pump pressure sensor
When C012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
SE-22 2
• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F
When C012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 45 Error code
C013
Trouble
P1 pump pressure sensor ’s wiring is disconnected.
Judging condition
The input voltage from P1 pump pressure sensor is 0.1 V or less.
Symptom
The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure (Hydraulic pump emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
7
C-1 PUMP P1
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P1 pump pressure sensor
When C013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
SE-22 2
• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F
When C013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-30
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 46 Error code
C014
Trouble
P1 pump pressure sensor ’s power source is shortcut.
Judging condition
The input voltage from P1 pump pressure sensor is 4.7 V or more.
Symptom
The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure (Hydraulic pump emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
7
C-1 PUMP P1
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P1 pump pressure sensor
When C014 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
SE-22 2
• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F
When C014 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 47 Error code
C022
Trouble
P2 pump pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P2 pump pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom
The P2 pump operability becomes poor.
Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
7
C-2 PUMP P2
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P2 pump pressure sensor
When C022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
SE-23 2
• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F
When C022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-31
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 48 Error code
C023
Trouble
P2 pump pressure sensor ’s wiring is disconnected.
Judging condition
The input voltage from P2 pump pressure sensor is 0.1 V or less.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure (Hydraulic pump emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
7
C-2 PUMP P2
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P2 pump pressure sensor
When C023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
SE-23 2
• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F
When C023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 49 Error code
C024
Trouble
P2 pump pressure sensor ’s power source is shortcut.
Judging condition
The input voltage from P2 pump pressure sensor is 4.7 V or more.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure (Hydraulic pump emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.
7
C-2 PUMP P2
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• P2 pump pressure sensor
When C024 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
SE-23 2
• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F
When C024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-32
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 50 Error code
C033
Trouble
Boom head pressure sensor ’s wiring is disconnected.
Judging condition
The input voltage from boom head pressure sensor is 0.1 V or less.
Symptom
Overload detection is not available.
Control in the Normal control. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
7
C-3 BOOM-HEAD
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• Boom head pressure sensor SE-24
When C033 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom head pressure sensor and controller CN-140F CN-103F
When C033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 51 Error code
C034
Trouble
Boom head pressure sensor ’s power source is shortcut.
Judging condition
The input voltage from boom head pressure sensor is 4.7 V or more.
Symptom
Then overload detection switch is ON, overload alarm sounds constantly.
Control in the Normal control. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
7
C-3 BOOM-HEAD
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Boom head pressure sensor SE-24
Checking contents and remedy When C034 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom head pressure sensor and controller CN-706F CN-104F
When C034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-33
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 52 Error code
D012
Trouble
P1 unload proportional valve and output transistor ON are failure.
Judging condition
The feed-back value from proportional valve is 1000 mA or more.
Symptom
Option conflux can not be done.
Control in the Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
8
D-1 P1 UN-LOAD (BP-CUT)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• P1 unload proportional valve PSV-D
When D012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P1 unload When D012 is displayed after turning the starter switch on after the connector proportional valve and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-120F and repair it if necessary. CN-105F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 53 Error code
D013
Trouble
P1 unload proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100 mA or less. (If output is 100 mA or less, judging is not done.)
Symptom
Option conflux can not be done.
Control in the Set output of P1 unload proportional valve to 0mA. (Valve emergency mode). event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
8
D-1 P1 UN-LOAD (BP-CUT)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• P1 unload proportional valve PSV-D
Checking contents and remedy When D013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P1 unload When D013 is displayed after turning the starter switch on after the connector proportional valve and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-120F and repair it if necessary. CN-105F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-34
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 54 Error code
D022
Trouble
P2 unload proportional valve and output transistor ON are failure.
Judging condition
The feed-back value from proportional valve is 1000 mA or more.
Symptom
Independent operations of boom up and of bucket digging/dump become slow.
Control in the Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode) event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
8
D-2 P2 UN-LOAD (BP-CUT)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• P2 unload proportional valve PSV-B
Checking contents and remedy When D022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 unload proportional valve and controller CN-118F CN-105F
When D022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-35
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 55 Error code
D023
Trouble
P2 unload proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100 mA or less. (If output is 100 mA or less, judging is not done.)
Symptom
Independent operations of boom up and of bucket digging/dump become slow.
Control in the Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode) event of failure Returned in It returns automatically in normal condition. normal condition Screen
8
No.
D-2 P2 UN-LOAD (BP-CUT)
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• P2 unload proportional valve PSV-B
When D023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 unload When D023 is displayed after turning the starter switch on after the connector proportional valve and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-118F and repair it if necessary. CN-105F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 56 Error code
D032
Trouble
Travel straight proportional valve and output transistor ON are failure.
Judging condition
The feed-back value from proportional valve is 1000 mA or more
Symptom
Travel deviation occurs by combined operation of travel and attachment.
Control in the Set Travel straight proportional valve output to 0 mA event of failure Returned in It returns automatically in normal condition. normal condition Screen
8
No.
D-3 S-TRAVEL
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Travel valve
straight
PSV-C
Checking contents and remedy
proportional When D032 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector proportional valve and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-119F and repair it if necessary. CN-105F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-36
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 57 Error code
D033
Trouble
Travel straight proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100 mA or le ss. (If output is 100 mA or less, judging is not done.)
Symptom
Travel deviation occurs by combined operation of travel and attachment.
Control in the Set Travel straight proportional valve output to 0 mA. event of failure Returned in It returns automatically in normal condition. normal condition Screen
8
No.
D-3 S-TRAVEL
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Travel valve
straight
PSV-C
Checking contents and remedy
proportional When D033 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between Travel straight proportional valve and controller CN-119F CN-105F
When D033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-37
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 58 Error code
D062
Trouble
Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging condition
The feed-back value from proportional valve is 1000 mA or more
Symptom
Operability of combined operation with arm-in becomes poor.
Control in the Set Arm-in spool 2 proportional valve output to 0 mA. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
8
D-4 ARM IN-2-SPEED
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Arm-in valve
spool 2
PSV-A
Checking contents and remedy proportional When D062 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector proportional valve and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-121F and repair it if necessary. CN-105F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-38
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 59 Error code
D063
Trouble
Arm-in spool 2 proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100 mA or le ss. (If output is 100 mA or less, judging is not done.)
Symptom
Operability of combined operation with arm-in becomes poor.
Control in the Set Arm-in spool 2 proportional valve output to 0 mA. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
8
D-4 ARM IN-2-SPEED
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Arm-in spool valve PSV-A
Checking contents and remedy
2 proportional When D063 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F
When D063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 60 Error code
D152
Trouble Judging condition Symptom Control in the event of failure Returned in normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1 2 3
•
T5-1-39
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 61 Error code
D153
Trouble Judging condition Symptom Control in the event of failure Returned in normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1 2 3
•
Table 62 Error code
E012
Trouble
P1 pump proportional valve and output transistor ON are failure.
Judging condition
The feed-back value from proportional valve is 1000 mA or more.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure (Hydraulic pump emergency mode) Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
9
E-1 PUMP P1
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• P1 pump proportional valve PSV-P1
Checking contents and remedy When E012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.
2
• Wiring between P1 pump When E012 is displayed after turning the starter switch on after the connector proportional valve and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-141F and repair it if necessary. CN-105F When replacing of connector is executed, turn off power source once.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-40
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 63 Error code
E013
Trouble
P1 pump proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100 mA or le ss. (If output is 100mA or less, judging is not done.)
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure (Hydraulic pump emergency mode) Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
9
E-1 PUMP P1
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• P1 pump proportional valve PSV-P1
Checking contents and remedy When E013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.
2
• Wiring between P1 pump proportional valve and controller CN-141F CN-105F
When E013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-41
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 64 Error code
E022
Trouble
P2 pump proportional valve and output transistor ON are failure.
Judging condition
The feed-back value from proportional valve is 1000 mA or more.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure (Hydraulic pump emergency mode) Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
9
E-2 PUMP P2
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• P2 pump proportional valve PSV-P2
When E022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.
2
• Wiring between P2 pump When E022 is displayed after turning the starter switch on after the connector proportional valve and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-142F and repair it if necessary. CN-105F When replacing of connector is executed, turn off power source once.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 65 Error code
E023
Trouble
P2 pump proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100 mA or less. (If output is 100 mA or less, judging is not done.)
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure (Hydraulic pump emergency mode) Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.
9
E-2 PUMP P2
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• P2 pump proportional valve PSV-P2
Checking contents and remedy When E023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.
2
• Wiring between P2 pump When E023 is displayed after turning the starter switch on after the connector proportional valve and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-142F and repair it if necessary. CN-105F When replacing of connector is executed, turn off power source once.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-42
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 66 Error code
F011
Trouble
ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition
The feed-back signal is grounding level while exciting command is output.
Symptom
ATT boost is not available.
Control in the Normal control. event of failure Returned in The feed-back signal is 24V level while exciting command is output. normal condition Screen No.
3
F-1 POWER BOOST
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• ATT boost solenoid valve
When F011 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
SV-2 2
• Wiring between ATT boost solenoid valve and controller CN-117F CN-105F
When F011 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-43
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 67 Error code
F013
Trouble
ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
The feed-back signal is 24 V level while exciting command is not output.
Symptom
ATT boost is not available or is leaving available.
Control in the Normal control. event of failure Returned in The feed-back signal is grounding level while exciting command is not output. normal condition Screen No.
3
F-1 POWER BOOST
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• ATT boost solenoid valve
When F013 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
SV-2 2
• Wiring between ATT boost solenoid valve and controller CN-117F CN-105F
When F013 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-44
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 68 Error code
F021
Trouble
Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition
The feed-back signal is grounding level while exciting command is output.
Symptom
Swing parking is not available.
Control in the Normal control. event of failure Returned in The feed-back signal is 24 V l evel while exciting command is output. normal condition Screen No.
3
F-2 SWING-BRAKE
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• Swing parking solenoid valve SV-1
When F021 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between swing parking solenoid valve and controller CN-123F CN-105F
When F021 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 69 Error code
F023
Trouble
Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
The feed-back signal is 24 V level while exciting command is not output.
Symptom
Swing parking is not available or is leaving available.
Control in the Normal control. event of failure Returned in The feed-back signal is grounding level while exciting command is output. normal condition Screen No.
3
F-1 POWER BOOST
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Swing parking solenoid valve SV-1
Checking contents and remedy When F023 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between swing parking solenoid valve and controller CN-123F CN-105F
When F023 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-45
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 70 Error code
F031
Trouble
Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition
The feed-back signal is grounding level while exciting command is output.
Symptom
Travel 2 speed is not obtainable.
Control in the Normal control. event of failure Returned in The feed-back signal is 24 V level while exciting command is output. normal condition Screen No.
3
F-3 1/2-TRAVEL
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Travel 1, 2 speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector for other solenoid valve. SV-3 Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between travel 1, 2 speed solenoid valve and controller CN-123F CN-105F
When F031 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-46
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 71 Error code
F033
Trouble
Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
The feed-back signal is 24 V level while exciting command is not output.
Symptom
Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the Normal control. event of failure Returned in The feed-back signal is grounding level while exciting command is not output. normal condition Screen No.
3
F-3 1/2-TRAVEL
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Travel 1, 2 speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector for other solenoid valve. SV-3 Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between travel 1, 2 speed solenoid valve and controller CN-122F CN-105F
When F033 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary..
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 72 Error code
F041
Trouble
Option selector solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition
The feed-back signal is grounding level while exciting command is output.
Symptom
Option selector valve does not change to breaker side.
Control in the Normal control. event of failure Returned in The feed-back signal is ground level while exciting command is output. normal condition Screen No.
11
F-4 OPT SELECT
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Option selector solenoid valve SV-13
Checking contents and remedy When F041 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid solenoid valve and controller valve. Check wiring for possible failure according to the wiring checking procedure CN-251F and repair it if necessary. CN-105F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-47
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 73 Error code
F043
Trouble
Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
The feed-back signal is 24 V level while exciting command is not output.
Symptom
Option selector valve does not change to breaker side or it does not change from breaker to nibbler.
Control in the Normal control. event of failure Returned in The feed-back signal is ground level while exciting command is not output. normal condition Screen No.
11
F-4 OPT SELECT
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Option selector solenoid valve SV-13
Checking contents and remedy When F043 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid solenoid valve and controller valve. Check wiring for possible failure according to the wiring checking procedure CN-251F and repair it if necessary. CN-105F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 74 Error code
G011
Trouble Judging condition Symptom Control in the event of failure Returned in normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1 2 3
•
T5-1-48
TROUBLESHOOTING (BY ERROR CODES)
Table 75 Error code
G013
Trouble Judging condition Symptom Control in the event of failure Returned in normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1 2 3
•
Table 76 Error code
G023
Trouble Judging condition Symptom Control in the event of failure Returned in normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1 2 3
•
T5-1-49
E215B-E245B
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 77 Error code
G032
Trouble
Mechatro controller direct input speed sensor is overrun.
Judging condition
Engine rpm input is 3000 rpm or more. (Only trouble history).
Symptom
Operate without problem.
Control in the Receive rpm from engine controller and control the rpm. event of failure Returned in It returns automatically in normal condition. normal condition Screen No. Service diagnosis Screen checking screen No.
2
G-3 MEAS 1 (for mechatro controller)
2
G-3 MEAS 2 (receive from engine controller)
Screen No. Checking object 1
Checking contents and remedy
• Engine speed sensor
Measure the resistance between terminals of speed sensor.
SV-13
Normal value: 1.6~2.0k
.
2
• Wiring between option selector Check wiring for possible failure according to the wiring checking solenoid valve and controller procedure and repair it if necessary. CN-251F Especially check wiring for false disconnection and noise included . CN-105F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 78 Error code
G033
Trouble
Mechatro controller direct input speed sensor, Disconnection.
Judging condition
Voltage of alternator is 12 V or more, and speed sensor indicates excess low engine rpm.
Symptom
Operate without problem.
Control in the Receive rpm from engine controller and control the rpm. event of failure Returned in It returns automatically in normal condition. normal condition Screen No. Service diagnosis Screen checking screen No.
2
G-3 MEAS 1 (for mechatro controller)
2
G-3 MEAS 2 (receive from engine controller)
Screen No. Checking object 1
• Engine speed sensor SE-13
Checking contents and remedy Measure the resistance between terminals of speed sensor. Normal value: 1.6~2.0k
.
2
• Wiring between engine speed sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-136F CN-106F
3
• Mechatro controller
Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.).
T5-1-50
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 79 Error code
H013
Trouble
Accel potentiometer is disconnected.
Judging condition
The input voltage from accel potentiometer is 0.1 V or less.
Symptom
LOW idling is fixed.
Control in the LOW idling is fixed. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
2
H-1 ACCEL VOLT.
Service diagnosis Screen checking screen No. Screen No. Checking object 1
Checking contents and remedy
• Accel potentiometer
Measure the resistance between terminals of speed sensor. 1.6~2.4k Turn the potentiometer and measure resistance between signal and GND.
SE-16 2
• Wiring between accel potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-402F CN-102F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 80 Error code
H014
Trouble
Accel potentiometer ’s power source is shortcut.
Judging condition
The input voltage from accel potentiometer is 4.7 V or more.
Symptom
LOW idling is fixed.
Control in the LOW idling is fixed. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
2
H-1 ACCEL VOLT.
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Accel potentiometer SE-16
Checking contents and remedy Measure the resistance between terminals of accel potentiometer. 1.6~2.0k . Turn the potentiometer and measure resistance between signal and GND.
2
• Wiring between accel potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-402F CN-102F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-51
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 81 Error code
H023
Trouble
Boom angle potentiometer ’s wiring is disconnected.
Judging condition
The input voltage from boom angle potentiometer is 0.1 V or less.
Symptom
Indications of rating load and working radius of High-reach crane become abnormal.
Control in the Normal control. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
12
H-2 BOOM
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Boom angle potentiometer SE-17
Checking contents and remedy Measure the resistance between terminals of boom angle potentiometer. 4.0~6.0k . Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0~6.0)k
2
• Wiring between boom angle potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-702F CN-103F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-52
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 82 Error code
H024
Trouble
Boom angle potentiometer ’s power source is shortcut.
Judging condition
The input voltage from boom angle potentiometer is 0.1 V or less.
Symptom
Indications of rating load and working radius of High-reach crane become abnormal.
Control in the Normal control. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
12
H-2 BOOM
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Boom angle potentiometer SE-17
Checking contents and remedy Measure the resistance between terminals of boom angle potentiometer. 4.0~6.0k . Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0~6.0)k
2
• Wiring between boom angle potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-702F CN-103F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-53
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 83 Error code
H033
Trouble
Arm angle potentiometer ’s wiring is disconnected.
Judging condition
The input voltage from arm angle potentiometer is 0.1 V or less.
Symptom
Indications of rating load and working radius of High-reach crane become abnormal.
Control in the Normal control. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
12
H-3 ARM
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Arm angle potentiometer SE-18
Checking contents and remedy Measure the resistance between terminals of arm angle potentiometer. 4.0~6.0k . Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0~6.0)k
2
• Wiring between arm angle potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-703F CN-103F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-54
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 84 Error code
H034
Trouble
Arm angle potentiometer ’s power source is shortcut.
Judging condition
The input voltage from arm angle potentiometer is 0.1 V or less.
Symptom
Indications of rating load and working radius of High-reach crane become abnormal.
Control in the Normal control. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
12
H-3 ARM
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Arm angle potentiometer SE-18
Checking contents and remedy Measure the resistance between terminals of arm angle potentiometer. 4.0~6.0k . Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0~6.0)k
2
• Wiring between arm angle potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-703F CN-103F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-55
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 85 Error code
H091
Trouble
Fuel sensor grounding is short-circuited.
Judging condition
The input voltage from fuel sensor is 0.1 V or less.
Symptom
Warning for low fuel level is indicated.
Control in the Fuel level becomes 0%. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
10
H-9 FUEL LEVEL
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• Fuel sensor potentiometer
Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15
EMPTY 95
.~ FULL 5
2
• Wiring between fuel sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-152F CN-104F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table 86 Error code
H093
Trouble
Fuel sensor’s wiring is disconnection.
Judging condition
The input voltage from fuel sensor is 4.7 V or more.
Symptom
Warning for low fuel level is indicated.
Control in the Fuel level becomes 0%. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.
10
H-9 FUEL LEVEL
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• Fuel sensor potentiometer
Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15
EMPTY 95
.~ FULL 5
2
• Wiring between fuel sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-152F CN-104F
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-56
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 87 Error code
I313
Trouble
Reception of cluster communication is abnormal. (Time-out error)
Judging condition
Reception from gauge cluster can not receive correctly.
Symptom
Switch operation of gauge cluster can not be done.
Control in the Keep the condition after immediately key-on is operated. event of failure Returned in It returns automatically in normal condition. normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Wiring between gauge cluster and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-600F CN-101F
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-57
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 88 Error code
K014
Trouble
Battery relay contact welded.
Judging condition
The power 24 V is continuously supplied to controller for 40 seconds or more while the key switch ON signal turned OFF.
Symptom
The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF.
Control in the Normal control with key switch OFF. event of failure Returned in Turn key switch ON. normal condition Or when the power supply 24 V to mechatro controller is stopped. Screen No. Service diagnosis Screen checking screen No.
4
K-1 AIS RELAY 2
4
K-3 KEY SWITCH OFF
Screen No. Checking object
Checking contents and remedy
1
• Battery relay R-1 CN-256F
Turn key switch off and disconnect the connector (CN-256F) on the battery relay coil. If 24 V power lives on battery relay secondary side, check on battery relay for failure and replace it if failed.
2
• Auto idle stop relay 2 R-24 • Alternator relay
Turn off the key switch, and remove the connector (CN-256F) on the battery relay coil side. If power of battery relay on secondary side falls, remove either auto idling stop relay 2 or alternator relay. The failure may be occurred in case where the power falls after the relay was removed, and therefore check on the relay unit and replace it with new one if failed.
R-28
3
• Wiring between auto idle stop relay/alternator relay and When K014 is left displayed with the relay removed. Check that no power 24 V is produced on relay (-) line according to the wiring controller checking procedure and replace it if necessary. CN-109F, CN2-1 When no failure found after checking on wiring and K014 is left displayed • Fuse& relay box Replace fuse/relay box. E-1
4
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-58
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 89 Error code
R014
Trouble
Wiper motor arc prevention relay error.
Judging condition
The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the power source.
Symptom
Wiper does not move.
Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.
25
PREVENT ARC
Service diagnosis Screen checking screen No. Screen No. Checking object 1
2
• Wiper motor arc relay R-31
prevention When error is cancelled after removing wiper motor arc prevention relay, check relay unit for failure, replace it with new one if failed.
• Wiring between wiper motor arc prevention relay and controller CN-109F, CN2-1 • Fuse& relay box E-1
3
Checking contents and remedy
• Mechatro controller
When resistance between relays (1) and (2) is 0
, it is in abnormal condition.
When R014 is left displayed with the relay removed. Check that no power 24 V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring a nd R014 is left displayed. Replace fuse/relay box. Check that the error is corrected after replacement of controller.
T5-1-59
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 90 Error code
R024
Trouble
Wiper motor forward rotation relay error.
Judging condition
The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the power source.
Symptom
Wiper does not move.
Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.
25
CW MOTOR RLY
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay, check relay unit for failure, replace it with new one if failed. relay R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between wiper motor forward rotation relay and When R024 is left displayed with the relay removed. Check that no power 24 V is produced on relay (-) line according to the wiring controller checking procedure and replace it if necessary. CN-109F, CN2-1 When no failure found after checking on wiring and R024 is left displayed. • Fuse& relay box Replace fuse/relay box. E-1
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-60
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 91 Error code
R034
Trouble
Wiper motor reverse rotation relay error.
Judging condition
The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the power source.
Symptom
Wiper does not move after forward rotation.
Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.
25
CCW MOTOR RLY
Service diagnosis Screen checking screen No. Screen No. Checking object
Checking contents and remedy
1
• Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay, check relay unit for failure, replace it with new one if failed. relay R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between wiper motor forward rotation relay and When R034 is left displayed with the relay removed Check that no power 24 V is produced on relay (-) line according to the wiring controller checking procedure and replace it if necessary. CN-109F, CN2-1 When no failure found after checking on wiring a nd R034 is left displayed • Fuse& relay box Replace fuse/relay box. E-1
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-61
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 92 Error code
R044
Trouble
Washer motor relay error.
Judging condition
The mechatro controller output line to washer motor relay is short-circuited with the power source.
Symptom
Washer motor does not move.
Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.
25
MOTOR RELAY
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Washer motor relay R-32
Checking contents and remedy When error is cancelled after removing washer motor relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0
, it is in abnormal condition.
2
• Wiring between washer motor When R044 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring CN-112F, CN2-1 checking procedure and replace it if necessary. • Fuse& relay box When no failure found after checking on wiring and R044 is left displayed Replace fuse/relay box. E-1
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-62
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 93 Error code
R134
Trouble
Swing flasher relay error.
Judging condition
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
Symptom
Right swing flasher does not light.
Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.
22
D13
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Swing flasher relay R-19
Checking contents and remedy When error is cancelled after removing connector (CN-74F) of swing flasher relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (HB) and (HC) is 0 condition.
, it is in abnormal
2
• Wiring between swing flasher When R134 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line (as shown right upper CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-63
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 94 Error code
R144
Trouble
Swing flasher relay error.
Judging condition
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
Symptom
Left swing flasher does not light.
Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.
22
D14
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Swing flasher relay R-19
Checking contents and remedy When error is cancelled after removing connector (CN-74F) of swing flasher relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (HB) and (HC) is 0 condition.
, it is in abnormal
2
• Wiring between swing flasher When R144 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line (as shown right upper CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-64
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 95 Error code
R154
Trouble
Travel alarm relay error.
Judging condition
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
Symptom
Travel alarm does not actuate.
Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.
23
D15
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Travel alarm relay R-8
Checking contents and remedy When error is cancelled after removing of travel alarm relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0
, it is in abnormal condition.
2
• Wiring between travel alarm When R154 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring CN-109F, CN2-2 checking procedure and replace it if necessary. • Fuse & relay box When no failure found after checking on wiring a nd R154 is left displayed. Replace fuse/relay box. E-1
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-65
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 96 Error code
R164
Trouble
Auto idle stop relay 2 relay error.
Judging condition
The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.
Symptom
Power source for mechatro controller often turns off. Auto idle stop relay 2 does not actuate.
Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.
4
K-1 AIS RELAY 2
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• Auto idle stop relay 2 relay R-24
When error is cancelled after removing of auto idle stop relay 2, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0
, it is in abnormal condition.
2
• Wiring between auto idle stop When R164 is left displayed with the relay removed relay 2 and controller Check that no power 24 V is produced on relay (-) line according to the wiring CN-109F, CN2-2 checking procedure and replace it if necessary. • Fuse & relay box When no failure found after checking on wiring and R164 is left displayed. Replace fuse/relay box. E-1
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-66
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 97 Error code
R174
Trouble
Engine forcibly stop relay error.
Judging condition
The mechatro controller output line to engine forcibly stop is short-circuited with the power source.
Symptom
When key switch is turned off but engine does not stop. Engine auto idle stop function does not actuate..
Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.
4
K-3 ENG STOP
Service diagnosis Screen checking screen No. Screen No. 1
Checking object
Checking contents and remedy
• Engine forcibly stop relay R-25
When error is cancelled after removing of engine forcibly stop relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0
2
• Wiring between engine forcibly stop relay and controller CN-109F, CN2-2 • Fuse & relay box E-1
3
• Mechatro controller
, it is in abnormal condition.
When R174 is left displayed with the relay removed Check that no power 24 V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring a nd R174 is left displayed. Replace fuse/relay box. Check that the error is corrected after replacement of controller.
T5-1-67
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
Table 98 Error code
R184
Trouble
Safety lock lever relay error.
Judging condition
The mechatro controller output line to safety lock lever relay is short-circuited with the power source.
Symptom
Safety lock lever timer does not actuate.
Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.
4
K-4 LOCK LEVER
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Safety lock lever relay R-26
Checking contents and remedy When error R184 is cancelled after removing of safety lock lever relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is
, it is in abnormal condition.
2
• Wiring between safety lock lever When R184 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring CN-109F, CN2-2 checking procedure and replace it if necessary. • Fuse & relay box When no failure found after checking on wiring and R184 is left displayed. Replace fuse/relay box. E-1
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-68
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
Table 99 Error code
R214
Trouble
Safety relay error.
Judging condition
The mechatro controller output line to safety relay is short-circuited with the power source.
Symptom
Safety relay does not actuate.
Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.
4
K-2 SAFETY RLY
Service diagnosis Screen checking screen No. Screen No. Checking object 1
• Safety lock lever relay R-26
Checking contents and remedy When error R214 is cancelled after removing of safety relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0
, it is in abnormal condition.
2
• Wiring between safety lock lever When R214 is left displayed with the relay removed relay and controller Check that no power 24V is produced on relay (-) line according to the wiring CN-109F, CN2-2 checking procedure and replace it if necessary. • Fuse & relay box When no failure found after checking on wiring a nd R214 is left displayed. Replace fuse/relay box. E-1
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
T5-1-69
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
[MEMO]
T5-1-70
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
TROUBLESHOOTING BY TROUBLE 1. HYDRAULIC SYSTEM
Preface: The troubleshooting for the failures shown below is explained here. Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number. 1. 2.
All controls do not function/slow Engine down/stalled
3.
Move at lever neutral position
4.
Poor fine operability
5.
Slow boom up, insufficient power
6.
Slow boom down, insufficient power for lifting up body
7.
Slow arm in, insufficient power
8.
Slow independent arm out (in the air)
9.
Slow bucket digging
10. Slow bucket dumping 11. Swing operation not functioned/slow 12. Noise during swing operation 13. Swing on a slope drifts when control lever is in neutral position 14. Swing drifts when swing operation is stopped 15. Slow travel speed/weak 16. Travel deviation 17. Travel 1st/2nd speed not changed 18. Travel parking on a slope is not held 19. Travel does not run straightly when both crawlers and attachment operated simultaneously. 20. Slow breaker (crusher) operation, weak power 21. Option selector valve malfunction: not switched to breaker circuit 22. Option selector valve malfunction: not switched to nibbler circuit
T5-2-1
E215B-E245B
1.
TROUBLESHOOTING (BY TROUBLE)
All controls do not function/slow
No.
Sections
Contents/normal value
Corrective action, others
1
Fuse
Check fuse No.4 (10 A)
If the fuse is blown out, check on the short-circuited section.
2
Safety lever lock switch
Carry out service diagnosis
No.4 K-4 switch: Check action of switch by Push down the lever and it turns on, push tester, or check that the power up and it turns off. voltage is lowered by pushing the lever down.
3
Safety lever lock switching
Check that the Measure both terminals of solenoid solenoid is switched connector. 24 V by pushing the lever correctly down, 0 V by pushing it up
4
Safety lever lock relay
Carry out service diagnosis
5
Pilot pressure sensor
6
Solenoid valve for safety lock lever
Measure pressure About 0 MPa by pushing the lever up, of solenoid A1 port and 4 MPa or more by push it down.
Replace solenoid valve
7
Pilot line filter
Disassemble and check it visually
Clean filter
8
Pilot gear pump
Measure pilot Check that it is 4 MPa or more in high primary pressure at idling gear pump
9
Multi control valve (in Change position case that travel is operable)
10 Actual measuring current value of P1/ P2 unload proportional valve 11
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
12 Actual measuring current value of P1/ P2 pump proportional valve
No.4 K-4 lock lever: Check action of relay by tester Push down the lever and it turns off, push up and it turns on. • Stop engine stop and key is on position. All pilot low pressure sensors are 0 MPa to 0.1 MPa.
Carry out service diagnosis
Carry out service diagnosis.
Check solenoid unit for possible failure. Check harness for possible failure.
Check filter for clogging
Check 5 V power for controller
Check gear pump and the relief valve for possible failure
Since all are blocked due to poor switching performance, check that the lever select pattern is set to the proper position. • No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.3 Boom up full lever & relief
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2 MPa in boom up full lever and high idling operation
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
T5-2-2
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
E215B-E245B
Corrective action, others
13 Secondary pressure Measure the pump of pump proportional proportional valve valve secondary pressure directly in idling operation. (Ports a3, a4)
Check that pump proportional valve Replace proportional valve secondary pressure is 2.7 MPa or more in right (left) travel full lever and high idling operation Right travel: P1 pump proportional valve Left travel: P2 pump proportional valve
14 Main relief pressure Carry out service diagnosis
• See Service Diagnosis Data List Measure the relief pressure Operation No.3 Boom up full lever & relief actually
15
Check set pressure Check that P1 and P2 pump pressures Reset or replace are 32 MPa in boom up full lever, high idling and H mode operation.
16 Pump regulator
Visual check
When removing, free from abnormal Replace resistance against sliding. Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.
17 Pump
Visual check
When removing, inside parts (cylinder Replace block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.
2.
Engine down/stalled Sections
No.
1
Actual measuring current value of P1/ P2 pump proportional valve
2
Contents/normal value Carry out service diagnosis
Corrective action, others
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No. 1 Operation is nil
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 pump proportional valve pressures are within the range of 0.5 to 1.0 MPa in control lever neutral and high idling operation.
Replace proportional valve
3
Pressure sensor of P1, P2 pump
Check pressure
• See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.3 Boom up full lever & relief
Check pressure sensor and replace it if necessary
4
Pump regulator
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.
Replace
5
Pump
Visual check
When removing, inside parts (cylinder Replace block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.
T5-2-3
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
3.
Move at lever neutral position
No. Sections
Contents/normal value
Corrective action, others
1
Pilot pressure sensor
Carry out service diagnosis
Check that targeted pilot pressure of sensor is 0MPa in high idling
Check remote control valve
2
Remote control valve
Check targeted remote control valve
Check that spool is free from abnormal damage and spring is free from breakage
Replace
3
Main spool
Check targeted spool visually
Check that spool is free from abnormal damage and spring is free from breakage
Replace
4
Over load relief valve
Check targeted spool visually
Free from dust entered in port relief valve. Seat is free from abnormality
Replace
5
Lock valve poppet Check targeted (in case of boom and poppet visually arm)
Seat is free from abnormality
Replace
6
Lock valve selector Exchange lock (in case of boom and valve selector of arm) boom/arm and boom/arm
Check that the trouble is reversed
Replace
7
Holding valve spool Check that smooth for boom sliding of spool in (in case of boom) sleeve
Free from abnormal resistance against sliding
Replace Do not pull spool out of sleeve forcibly.
8
Holding valve relief valve for boom (in case of boom)
Check targeted spool visually
Filter free from abnormal contamination Replace
9
Cylinder
Check targeted cylinder visually
Make sure of no problem of seals by disassembling and investigation
4.
Replace cylinder or seals
Poor fine operability
No. Sections
Contents/normal value
Corrective action, others
1
Pressure sensor
Carry out service diagnosis
• See Service Diagnosis Data List Replace pressure sensor Operation No. 1 Operation is nil • All low pressure sensors are 0MPa to 0.1 MPa
2
Actual measuring current value of P1/ P2 unload proportional valve
Carry out service diagnosis
• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No. 1 Operation is nil
3
Secondary pressure Measure the of unload proportional valve proportional valve secondary pressure directly at the ports A7 and A8 of 8 sections solenoid block
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that P1/P2 unloads secondary Replace proportional valve pressures is within the range of 2.7 MPa or more in control lever neutral and high idling operation
T5-2-4
TROUBLESHOOTING (BY TROUBLE) No. Sections
E215B-E245B
Contents/normal value
Corrective action, others
Carry out service diagnosis
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No. 1 Operation is nil
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
4
Actual measuring current value of P1/ P2 pump proportional valve
5
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly. (Ports a3, a4)
Check that P1/P2 pump proportional valve pressures are within the range of 0.5 to 1.0 MPa in control lever neutral and high idling operation
Replace proportional valve Check regulator
6
Command current Carry out service value of short-circuit diagnosis.
• No.15 D-15 • See Service Diagnosis Data List Operation No. 1 Operation is nil.
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
7
Secondary pressure Measure the Control lever is neutral, high idling and of proportional valve secondary pressure secondary pressure is within the range in short-circuit valve. of proportional of 0.5 -1.0 MPa. valve in short-circuit valve directly. (G Port)
Replace proportional valve.
8
Slow return check Visual check valve of pilot line (in case of boom up or arm out)
Check that slow return check valve installed on pilot line is free from dust entered
Clean and replace
9
Short-circuit valve spool.
When removing, free from abnormal resistance against free from abnormal damage, etc on outside surface Spring is free from breakage, damage, etc.
Replace (Check on the casing site for damage).
5.
Visual check
Slow boom up, insufficient power
No. Sections
Contents/normal value
Corrective action, others
1
Boom up pressure sensor
Carry out service diagnosis
• See Service Diagnosis Data List Check and replace pressure Operation No.3 boom up full lever and sensor relief Check remote control valve
2
Remote control valve
Measure directly remote control pressure of boom up
Check that pressure is 3.0 MPa or more Check remote control valve in boom up full lever and high idling When equipped with multi operation control valve, check it while changing lever pattern
3
Pump pressure sensor
Carry out service • See Service Diagnosis Data List diagnosis for P1, P2 Operation No.4 boom up full lever and pump pressures in in operation operation.
When there is difference between P1 and P2 pump pressures, check high pressure sensor.
4
Actual measuring current value of P1/ P2 unload proportional valve
Carry out service diagnosis
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.3 Boom up full lever & relief
T5-2-5
E215B-E245B
No. Sections
TROUBLESHOOTING (BY TROUBLE) Contents/normal value
Corrective action, others
5
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary pressures are within the range of 0.5~1.2 MPa in boom up full lever and high idling operation
Replace proportional valve
6
Actual measuring current value of P1/ P2 pump proportional valve
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.4 boom up full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
7
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are within the range of 1.8 to 3.0 MPa in boom up full lever and high idling operation
8
P2 by-pass cut valve Visual check Only P2 pressure is low.
No problem for sliding ability of main Clean and replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)
9
Remote control valve
Check targeted remote control valve
Check that spool is free from abnormal damage and spring is free from breakage
Replace
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
Conflux check valve Visual check Only P2 pressure is high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
13 Boom spool Visual check Only P1 pressure is high.
When removing, free from abnormal resistance against sliding Spring is free from breakage.
Replace (Check on the casing side for damage)
14 Check boom spool Disassembly and and recirculation investigation Only P1 pressure is low.
Free from abnormal resistance against sliding Spring is free from breakage.
Replace spool assembly
15
When removing, free from abnormal resistance against sliding Spring is free from breakage. Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
10 Lock valve poppet Both P1 and P2 pressures are low. 11
12 Holding valve for boom (poppet) Both P1 and P2 pressures are high.
Carry out service diagnosis
Conflux spool Visual check Only P2 pressure is high.
T5-2-6
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
No. Sections
Contents/normal value
16
Main relief valve Relief pressure is low.
Check set pressure • See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
17
Over load relief valve Relief pressure is low.
Visual check (Head Pressure is 32 MPa or more in boom up When only relief pressure of side) full lever and high idling. Free from dust boom up is low, replace valve entered in over load relief valve. Seat is free from abnormality
6.
Corrective action, others
Slow boom down, insufficient power for lifting up body
No. Sections
Contents/normal value
Corrective action, others
1
Boom down pressure sensor
Carry out service diagnosis
Check and replace pressure sensor. Check remote control valve.
2
Remote control valve
Measure remote Check that pressure is 3.0 MPa or more Check remote control valve control pressure of in boom down full lever and high idling When equipped with multi boom down directly operation control valve, check it while changing lever pattern.
3
Actual measuring current value of P1 unload proportional valve
Carry out service diagnosis
4
Secondary pressure Measure the of P1 unload proportional valve proportional valve secondary pressure directly at the ports A7 of 8 sections solenoid block.
Check that P1 unload secondary Replace proportional valve pressures are within the range of 0.8 to 1.2 MPa in boom down full lever and high idling operation
5
Actual measuring current value of P1 pump proportional valve
• No.9 E-1 P1 pump • See Service Diagnosis Data List Operation No.5 boom down full lever & in operation
6
Secondary pressure Measure the pump of P1 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1 pump proportional valve Replace proportional valve pressures are within the range of 2.0 to 2.5 MPa in boom down full lever and high idling operation
7
Actual measuring current value of travel straight proportional valve
Check that the value is not change • Check pressure sensor of regardless of operation travel • See Service Diagnosis Data List • In case where the reading is Operation No. 1 Operation is nil largely differed from the Operation No.18 Travel right full lever actually measured value, & idling check proportional valve Operation No.19 Travel left full lever & and controller for possible idling failure.
Carry out service diagnosis
Carry out service diagnosis
• See Service Diagnosis Data List Operation No.5 boom down full lever & in operation
P1 unload valve (cut valve) • See Service Diagnosis Data List Operation No.5 boom down full lever & in operation
T5-2-7
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
E215B-E245B
No. Sections
TROUBLESHOOTING (BY TROUBLE)
Contents/normal value
Corrective action, others
8
Travel straight Measure directly proportional valve the travel straight secondary pressure proportional valve secondary pressure.
High idling pressure is 0.8 MPa or less regardless neutral/operation
9
Actual measuring current value of short-circuit valve.
Check that the value is not change • Check pressure sensor of regardless of operation No 15 D-15 travel. • See Service Diagnosis Data List • In case where the reading is Operation No. 1 Operation is nil. largely differed from the Operation No.18 travel right full lever actually measured value, & idling. Operation No.19 travel left full check proportional valve lever & idling and controller for possible failure.
Carry out service diagnosis
Replace proportional valve
10 Secondary pressure Measure directly of proportional valve the travel straight in short-circuit valve proportional valve secondary pressure. (G Port)
High idling pressure is 0.8 MPa or less regardless neutral/operation
Replace proportional valve
11
Check targeted remote control valve
Check that spool is free from abnormal damage and spring is free from breakage
Replace
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
13 Holding valve Visual check (poppet) Boom down is slow.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
14 Boom spool Visual check Boom down is slow.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
15 Check boom spool Disassembly and and recirculation investigation Machine can not be lifted by supporting with boom.
Free from abnormal resistance against sliding Spring is free from breakage.
Replace spool assembly
16 short-circuit valve spool.
When removing, free from abnormal resistance against free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing site for damage).
Remote control valve
12 Lock valve poppet Boom down is low.
Visual check.
T5-2-8
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
No. Sections
Contents/normal value
17
Main relief valve Relief pressure is low.
Check set pressure • See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
18
Over load relief Visual check valve Machine can not be lifted by supporting with boom.
7. No.
Corrective action, others
Free from dust entered in port relief valve. Seat is free from abnormality
Replace
Slow arm in, insufficient power Sections
Contents/normal value
Corrective action, others
1
Arm in pressure sensor
Carry out service diagnosis
• See Service Diagnosis Data List Operation No.6 arm in full lever and relief
2
Remote control valve pressure
Measure directly remote control pressure of arm in
Check that pressure is 3.0 MPa or more Check remote control valve in arm in full lever and high idling When equipped with multi operation control valve, check it while changing lever pattern
3
Pump pressure sensor
Carry out service • See Service Diagnosis Data List diagnosis for P1, P2 Operation No.7 arm in full lever and in pump pressures in operation operation.
When there is difference between P1 and P2 pump pressures, check high pressure sensor
4
Actual measuring current value of P1/ P2 unload proportional valve
Carry out service diagnosis
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
5
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2 MPa in arm in full lever and high idling operation.
6
Actual measuring current value of P1/ P2 pump proportional valve
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.7 Arm in full lever & in operation
Carry out service diagnosis
• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.6 Arm in full lever & relief
T5-2-9
Check and replace pressure sensor Check remote control valve
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
E215B-E245B
No.
TROUBLESHOOTING (BY TROUBLE)
Sections
Contents/normal value
Corrective action, others
7
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly. (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are 2.0 MPa or more in arm in full lever and high idling operation. (Secondary pressure is affected by oil temperature and attachment weight)
8
Actual measuring Carry out service current value of arm diagnosis in spool 2 proportional valve
• See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.6 Arm in full lever & relief Operation No.7 Arm in full lever & in operation
9
Secondary pressure Measure directly of arm in spool 2 the proportional proportional valve valve secondary pressure at the ports A8 (arm 2 spool) of 8 sections solenoid block.
Check that secondary pressure of Replace proportional valve proportional valve secondary pressures are within the range of following Lever neutral: 0 MPa Motion in the air: 1.7 to 2.2 MPa Arm in relief: 2.5 MPa or more
10 Actual measuring current value of travel straight proportional valve
11
Carry out service diagnosis
Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that the value is not change • Check pressure sensor of regardless of operation travel • See Service Diagnosis Data List • In case where the reading is Operation No. 1 Operation is nil largely differed from the Operation No.18 Travel right full lever actually measured value, & idling check proportional valve Operation No.19 Travel left full lever & and controller for possible idling failure. 0.8 MPa or less in high idling operation Replace proportional valve regardless of neutral/operation
12 Remote control valve
Check targeted remote control valve
Check that spool is free from abnormal damage and spring is free from breakage
13 Main relief valve Relief pressure is low.
Check set pressure • See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
14 Over load relief valve P1, P2 pressure is low.
Visual check (Head Pressure is 32 MPa or more in arm in When only relief pressure of side) and relief. arm in is low, replace valve Free from dust entered in over load relief valve. Seat is free from abnormality
T5-2-10
Replace
TROUBLESHOOTING (BY TROUBLE)
No.
Sections
Contents/normal value
E215B-E245B
Corrective action, others
15
Over load relief valve P1, P2 pressure is low.
Visual check (Rod side)
Pressure is 32 MPa or more in arm out When only relief pressure of and relief. arm out is low, replace valve Free from dust entered in over load relief valve. Seat is free from abnormality.
16
Arm 1 spool P1, P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
17
Arm 2 spool P1, P2 pressure is high or low.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
18 Check arm 2 spool and recirculation Arm in power is poor.
Disassembly and investigation
Free from abnormal resistance against sliding Spring is free from breakage.
Replace spool assembly
19 Check lock valve poppet Both P1, P2 pressures are high.
Visual check
Free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
8. No .
Slow independent arm out (in the air) Sections
Contents/normal value
Corrective action, others
1
Arm out pressure sensor
Carry out service diagnosis
• See Service Diagnosis Data List Check and replace pressure Operation No.8 arm out full lever and sensor relief Check remote control valve
2
Remote control valve
Measure directly Check that pressure is 3.0 MPa or more Check remote control valve remote control in arm out full lever and high idling When equipped with multi pressure of arm out operation control valve, check it while changing lever pattern
3
Pump pressure sensor
Carry out service • See Service Diagnosis Data List diagnosis for P1, P2 Operation No.9 arm out full lever and pump pressures in in operation operation.
When there is difference between P1 and P2 pump pressures, check high pressure sensor
4
Actual measuring current value of P1/ P2 unload proportional valve
Carry out service diagnosis
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.8 Arm out full lever & relief
T5-2-11
E215B-E245B
No .
TROUBLESHOOTING (BY TROUBLE)
Sections
Contents/normal value
Corrective action, others
5
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2 MPa in arm out full lever and high idling operation
6
Actual measuring current value of P1/ P2 pump proportional valve
• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.9 Arm out full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
7
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 pump proportional valve pressures are within the range of 1.5 to 2.7 MPa in arm out full lever and high idling operation (Secondary pressure is affected by oil temperature and attachment weight)
Replace proportional valve
8
Actual measuring current value of travel straight proportional valve
Check that the value is not change • Check pressure sensor of regardless of operation travel • See Service Diagnosis Data List • In case where the reading is Operation No. 1 Operation is nil largely differed from the Operation No.18 Travel right full lever actually measured value, & idling check proportional valve Operation No.19 Travel left full lever & and controller for possible idling failure.
9
Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Carry out service diagnosis
Carry out service diagnosis
0.8 MPa or less in high idling operation Replace proportional valve regardless of neutral/operation
10 Remote control valve
Check targeted remote control valve
11
Check set pressure • See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
Main relief valve Relief pressure is low.
12 Over load relief valve P1, P2 pressure is low.
Visual check (Rod side)
13 Arm 1 spool Visual check P2 pressure is high.
Check that spool is free from abnormal damage and spring is free from breakage
Replace
Pressure is 32 MPa or more in arm out When only relief pressure of and relief. arm out is low, replace valve Free from dust entered in over load relief valve. Seat is free from abnormality When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
T5-2-12
Replace (Check on the casing side for damage)
TROUBLESHOOTING (BY TROUBLE) No . 14
Sections
Contents/normal value
Arm 2 spool Visu isual check P1 pressure is high.
E215B-E245B
Corrective action, others
When removi oving, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
15 Chec Checkk arm arm 2 spo spoo ol and recirculation Both P1, P2 pressures are low.
Disassembly and investigation (spring side)
Free from abnormal resistance against sliding Spring is free from breakage.
Replace spool assembly
16 Chec Checkk loc lockk val valve ve poppet Both P1, P2 pressures are high.
Visu isual ch check
Free frfrom ab abnormal re resist istance ag against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
9. Slow Slow bu bucket cket di diggin gging g No. Sections
Contents/normal value
Corrective action, others
1
Bucket digging pressure sensor
Carry out service diagnosis
• See Service Service Diagnosi Diagnosiss Data Data List List Operation No.12 bucket digging full lever and relief
Check and replace pressure sensor Check remote control valve
2
Remote control valve
Measure directly remote control pressure of bucket digging
Check that pressure is 3.0M Pa or more Check remote control valve in bucket digging full lever and high When equipped with multi idling operation control valve, check it while changing lever pattern
3
Pump pressure sensor
Carry out service • See Service Service Diagnosi Diagnosiss Data Data List List diagnosis for P1, P2 Operation No.13 Bucket digging full pump pressures in lever and in operation operation.
When there is difference between P1 and P2 pump pressures, check high pressure sensor
4
Actual me measuring current value of P1/ P2 unload proportional valve
Carry out service diagnosis
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
5
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2 MPa in bucket digging full lever and high idling operation
6
Actual me measuring current value of P1/ P2 pump proportional valve
• No.9 No.9 E-1 E-1 P1 P1 pum pump p E-2 P2 pump • See Service Service Diagnosi Diagnosiss Data Data List List Operation No.13 Bucket digging full lever & in operation
7
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Carry out service diagnosis
• No.8 D-1 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Service Diagnosi Diagnosiss Data Data List List Operation No.12 Bucket digging full lever & relief
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that P1 pump proportional valve Replace proportional valve pressures is 2.7 MPa or more and P2 pump proportional valve pressure is 1.6 to 2.2 MPa in bucket digging full lever and high idling operation. T5-2-13
E215B-E245B
TROUBLESHOOTING (BY TROUBLE)
No. Sections
Contents/normal value
8
Attachment bo boost solenoid command
Carry out service diagnosis
No.3 POWER BOOST Check harness Bucket digging COMP OFF, OFF, MEAS OFF Replace solenoid valve
9
Attachment bo boost solenoid secondary pressure
Measure switching valve secondary pressure
Check that pressure is 0 MPa in bucket Replace solenoid valve digging full lever and high idling operation
Carry out service diagnosis
• See Service Service Diagnosi Diagnosiss Data Data List List Operation No.12 Bucket digging full lever & relief
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Seco Second ndar aryy pres pressu sure re Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Check that travel straight secondary pressure is 2.7 MPa or more in bucket digging full lever and high idling operation
Replace proportional valve
10 Actu Actual al meas measur urin ing g current value of travel straight proportional valve 11
Corrective action, others
12 P2 by-p by-pas asss cut cut valv valve e Visual check Only P2 pressure is low.
No problem for sliding ability of main ain Clean or replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)
13 Chec Checkk str strok oke e lim limit iter er Visual ch check Both P1, P2 pressures are high.
When pi piston is is re removed fr from co cover, itit is is Replace free from abnormal resistance against (Check on the casing side for sliding damage.) Free from abnormal damage, etc on outside surface
14 Rem Remote ote con conttrol rol valve
Check targeted remote control valve
Check that spool is free from abnormal damage and spring is free from breakage
15
Check se set pr pressure • See Se Service Di Diagnosis Da Data Li List Reset or replace Operation No.3 Boom up full lever and relief
Main re relief va valve
Replace
16 Trave ravell stra straig ight ht spo spool ol Visual check P2 pressure is high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
17
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
Check targeted spool visually
Free from dust entered in over load relief Replace valve. Seat is free from abnormality. abnormality.
Bucket spool Both P1, P2 pressures are high.
18 Over Over load load reli relief ef valve
T5-2-14
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
10. 10. Slow Slow buc bucke kett dump dump No.
Sections
Contents/normal value
Corrective action, others
1
Bucket dump pressure sensor
Carry out service diagnosis
• See Service Service Diagnosi Diagnosiss Data Data List List Operation No.14 Bucket dump full lever and relief
2
Remote control valve
Measure directly remote control pressure of bucket dump
Check that pressure is 3.0 MPa or more Check remote control valve in bucket dump full lever and high idling When equipped with multi operation control valve, check it while changing lever pattern
3
Pump pressure sensor
Carry out service • See Service Service Diagnosi Diagnosiss Data Data List List diagnosis for P1, P2 Operation No.15 Bucket dump full pump pressures in lever and in operation operation.
When there is difference between P1 and P2 pump pressures, check high pressure sensor
4
Actual me measuring current value of P1/ P2 unload proportional valve
Carry out service diagnosis
• No.8 D-1 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Service Diagnosi Diagnosiss Data Data List List Operation No.14 Bucket dump full lever & relief
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
5
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary pressures are within the range of 0.5~1.2 MPa in bucket dump full lever and high idling operation. Replace proportional valve
Replace proportional valve
6
Actual me measuring current value of P1/ P2 pump proportional valve.
• No.9 No.9 E-1 E-1 P1 P1 pum pump p E-2 P2 pump • See Service Service Diagnosi Diagnosiss Data Data List List Operation No.15 Bucket dump full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
7
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1 pump proportional valve Replace proportional valve pressures is 2.7 MPa or more and P2 pump proportional valve pressure is 0.9 to 1.4 MPa in bucket dump full lever and high idling operation.
8
Actual me measuring current value of travel straight proportional valve
• See Service Service Diagnosi Diagnosiss Data Data List List Operation No.14 Bucket dump full lever & relief
9
Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Carry out service diagnosis
Carry out service diagnosis
Check and replace pressure sensor Check remote control valve
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that travel straight secondary Replace proportional valve pressure is 2.7 MPa or more in bucket dump full lever and high idling operation
T5-2-15
E215B-E245B
No.
TROUBLESHOOTING (BY TROUBLE)
Sections
Contents/normal value
Corrective action, others
10 P2 by-p by-pas asss cut cut valv valve e Visual check Only P2 pressure is low.
No problem for sliding ability of main ain Clean and replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBP2 port.)
11
Free from abno bnormal damage and wea wear on outside of piston inside cover
Replace (Check on the casing side for damage.)
Check that spool is free from abnormal damage and spring is free from breakage
Replace
Chec Checkk str strok oke e lim limit iter er Visual check Pilot pressure is low.
12 Rem Remote ote con conttrol rol valve
Check targeted remote control valve
13 Main ain rel relie ieff val valve ve Relief pressure is low.
Check Check set set pressu pressure re • See Servic Service e Diagn Diagnosi osiss Data Data List Reset or replace Operation No.3 Boom up full lever and relief
14 Trave ravell stra straig ight ht spo spool ol Visual check P2 pressure is high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
15
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
Check targeted spool visually
Free from dust entered in over load relief Replace valve. Seat is free from abnormality. abnormality.
Bucket spool Both P1, P2 pressures are high.
16 Over Over load load reli relief ef valve
11. Swing operation operation not functio functioned/sl ned/slow ow No. Sections
Contents/normal value
Corrective action, others
1
Swing pressure sensor
Carry out service diagnosis
• See Service Service Diagnosi Diagnosiss Data Data List List Operation No.11 Swing full lever and in operation
Check and replace pressure sensor Check remote control valve
2
Remote control valve
Measure directly remote control pressure of swing
Check that pressure is 3.0 MPa or more Check remote control valve in boom up full lever and high idling When equipped with multi operation control valve, check it while changing lever pattern
3
Swing parking brake Carry out service solenoid diagnosis
No.3 F-2 SWING-BRAKE Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF
Check swing pressure sensor Check harness
4
Swing parking brake Measurement of solenoid solenoid valve A2 port
Lever neutral: 0 MPa In operation: 4 MPa or more
Replace solenoid valve
T5-2-16
TROUBLESHOOTING (BY TROUBLE)
No. Sections
Contents/normal value
E215B-E245B
Corrective action, others
5
Shuttle valve Visu isual ch check Pilot pressure is low.
No co contamination on on sp spool co cover (short Clean or replace side) and orifice No damage on spool cover (long side) and shuttle
6
Pump pressure sensor
Carry out service diagnosis for P2 pump pressures in operation
• See Service Service Diagnosi Diagnosiss Data Data List List Operation No.11 Swing full lever and in operation
Check high pressure sensor
7
Actual me measuring current value of P2 unload proportional valve
Carry out service diagnosis
• No.8 D-2 D-2 P2 unload valve (cut valve) • See Service Service Diagnosi Diagnosiss Data Data List List Operation No.11 Swing full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
8
Secondary pressure Measure the of P2 unload proportional valve proportional valve secondary pressure directly at the ports A5 of 8 sections solenoid block
Check that P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2 MPa in swing full lever and high idling operation
9
Actual me measuring current value of P2 pump proportional valve
• No.9 No.9 E-2 E-2 P2 P2 pum pump p • See Service Service Diagnosi Diagnosiss Data Data List List Operation No.11 Swing full lever & in operation
Carry out service diagnosis
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
10 Seco Second ndar aryy pres pressu sure re Measure the pump Check that P2 pump proportional valve Replace proportional valve of P2 pump proportional valve pressure is 2.7 MPa or more in swing full proportional valve secondary pressure lever and high idling operation directly (Ports a3, a4) 11
Actu Actual al meas measur urin ing g current value of travel straight proportional valve (Check this trouble by only swing operation)
12 Seco Second ndar aryy pres pressu sure re of travel straight proportional valve (Check this trouble by only swing operation)
Carry out service diagnosis
Check that the value is not change • Check Check press pressure ure sens sensor or of regardless of operation travel • See Service Service Diagnosis Diagnosis Data List • In case case where where the the readi reading ng is Operation No. 1 Operation is nil largely differed from the Operation No.18 Travel right full lever actually measured value, & idling check proportional valve Operation No.19 Travel left full lever & and controller for possible idling failure.
Measure directly the proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
0.8 MPa or less in high idling operation regardless of neutral/operation
T5-2-17
Replace proportional valve
E215B-E245B
No. Sections
TROUBLESHOOTING (BY TROUBLE)
Contents/normal value
Corrective action, others
13 Comm Comman and d cur current rent Carry out service value of short-circuit. diagnosis
Check that the value is not change • Check Check pressu pressure re sensor sensor of regardless of operation No 15 D-15 travel. • See Service Service Diagnosi Diagnosiss Data Data List List • In case case where where the the readi reading ng is Operation No. 1 Operation is nil. largely differed from the Operation No.18 travel right full lever actually measured value, & idling. Operation No.19 travel left full check proportional valve lever & idling and controller for possible failure.
14 Seco Second ndar aryy pres pressu sure re Measure directly of proportional valve the secondary in short-circuit valve. pressure of the proportional valve in short-circuit valve. (G Port)
0.8 MPa or less in high idling operation regardless of neutral/operation.
Replace proportional valve.
15 Rem Remote ote con conttrol rol valve
Check that spool is free from abnormal damage and spring is free from breakage
Replace
16 Trave ravell stra straig ight ht spo spool ol Visual check P2 pressure is low.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
17
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
Check targeted remote control valve
Swing sp spool Visual check P2 pressure is high.
18 Shor Shortt-ci circ rcui uitt valve valve spool.
Visual ch check.
19 Swin Swing g reli relief ef valv valve e Relief pressure is low.
Check Check set set pressu pressure re • See Servic Service e Diagn Diagnosi osiss Data Data List Reset or replace Operation No.10 Swing full lever and relief
20
Visual check
Swing motor
• When re removing, fr free fr from ab abnormal Replace (Check on the casing resistance against free from abnormal site for damage). damage, etc on outside surface Spring is free from breakage.
Inner parts (cylinder block, piston, valve Replace brake etc) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)
21 Swing wing red reduc ucti tion on gear oil
Take sample oil Sampling oil does not include a lot of from swing metal powder. reduction gear drain
Disassemble and inspect reduction gear
22
Visual check
Replace
Swing reduction
Tooth surface is not worn abnormally and is not chipped.
T5-2-18
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
12. Noise during swing operation No. Sections
Contents/normal value
Corrective action, others
1
Carry out service No.3 F-2 SWING-BRAKE diagnosis Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF
Check swing pressure sensor Check harness
Measurement of Lever neutral: 0 MPa solenoid valve A2 In operation: 4 MPa or more port
Replace solenoid valve
Swing parking brake solenoid
2
3
Boost check valve Visual check (Sound of cavitation at stopping)
When removing, free from abnormal Replace resistance against sliding Spring is free from breakage.
4
By-pass check valve (Sound of cavitation at stopping)
Visual check
When removing, free from abnormal Replace resistance against sliding Spring is free from breakage.
5
Swing motor (Brake valve/ friction plate)
Visual check
Disassemble and inspect abnormal Replace wear and scuffing
6
Swing motor piston
Visual check
When removing, free from abnormal Replace resistance against sliding Spring is free from breakage.
7
Swing reduction gear oil
Take sample oil from swing reduction gear drain.
Sampling oil does not include a lot of Disassemble and inspect metal powder. reduction gear
8
Swing reduction
Visual check
Tooth surface has no abnormally worn and chipped.
Replace
13. Swing on a slope drifts when control lever is in neutral position No.
Sections
Contents/normal value
1
Swing sensor
2
Remote valve
3
Swing parking brake Carry out service No.3 F-2 SWING-BRAKE solenoid diagnosis Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF
4
Corrective action, others
pressure Carry out service • •Engine stop & starter key ON Check and replace pressure diagnosis All pilot low pressure sensors are sensor within range of 0 to 0.1 MPa. control Check remote valve
targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage
Measurement of Lever neutral: 0 MPa solenoid valve A2 In operation: 4 MPa or more port
T5-2-19
Check swing pressure sensor Check harness Check parking brake release switch Replace solenoid valve
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
No.
Sections
Contents/normal value
Corrective action, others
5
Swing motor Visual check (Brake valve/friction plate)
Disassemble and inspect abnormal Replace wear and scuffing
6
Parking brake
Piston and friction plate do not have Replace abnormal resistance against sliding Free from spring damage
Visual check
14. Swing drifts when swing operation is stopped No .
Sections
Contents/normal value
1 Shuttle valve Visual check Pilot pressure is low 2 Swing sensor
No contamination on spool cover Clean or replace (short side) and orifice. No damage on spool cover (long side) and shuttle.
pressure Carry out service • Engine stop & starter key ON Replace pressure sensor diagnosis All pilot low pressure sensors are within range of 0 to 0.1 MPa.
3 Swing relief valve Check pressure Relief pressure is low.
set • See Service Diagnosis Data List Reset or replace Operation No.10 Swing full lever and relief
4 Anti-reaction valve Visual check
5 Remote valve
Corrective action, others
control Check remote valve
6 Swing motor
Free from dirt entering Clean or replace Sliding part should be free from foreign matter entering, abnormal damage and wear.
targeted Check that spool is free from Replace control abnormal damage and spring is free from breakage
Visual check
Inner parts (cylinder block, piston, Replace valve brake etc) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)
15. Slow travel speed/weak No.
Sections
Contents/normal value
Corrective action, others
1
Travel right and left Carry out service • See Service Diagnosis Data List Check and replace pressure pressure sensor diagnosis Operation No.18 Travel right full lever sensor and idling Check remote control valve Operation No.19 Travel left full lever and idling
2
Remote valve
control Measure directly Check that pressure is 2.1 MPa or more Check remote control valve remote control in travel right (left), forward (reverse) full pressure of travel lever and high idling operation right and left
T5-2-20
TROUBLESHOOTING (BY TROUBLE)
No.
Sections
Contents/normal value
E215B-E245B
Corrective action, others
3
Actual measuring Carry out service • No.9 D-1 P1 unload valve (cut valve) current value of P1/ diagnosis D-1 P2 unload valve (cut valve) P2 unload • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
4
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
5
Actual measuring Carry out service • No.9 E-1 P1 pump current value of P1/ diagnosis E-2 P2 pump P2 pump • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
6
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
7
Actual measuring Carry out service Check that the value is not change • Check voltage of low current value of diagnosis regardless of operation pressure sensor other than travel straight • See Service Diagnosis Data List sensor for travel proportional valve Operation No. 1 Operation is nil • In case where the reading is Operation No.18 Travel right full lever largely differed from the & idling actually measured value, Operation No.19 Travel left full lever & check proportional valve idling and controller for possible failure
8
Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve of travel straight the proportional regardless of neutral/operation proportional valve valve secondary pressure
9
Command current Carry out service Check that the value is not change • Check pressure sensor of value of short-circuit diagnosis regardless of operation No 15 D-15 travel. • See Service Diagnosis Data List • In case where the reading is Operation No. 1 Operation is nil. largely differed from the Operation No.18 travel right full lever actually measured value, & idling. Operation No.19 travel left full check proportional valve lever & idling and controller for possible failure.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 unload): 0.5 to 1.0 MPa Travel left (P2 unload): 0.5 to 1.0 MPa In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.7 MPa or more Travel left (P2 pump): 2.7 MPa or more
10 Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve. of proportional valve the secondary regardless of neutral/operation. in short-circuit valve. pressure of the proportional valve in short-circuit valve. (G Port)
T5-2-21
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
No.
Sections
11 Remote valve
Contents/normal value
control Check remote valve
targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage Check sealing ability of shuttle valve and entry of dust in orifice
12 Travel straight spool Visual check P1 pressure is high.
13 Travel spool Visual check targeted spool Pump pressure is high. 14 short-circuit spool.
valve Visual check.
When removing, free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface Spring is free from breakage. of When removing, free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface Spring is free from breakage. When removing, free from abnormal Replace (Check on the casing resistance against free from abnormal site for damage). damage, etc on outside surface Spring is free from breakage
15 Travel motor relief Check set pressure Check P1 and P2 pump pressures are valve 32 MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling 16 Travel motor
17 Parking brake travel motor
18 Travel gear oil
Corrective action, others
If P1 is low, right travel motorÅfs relief valve is failed. If P2 is low, left travel motorÅfs relief valve is failed.
Visual check
Inner parts (piston, cylinder block, valve Replace plate, brake valve spool) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)
in Visual check
When removing, free from abnormal Replace resistance against sliding No sticking on friction plate and separator plate
reduction Take sample oil Sampling oil does not include a lot of Disassemble and from travel metal powder. reduction gear reduction gear drain
19 Travel reduction
Visual check
Tooth surface is not worn abnormally Replace and is not chipped.
T5-2-22
inspect
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
16. Travel deviation No.
Sections
Contents/normal value
Corrective action, others
1
Travel right and left Carry out service • See Service Diagnosis Data List Check and replace pressure pressure sensor diagnosis Operation No.18 Travel right full lever sensor and idling Check remote control valve Operation No.19 Travel left full lever and idling
2
Remote valve
3
Actual measuring Carry out service Check that the value is not change • Check voltage of low current value of diagnosis regardless of operation pressure sensor other than travel straight • See Service Diagnosis Data List sensor for travel proportional valve Operation No. 1 Operation is nil • In case where the reading is Operation No.18 Travel right full lever largely differed from the & idling actually measured value, Operation No.19 Travel left full lever & check proportional valve idling and controller for possible failure.
4
Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve of travel straight the proportional regardless of neutral/operation proportional valve valve secondary pressure
5
Actual measuring Carry out service • No.8 D-1 P1 unload valve (cut valve) current value of P1/ diagnosis D-1 P2 unload valve (cut valve) P2 unload • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
6
Secondary pressure Measure the of P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
7
Actual measuring Carry out service • No.9 E-1 P1 pump current value of P1/ diagnosis E-2 P2 pump P2 pump • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
8
Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
control Measure directly Check that pressure is 2.1 MPa or more Check remote control valve remote control in travel right (left), forward (reverse) full pressure of travel lever and high idling operation right and left
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 unload): 0.5 to 1.0 MPa Travel left (P2 unload): 0.5 to 1.0 MPa In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.7 MPa or more Travel left (P2 pump): 2.7 MPa or more
T5-2-23
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
Sections
No.
9
Contents/normal value
Exchange P1 for P2 Exchange delivery Check the direction of deviation pipe of P1 for P2
10 Remote valve
control Check remote valve
12 Travel spool Visual check targeted spool Pump pressure is high.
When removing, free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface Spring is free from breakage of When removing, free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface Spring is free from breakage
13 Travel motor relief Check set pressure Check P1 and P2 pump pressures are valve 32 MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling
15 Travel gear oil
If the direction is changed, inspect a pump. If the direction is not changed, inspect a valve and travel unit.
targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage Check sealing ability of shuttle valve and entry of dust in orifice
11 Travel straight spool Visual check P1 pressure is high.
14 Travel motor
Corrective action, others
Visual check
If P1 is low, right travel motorÅfs relief valve is failed. If P2 is low, left travel motorÅfs relief valve is failed. Replace as necessary
Inner parts (piston, cylinder block, valve Replace plate, brake valve spool) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)
reduction Take sample oil Sampling oil does not include a lot of Disassemble and from travel metal powder. reduction gear reduction gear drain
16 Travel reduction
Visual check
Tooth surface is not worn abnormally Replace and is not chipped.
17 Pump regulator
Visual check
When removing, free from abnormal Replace resistance against sliding Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.
18 Pump
Visual check
When removing, inside parts (cylinder Replace block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.
T5-2-24
inspect
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
17. Travel 1st/2nd speed notchanged (In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the speed may sometimes does not change from 1st to 2nd because this machine equips the function of automatic speed change.) No.
Sections
Contents/normal value
Corrective action, others
1
Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed switching solenoid diagnosis No.3 F-3 1/2-TRAVEL Lever neutral COMP OFF, MEAS OFF Travel operation COMP ON, MEAS ON
Check pressure sensor Check harness Check travel 1/2 speed switch on gauge cluster
2
Travel 1/2 speed Measure A3 port Lever neutral: 0 MPa switching solenoid pressure on In operation: 4 MPa or more solenoid valve
Replace solenoid valve
3
1/2 speed switching Visual check spool in travel motor
Check that spool is free from abnormal Replace damage and spring is free from (Check on the casing side for breakage damage)
4
1/2 speed switching Visual check orifice in travel motor
Free from entry of dust
5
Tilting piston travel motor
Free from abnormal wear on piston and Replace seal (Check on the casing side for damage)
in Visual check
Remove dust or replace
18. Travel parking on a slope is not held No.
Sections
Contents/normal value
1
Pilot sensor
2
Remote valve
3
Parking brake travel motor
4
Orifice of passage Visual check for parking brake in travel motor
Corrective action, others
pressure Carry out service • Engine stop & starter key switch is ON Check pressure sensor and diagnosis Targeted pilot low pressure sensor is replace as necessary in range of 0 to 0.1 MPa Check remote control valve control Check remote valve
targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage
in Visual check
When removing, free from abnormal Replace resistance against sliding Spring free from breakage, damage, etc. Free from entry of dust
Remove dust or replace
19. Travel does not run straightly when both crawlers and attachment operated simultaneously . No.
1
Sections
Contents/normal value
Corrective action, others
Actual measuring Carry out service No. 8 D-3 S-TRAVEL is should be • Check voltage of low current value of diagnosis COMP 557 mA and MEAS 557±30 mA pressure sensor other than travel straight in both travel full lever and in boom-up travel sensor proportional valve full lever at high idling (Command value • In case where the reading is is changed according to operation. largely differed from the Above mentioned values indicate while actually measured value, boom-up and full lever operation are check proportional valve performed). and controller for possible failure.
T5-2-25
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
No.
Sections
Contents/normal value
Corrective action, others
2
Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure
3
Command current Carry out service No 15 D-15 is should be COMP 530 mA • Check voltage of low value short-circuit diagnosis. and MEAS 530±30 mA in both travel full pressure sensor other than valve lever and in boom-up full lever at high travel sensor. idling • In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
4
Secondary pressure Measure directly Check secondary pressure is within Replace proportional valve. of proportional valve the secondary range of 1.5 to 1.9 MPa in both travel full in short-circuit valve. pressure of the lever and in boom-up full lever at high proportional valve idling. in short-circuit valve. (G Port)
5
Travel straight spool Visual check
When removing, free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface Spring is free from breakage.
6
Short-circuit spool.
When removing, free from abnormal Replace (Check on the casing resistance against free from abnormal site for damage). damage, etc on outside surface Spring is free from breakage.
valve Visual check.
Check secondary pressure is within Replace proportional valve range of 1.7 to 2.1 MPa in both travel full lever and in boom-up full lever at high idling. (Command value is changed according to operation. Above mentioned values indicate while boomup and full lever operation are performed).
20. Slow breaker (crusher) operation, weak power (In case of conflux, check p1 unload/pump and travel straight) No.
Sections
Contents/normal value
Corrective action, others
1
Pressure sensor for Carry out service • See Service Diagnosis Data List Check and replace pressure optional attachment diagnosis Operation No.16 P2 side OPT full sensor lever and relief Check remote control valve
2
Remote valve
3
Actual measuring Carry out service • See Service Diagnosis Data List •In case where the reading is current value of P1/ diagnosis Operation No.16 P2 side OPT full largely differed from the P2 unload lever and relief actually measured value, proportional valve check proportional valve and controller for possible failure.
control Measure directly Check that pressure is 2.1 MPa or more Check remote control valve remote control in optional attachment full lever and high pressure of travel idling operation right and left
T5-2-26
TROUBLESHOOTING (BY TROUBLE) Sections
No.
Contents/normal value
E215B-E245B
Corrective action, others
4
Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve of P1, P2 unload proportional valve pressures are within the range of 0.5 to proportional valve secondary pressure 1.2 MPa directly at the ports A7 and A5 of 8 sections solenoid block
5
Actual measuring Carry out service • See Service Diagnosis Data List • Check voltage of low current value of diagnosis Operation No.16 P2 side OPT full pressure sensor other than travel straight lever & relief sensor for optional proportional valve attachment • In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
6
Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Check that travel straight secondary Replace proportional valve pressure is 2.7 MPa or more in optional attachment full lever and high idling operation
7
P1 by-pass cut valve Visual check Only P1 pressure is low.
No problem for sliding ability of main Clean or replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)
8
Relief pressure
9
Remote valve
Check set pressure • See Service Diagnosis Data List Reset or replace Operation No.16 P2 side OPT full lever and relief (Set value of factory shipment is 24.5 MPa.)
control Check remote valve
targeted Check sealing ability of shuttle valve and Replace control entry of dust in orifice.
10 Travel straight spool Visual check P1 pressure is high.
When removing, free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface Spring is free from breakage.
11 Spool for optional Visual check attachment P1, P2 pressures are high.
When removing, free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface Spring is free from breakage.
12 Over valve
load
relief Check targeted Free from dust entered in over load relief Replace spool visually valve Seat is free from abnormality.
T5-2-27
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
21. Option selector valve malfunction: not switched to breaker circuit. (Indication of failure is displayed. For reference, see "Table47-1 Action of optional se lector solenoid valve") No.
Sections
Contents/normal value Visual check
Corrective action, others
1
N&B selector spool
When removing, free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface Spring is free from breakage
2
N&B solenoid
selector Screw emergency
3
N&B solenoid
selector Carry out service • No.11 F-4 Option selector is B mode diagnosis COMP ON, MEAS ON Spool position BRK Selector switch BRK
4
N&B selector Carry out service • No.16 B-11 Check pressure sensor pressure sensor diagnosis Data List Check harness 3.0 MPa at B mode and 0.0 MPa at A mode
for Check that the error indication is Replace solenoid valve disappeared by turning emergency screw Check solenoid valve Check harness
22. Option selector valve malfunction: not switched to nibbler circuit. (Indication of failure is displayed. For reference, see "Table47-1 Action of optional se lector solenoid valve") No.
Sections
1
N&B selector spool
2
N&B solenoid
Contents/normal value Visual check
Corrective action, others
When removing, free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface Spring is free from breakage.
selector Carry out service • No.11 F-4 Option selector is A mode diagnosis COMP OFF, MEAS OFF Spool position NIB Selector switch NIB
T5-2-28
Check solenoid valve Check harness
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
Table 1 - Action of optional selector solenoid valve Safety Engine lock lever No. SW's condition input
Safety lock lever relay's output
Work mode
Optional selector valve COMP. MEAS.
Selector valve Spool detecting position pressure sensor
1
Running
ON
OFF
A
OFF
Nibbler
Normal
2
Running
ON
OFF
A
ON
Breaker Normal
3
Running
ON
OFF
A
OFF
Breaker Normal
4 5
Running Running
ON ON
OFF OFF
A B
ON ON
Nibbler Normal Breaker Normal
6
Running
ON
OFF
B
OFF
Nibbler
Normal
7
Running
ON
OFF
B
ON
N&B
Normal
8
Running
ON
OFF
B
OFF
9
Running
ON
OFF
—
—
—
Failure
10 Stopping 11 — 12 —
— OFF —
— — ON
— — —
— — —
— — —
— — —
Breaker Normal
T5-2-29
Warning display — "SELECTOR FAILURE" "SELECTOR FAILURE" — — "SELECTOR FAILURE" "SELECTOR FAILURE" — "SELECTOR FAILURE" — — —
Failure diagnosis display
— VALVE [F042] displayed simultaneously VALVE — [F042] displayed — VALVE [F043] displayed simultaneously VALVE — [F043] displayed VALVE [B113] displayed — — —
E215B-E245B
TROUBLESHOOTING (BY TROUBLE)
2. ELECTRIC SYSTEMS 2.1 WIRING CHECKING PROCEDURE
Check for continuity between connector terminals, presence or absences of short-circuit with other wires, and presence or absences of short-circuit with machine body grounding. 1. Checking for disconnection between connectors. (When both ends measurement is easy because of short distance between connectors) Measure the resistance using tester. Pull out opposite connector first. When the resistance is zero (0), it is in normal condition.
CONNECTOR
WIRE
TESTER SM0104
(When both ends measurement is difficult because of long distance between connectors) Measure the resistance using tester. Pull out opposite connector first. Where the resistance is zero (0), if the terminal on one side is connected to frame body grounding with jumper wire, it is in normal condition. The resistance is 1 M or more when the terminal on one side is not connected to frame body grounding with jumper wire, it is in normal condition.
2.
JUMPER WIRE
TESTER FRAME BODY GROUNDING SM0105
Checking for presence or absence of shortcircuit with machine body Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1 M or more, it is in normal condition.
TESTER
FRAME BODY GROUNDING SM0106
3.
Checking for presence or absence of shortcircuit between wirings. Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1 M or more, it is in normal condition.
TESTER SM0107
T5-2-30
TROUBLESHOOTING (BY TROUBLE) 4.
Checking connector terminal for contact Insert male terminal into female terminal unit, and then check that the inserting force is equivalent to other female terminals. If looseness is there, replace the female terminal with new one. Clean the dirt terminal.
E215B-E245B
INSERT
MALE TERMINAL
FEMALE TERMINAL SM0108
ATTENTION
Do not insert the male terminal the thickness differs. It may cause loose connection. 5.
Caution which should be paid in measuring voltage When measuring the power supply to electric equipment at connector position with the grounding terminal contained inside of connector, measure the voltage between grounding inside of connector and power terminal. When measuring the voltage between frame body grounding and power source, the disconnection of wiring to grounding inside of connector cannot be identified. Since the voltage may vary between with connector connected and with connector not connected. Measure the voltage with each connector connected whenever possible.
6.
Checking the general view of connector CRIMPED PART
a. Check the terminal crimped condition. Pull one electric cable with the about 3kg force, and make sure that the cable does not come out of the terminal. When came out, replace the terminal and crimp it again. b. Check connector for imperfect insertion Check that all top ends form a line on the same position as seen from the connector engaged side. When moved along, push it in further through wire inserting hole. c. Check connector for intruding of water. Pull out the connector and check that the inside is free from intruding of water. When water intruding is found, check rubber plug for damage and also that the sealing is fitted properly.
T5-2-31
RUBBER PLUG RECEPTACLE. CONTACT PLUG SEALING (is housed in plug) DOUBLE LOCK PLATE FOR PLUG DOUBLE LOCK PLATE FOR CAP CAP TAB.CONTACT RUBBER PLUG
SM0109
E215B-E245B
TROUBLESHOOTING (BY TROUBLE)
7.
When abnormality occurs at intervals When the abnormality situation can not be reoccurred during checking operation, try the following operations. a. Check that variable of display exists or not on the service diagnosis screen while shaking the harness or giving shock by operating the machine. b. Check that variables of resistance and voltage exist or not using tester while shaking the harness. c. Turn starter switch on and apply electricity continuously, and check it again after the temperature of wiring and equipment was raised.
8.
Checking on body grounding Check attaching bolts of grounding terminal for loosening. And also check that there is no loose connection due to corrosion. There are multiple groundings like centralized grounding box shown in the figure and battery grounding, engine grounding, horn grounding fixed together with horn, body grounding placed on attaching section of boom working light. Block of grounding is located under floor plate of cab.
T5-2-32
SM0110
TROUBLESHOOTING (BY TROUBLE)
2.2 TROUBLE
1. 2.
Engine does not stop. "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
3.
Auto accel does not actuate. (The engine speed does not automatically slow down.)
4.
Auto accel does not actuate. (The engine speed does not automatically speed up.)
5.
Wiper does not function.
T5-2-33
E215B-E245B
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
1.
Engine does not stop.
No .
Sections
Contents/normal value
1 Starter key switch Check signal of No.4 K-3 Key switch starter key switch OFF at starter key switch OFF ON by carrying position out service ON at starter key switch ON position diagnosis. 2 Engine forcible When ON is No.4 K-3 Key switch stop relay displayed with the OFF at starter key switch OFF starter switch position OFF, then pull out ON at starter key switch ON position R-25 engine forcible stop relay and carry out the service diagnosis. 3 Wiring Voltage between 0 V when starter switch is OFF line No.62 among starter switch, engine forcible stop relay, enginestop solenoid and the body grounding
2.
Corrective action, others
Check continuity between terminals of starter switch using tester
Check on engine forcible stop relay
Check harness Check diode D-9 between starter switch and auto idling stop relay 1
"CPU DATA COMMUNICATION ERROR" is displayed on multi display.
No .
Sections
1 Fuse 2 Mechatro controller
3 Wiring
4 Gauge cluster
Contents/normal value
No.1 fuse (5 A)
Not blown fuse
Corrective action, others
Check harness Replace fuse Accel control Engine speed varies according to Check mechatro controller accel potentiometer operation. and replace as necessary (Use remote control because the auto accel function is working.) Transmission See “WIRING CHECKING Repair wiring circuit line No.770 PROCEDURE" from mechatro controller to gauge cluster Gauge cluster Replace gauge cluster
T5-2-34
TROUBLESHOOTING (BY TROUBLE) 3. No .
No .
E215B-E245B
Auto accel does not actuate. (The engine speed does not automatically slow down.) Sections
Contents/normal value
1 Engine coolant Check engine No.2 G-5 WATER TEMP temperature coolant Auto accel does not work in the temperature by temperature -15 °C or less. carrying out Warm up and raise the coolant service diagnosis. temperature to – 15 °C or more 2 Gauge cluster Indication of auto Mark "Display/not display" for auto accel accel switches by auto accel switch operation on gauge cluster. 3 Low pressure Service diagnosis Each control pressure of No.5 and sensor No.6 is in the range of 0~0.1 MPa at control lever neutral position. 4.
Corrective action, others
Replace engine coolant sensor
Replace gauge cluster
Check low pressure sensor
Auto accel does not actuate. (The engine speed does not automatically speed up.) Sections
Contents/normal value
Corrective action, others
1 Low pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor sensor No.6 is raised with control lever operated.
T5-2-35
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
5.
Wiper does not function.
Wiping range of forward and reverse movements
Wiper motor Rise up limit switch's ON range Reverse limit switch's ON range
Rise up (storing) position Upper reversing position Lower reversing position
SM0111
No.
1 2
3
Sections
Contents/normal value
Corrective action, others Fuse Check fuse No.20 Replace fuse SW-19: Service diagnosis No.19 D125 Check wiper interlock switch Wiper interlock Wiper switch display (D125) is OFF with front window closed. and repair it if necessary switch Check according to "WIRING CHECKING PROCEDURE" and repair it if necessary Rise up limit switch Service diagnosis No.25 Wiper system Check according to "WIRING built-in wiper motor CHECKING PROCEDURE" Reverse limit switch Switch action in operation Normal condition
4
Rise up limit switch
ON
OFF
OFF
Reverse limit switch
ON
ON
OFF
R-31: Service diagnosis No.25 Wiper system Arc prevention relay When started by forward rotation: STOP START R-29: OFF ON ON ON ON Arc prevention relay Forward rotation OFF ON ON ON ON Forward rotation relay OFF OFF OFF OFF OFF Reverse rotation relay relay Check that the relay is worked as shown in the table. R-30: * When the limit switch does not change in OFF after 4 seconds Reverse rotation from the wiper startup, turn OFF all relay's outputs. relay
T5-2-36
(STOP) (REVERSE) OFF
(STOP) OFF
(FORWARD)
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
ON
ON
OFF
OFF
Check that the relay is excited. Check relay & fuse box and replace it if necessary.
ON
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
E215B-E245B
1. TROUBLE DIAGNOSIS MODE
The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal output. 1.
Function There are two types of trouble diagnosis mode. 1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and engine system. 2) Trouble diagnosis mode 2: Used to diagnose pilot system. In any mode, with the attachment not operated, both selector valve and proportional valve are automatically actuated, the sensor detects the machine con dition and the mechatro controller identifies the normal condition or failed condition of the system.
2.
How to use and flow chart The operation is performed through gauge cluster. No.1 Select service adjustment select screen. (Switch starter key on while pressing buzzer stop switch an d press select switch three times while pressing buzzer stop switch on the service diagnosis screen No.1.) No.2 Select Trouble diagnosis mode (Move the cursor to the desired position with screen change switch "
", and press the select switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2" (Move the cursor to the desired position with screen change switch "
", and press the select switch.)
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.
T5-3-1
E215B-E245B
No.1
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
No.2
LANGUAGE/LOGO
No.3
8 FAULT DIAG MODE
SELECT SWITCH
DIAG MODE 1
BUZZER STOP SWITCH
DIAG MODE 2
ADJUSTING MODE 1 PRESET BY FACTORY
FEED
SCREEN CHANGE SWITCH
CASE OF DIAG MODE 1 SENSOR CHECK
CHECK
START ENG ENGINE SPEED 0000 rpm PRESSURE C 1 00.0M PROPO-VALVE E 1 005mA D 1 300mA
-
DIAG MODE 1
LOWER BOOM RELEASE LOCK LEVER
TO GROUND C 2 00.0M
E-2 D-2
About 15 minutes
005mA 300mA
Turn engine on manually.
When not failed,
DIAG MODE 1
For Forthe thediagnosing diagnosingitems, items, see seeTable Table48-1. 1. When Whenrequired requiredto tostop stopin indiagnosis diagnosis operation, operation,press pressthe thebuzzer buzzer stop stop switch switch and andthe theoperation operationisisforcedly forcedlystopped. stopped.
BACK TO No.3
RESULT OF DIAGNOSIS
END
In diagnosis operation
START
ENGINE STOP
RESULT OF DETAIL
DIAG MODE 1
1 P1 UNLOAD
OK
O K DATA END
Engine stops automatically.
FEED
DIAG MODE 1 RESULT 1 P1 UN-LOAD PSV NG P1 UN-LOAD SPOOL NG
DATA END
BACK TO No.3
FEED
ENGINE SPEED 0000 rpm PRESSURE C 1 00.0M PROPO-VALVE E 1 005mA D 1 300mA
-
C 2 00.0M
-
E 2 005mA D 2 300mA
The other judgments can be confirmed with the feed button.
RESULT OF DIAGNOSIS
When failed,
The data at the time of judgment can be confirmed with the select switch.
1 P1 UNLOAD
NG DATA END
FEED
ENGINE SPEED 0000 rpm PRESSURE C 1 00.0M PROPO-VALVE E 1 005mA D 1 300mA
-
C 2 00.0M
-
E 2 005mA D 2 300mA
-
-
The suspected trouble sections are displayed in order of possibility. The suspected three sections in maximum are displayed. When desired to see other suspected trouble sections, press feed " " button. For diagnosis results and corrective actions to be t aken, see Table 2.
SM0114
Notes: 1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. 2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve for possible abnormality. Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis. The preliminary investigation of electric system makes the time saving and high precision diagnosis possible. 3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an example. When multiple troubles are occurred at the same time, there is a case no accordance of diagnosis obtained. In this case, contact our dealer/distributor. 4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring to the trouble history.
T5-3-2
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
E215B-E245B
No.4 CASE OF DIAG MODE 2 SENSOR CHECK
CHECK
START ENG ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
C-2 00.0M
DIAG MODE 2
LOWER BOOM
START
TO GROUND
E-2 005mA D-2 300mA
Turn engine on manually.
AT CONTROL LEVER IS NEUTRAL
Example: Case of boom up WHEN FINISHING OF DIAGNOSIS IS REQUIRED. BOOM UP
BOOM UP
OK PRESSURE 0.0
MPa
PRESSURE 1.5
MPa
PRESSURE 3.0
BACK TO No.3 MPa
In the normal condition, OK is displayed when the control lever is moved to stroke end.
SM0115
SEARCHABLE OPERATION Boom up Boom down Bucket digging Bucket dump Arm in Arm out Swing Travel right Travel left P1 side option P2 side option
Notes: 1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers. 2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate attachment. When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UNLOAD PSV NG" is displayed. Check the troubled section according to indication. 3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring to the trouble history.
T5-3-3
E215B-E245B
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
Table 1 - Failure diagnosis Mode-1/Diagnosis item No.
Display
Contents of diagnosis Is normal pressure generated in the condition that the flow rate at P1 side is minimum
1
1 P1 UNLOAD
2
2 P1 UNLOAD
Is normal pressure generated in the condition that the minimum flow rate is relieved at P1 side?
3
3 P1 UNLOAD
Is normal pressure generated in the condition that the unload valve is fully opened, and P1 side flow rate is minimum?
4
1 P2 UNLOAD
Is normal pressure generated in the condition that the unload valve is in emergency position, and P2 side flow rate is minimum?
5
2 P2 UNLOAD
Is normal pressure generated in the condition that the minimum flow rate is relieved at P2 side?
6
3 P2 UNLOAD
7
1 P1 PUMP
Is normal pressure generated in the condition that the flow rate at P1 side is emergency and the unloading valve is in the emergency position?
8
2 P1 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P1 side flow rate is minimum?
9
3 P1 PUMP
and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is fully opened, and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position, and P1 side flow rate is maximum?
10 1 P2 PUMP
Is normal pressure generated in the condition that the flow rate at P2 side is emergency and the unloading valve is in the emergency position?
11 2 P2 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P2 side flow rate is minimum?
12 3 P2 PUMP
Is normal pressure generated in the condition that the unload valve is in emergency position, and P2 side flow rate is maximum?
13 1 TRAVEL-S
Is normal pressure generated in the condition that P1 side flow rate is minimum, unload valve is emergency position and travel straight is stroked fully?
14 2 TRAVEL-S
Is normal pressure generated in the condition that P2 side flow rate is minimum, unload valve is emergency position and travel straight is stroked fully?
15 1 P1 ENGINE
Is rated engine speed obtained in the condition that P1 side flow rate increases little by little when P1 side flow rate is relieved?
16 2 P2 ENGINE
Is rated engine speed obtained in the condition that P2 side flow rate increases little by little when P2 side flow rate is relieved?
Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy Diagnosis (Display) SENSOR CHECK NG
P1 UN-LOAD PSV NG
P1 UN-LOAD SPOOL NG
Possible cause
Remedy
Check each pressure sensor by Disconnection of pressure sensor, Short service diagnosis and replace it if circuit, Abnormal output necessary Secondary pressure against the command
is
Secondary pressure against the command
is
excessive excessive
Stuck at full-stroke side
high Check P1 unload proportional valve low and replace it if necessary Check P1 unload spool and replace it if necessary
Stuck at neutral side
T5-3-4
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
E215B-E245B
Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy Diagnosis (Display)
P2 UN-LOAD PSV NG
P2 UN-LOAD SPOOL NG P1 B-P CUT NG P2 B-P CUT NG
P1 PUMP PSV NG
P1 PUMP NG
P2 PUMP PSV NG
P2 PUMP NG
S-TRAVEL PSV NG
S-TRAVEL SPOOL NG
Possible cause Secondary pressure against the command
is
Secondary pressure against the command
is
excessive excessive
Remedy high Check P2 unload proportional valve low and replace it if necessary
Stuck at full-stroke side
Check P2 unload spool and replace it if necessary
Stuck at neutral side Stuck at closing side
Check P1 by-pass cut valve and replace it if necessary
Stuck at neutral side Stuck at closing side
Check P2 by-pass cut valve and replace it if necessary
Stuck at neutral side Secondary pressure against the command
is
Secondary pressure against the command
is
excessive excessive
high Check P1 pump proportional valve low and replace it if necessary
Delivery rate is excessive large against the Check P1 pump regulator and command replace it if necessary. Delivery rate is excessive small against the Check P1 pump and replace it if necessary. command Secondary pressure against the command
is
Secondary pressure against the command
is
excessive excessive
high Check P2 pump proportional valve low and replace it if necessary
Delivery rate is excessive large against the Check P2 pump regulator and command replace it if necessary. Delivery rate is excessive small against the Check P2 pump and replace it if necessary. command Secondary pressure against the command
is
Secondary pressure against the command
is
excessive excessive
Stuck at full-stroke side
high Check travel straight proportional low valve and replace it if necessary Check travel straight replace it if necessary
Stuck at neutral side
spool
and
PUMP 1 PRESS. SENPressure is recognized lower than it is SOR NG
Check P1 high pressure sensor and replace it if necessary
PUMP 2 PRESS. SENPressure is recognized lower than it is SOR NG
Check P2 high pressure sensor and replace it if necessary
MAIN RELIEF NG ENGINE NG E/G R SENSOR NG
Set pressure decreases
Check main relief valve and replace it if necessary
Set pressure increases Output is lowered
Check engine and replace it if necessary
Characteristics is misaligned
Check engine speed sensor and replace it if necessary
T5-3-5
E215B-E245B
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
[MEMO:]
T5-3-6
REPAIR INSTRUCTIONS
M0103
REPAIR INSTRUCTIONS
E215B-E245B
SECTION AND GROUP CONTENTS Section 1
GENERAL INFORMATION
Group 1 Group 2
Precautions for Disassembly and Assembly Tightening Torque
Section 2
UPPERSTRUCTURE
Group 1 Group 2 Group 3
Section 3 Group Group Group Group Group Group Group Group
1 2 3 4 5 6 7 8
UNDERCARRIAGE
Section 4 Group Group Group Group Group Group Group Group
1 2 3 4 5 6 7 8
CCCCC GGGGGGG wwwww
AAAAAA zzzzzz wwwww zzzzzz AAAAAA zzzzzz wwwww zzzzzz
FRONT ATTACHMENT
AAAAAA zzzzzz wwwww
zzzzzz AAAAAA zzzzzz wwwww zzzzzz
SECTION 1
E215B-E245B
GENERAL INFORMATION
CONTENTS Group 1 - Precautions for Disassembly and Assembly Precautions for Disassembly and Assembly .......................................... W1-1-1
Group 2 - Tightening Torque Torque Chart .......................................... W1-2-1 Piping Joint............................................. W1-2-4
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
E215B-E245B
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY PREPARATIONS FOR DISASSEMBLY - Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work. - Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. - Check and record the items listed below to prevent problems from occurring in the future. 1. The machine model, machine serial number, and hour meter reading. 2. Reason for disassembly (symptoms, failed parts, and causes). 3. Clogging of filters and oil, water or air leaks, if any. 4. Capacities and condition of lubricants. 5. Loose or damaged parts. - Prepare the necessary tools to be used and the area for disassembling work. - Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves. - Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency measure and ambulance to prepare for accidents and fire. - Attach "Don’t operate" tag to control lever, and begin a meeting before starting the work.
- If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified through service training. - Make match mark on parts for reassembling. - Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and assembly are permitted or not. - For parts which are required to use jig and tools, don’t fail to use the specified jig and tools. - For parts which can not be removed in the specified procedure, never force removal. First check for the cause. - Inspecting parts. Measure the wear of parts and clearance, and record the measured values. - If an abnormality is detected, repair or replace the parts. - The removed parts should be put in order and tagged so as to install on proper places without confusion. - For common parts, pay attention to the quantity and places. REASSEMBLING HYDRAULIC EQUIPMENT - During the parts cleaning, ventilate the room. - Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them. - Replace the removed O-ring, back-up rings and oil seal with new ones, and apply gear oil on them before assembling. - Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid sealant on them.
DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT - Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return side to tank, and take out the filter. - Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground. - Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.
- Before assembling, remove rust preventives on new parts. - Use special tools to fit bearings, bushing and oil seal. - Assemble parts matching to the marks. - After completion, check that there is no omission of parts.
- Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before putting them on working. DISASSEMBLING HYDRAULIC EQUIPMENT - Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from responsibility on the manufacture’s side, disassembly, assembly and modification without permission are strictly prohibited. W1-1-1
E215B-E245B
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
INSTALLING HYDRAULIC EQUIPMENT - Confirm hydraulic oil and lubrication oil. - Bleeding Air from Hydraulic System Air release is required in the following cases: 1. Change of hydraulic oil 2. Replacement of parts on suction pipe side 3. Removing and attaching hydraulic pump 4. Removing and attaching swing motor 5. Removing and attaching travel motor 6. Removing and attaching hydraulic cylinder IMPORTANT: if hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged. - For air bleed of hydraulic pump and swing motor, loosen drain plug on the upper part, start engine, and run in low idling, then bleed air until hydraulic oil is comes out. After completion of comes, tighten plug securely. - For air bleed of travel motor and hydraulic cylinder, starts engine and operate it for 10 minutes or more at no-load and low speed. IMPORTANT: for cylinder, don’t move it to the stroke end at beginning. - Air in pilot circuit can be bleed out by only operating digging, swing and travelling motions thoroughly. - Check hydraulic oil level. Move attachments to hydraulic oil check position, as indicated in the figure. - Open the hydraulic pump compartment door, then check the oil level on visual indicator ( 1) located on the hydraulic oil reservoir. If the indicator is within level marks, the oil quantity is acceptable.
W1-1-2
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
E215B-E245B
Floating Seal Precautions 1.
In general, replace the floating seal with a new one. If the floating is to be reused, follow these procedures:
A
1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. 2) Check the seal ring face (A) for scuffing, scoring, corrosion, deformation or uneven wear. 3) Check O-Ring (B) for deformation or hardening.
tears,
breaks, B
2.
If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble.
SM0172
1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air. 2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it. 3) Check that the O-Ring is not twisted, and that it is installed correctly on the seal ring. 4) After installing the floating seal, check that seal ring surface (C) is parallel with mating face (A) by measuring the distances (a) and (b), as illustrated. If these distances differ, correct the O-Ring (B) seating.
RIGHT
WRONG
SM0173
RIGHT
WRONG a
A
a
C
B
b
b a=b
a≠b SM0174
W1-1-3
E215B-E245B
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
ELECTRICAL EQUIPMENT - The disassembly of electrical equipment is not allowed. - Handle equipment with care so as not to drop it or bump it. - Connector should be removed by unlocking while holding the connector. Never stress in tension to the caulked section by pulling wire. - Check that connector is connected and locked completely. - Engine key off before removing and connecting connector. - Engine key off before touching terminals of starter and alternator. - Wash machine with care so as not to splash water on electrical equipment and connector. - When water has entered in the waterproofed connector, the removing of water is not easy. So check the removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before connecting. - Remove battery grounding terminal before beginning work close to battery and battery relay with tools.
WARNING Battery fluid is dangerous. The battery fluid is dilute sulfuric acid, and causes scal d and loss of eyesight by adhering on eyes, skin and clothes. When the fluid has adhered on them, take an emergency measure immediately and see a doctor for medical advice. - When it has adhered on skin: wash with soap and water. - When it has got in eyes: wash in water for 10 minutes or more immediately. - When it was swallowed: drink milk or water.
W1-1-4
TIGHTENING TORQUE
TORQUE CHART
WARNING Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use the correct tools. Avoid bodily injury caused by slipping wrenches. Bolt Types Tighten nuts or bolts correctly to torque specifications. Two kinds of bolts, hexagon bolts T and socket bolt, each made of different material, are used. Make sure to employ the correct bolts and tighten them to specification when assembling the machine or components. Hexagon T Bolt
Socket Bolt
SM0175
Specified Tightening Torque Chart T Bolt, Socket bolt (Nm)
Bolt Dia.
Wrench Size
Hexagon Wrench Size
M18
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
1370
M30
46
22
1910
M33
50
24
2550
M36
55
27
3140
W1-2-1
E215B-E245B
E215B-E245B
TIGHTENING TORQUE
IMPORTANT 1.
Apply lubricant (i. e. white zinc B dissolved into spindle oil) to nuts and bolts to stabilize their friction coefficients.
2.
Torque tolerance is ± 10%.
3.
Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force.
4.
The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application.
5.
Make sure that the nut and bolt threads are clean before installing. Remove dirt or corrosion, if any.
Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.
Equally tighten upper and lower alternately
Tighten diagonally 1
1.4
2.3
6
3
4
5 2
Tighten from center and diagonally 12
9
4
1
6
7
14
13
8
5
2
3
10
11
SM0176
W1-2-2
TIGHTENING TORQUE
E215B-E245B
Service Recommendations for Split Flange IMPORTANT 1.
Be sure to clean and inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component.
2.
Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file Oring surfaces. When installing an O-ring into a groove, use grease to hold it in place.
3.
Loosely assemble split flange halves. Make sure that the split is centrally located and perpendicular to the port. Hand-tighten the bolts to hold the parts in place. Take care not to pinch the O-ring.
4.
Tighten bolts alternately and diagonally, as shown, to ensure even tightening.
5.
Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to Orings or uneven tightening of bolts.
SM0177
WRONG
SM0178
Nut and Bolt Lockings •
SM0179
Lock Plate
RIGHT
WRONG
IMPORTANT: do not reuse lock plates. Do not try to bend the same point twice. •
Cotter Pin
IMPORTANT: do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening.
RIGHT
•
Do not bend it round
Bend along edge sharply
RIGHT
WRONG
Lock Wire
IMPORTANT: apply wire to bolts in the bolttightening direction, not in the bolt-loosening direction. Bend along edge sharply
RIGHT
RIGHT
SM0180
RIGHT
WRONG
WRONG
Loosen Tighten
SM0181
W1-2-3
E215B-E245B
TIGHTENING TORQUE
PIPING JOINT Pipe Thread Connection / Union Tightening Torque Specifications
Joint 4
1
5
3
2
Union Joint Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. Joint Body
SM0182
IMPORTANT 1.
2.
Excessive Do not over-tighten union nut ( 3 ). 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° 37°
Scratches or other damage to sealing surfaces ( 4 ) or ( 5 ) will cause oil leakage at the joint. Take care not to damage them when connecting /disconnecting.
Male Union Joint
Female Union Joint SM0183
Wrench Size
Tightening Torque
Type 37° Union Joint
Union Nut
Joint Body
(Nm)
19
17
29
22
19
39
27
22
78.5
36
30, 32
157
41
36
205
50
46
323.6
NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.
W1-2-4
TIGHTENING TORQUE
E215B-E245B
O-Ring Seal Joint O-Ring (6) seats against the end face of adaptor ( 7) to seal pressure oil.
7
9
6
IMPORTANT 1.
Be sure to replace O-Ring ( 6 ) with a new one when reconnecting.
2.
Before tightening union nut ( 9 ), confirm that ORing ( 6 ) is seated correctly in O-Ring groove Tightening union nut ( 9 ) with O-Ring ( 6 ) ( 8 ). displaced will damage O-Ring, resulting in oil leakage.
3.
Take care not to damage O-Ring groove ( 8 ) or sealing face ( 10 ). Damage to O-Ring ( 6 ) will cause oil leakage.
4.
If union nut ( 9 ) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-Ring ( 6 ) with a new one, then tighten union nut ( 9 ) after confirming that O-Ring ( 6 ) is securely seated in place.
Wrench Size
Tightening Torque
Union Nut
Joint Body
(Nm)
19
17
29.4
22
19
68.6
27
22
93
30
27
137.3
36
30
175
41
36
205
50
46
320
W1-2-5
8
10
Joint body SM0184
E215B-E245B
TIGHTENING TORQUE
Screwed-In Connection IMPORTANT: many types of screwed-in connections are used for hose connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. Male Tapered Thread
PT
PF 30°
Male Tapered Thread
Wrench Joint Body
Tightening Torque (Nm)
17, 19
34
22
49
27
93
36, 32
157
41
205
50
320
60
410
Male Straight Thread SM0185
Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap. •
Internal Thread
Clearance External Thread
SM0186
Application Procedure Leave one to two pitch threads uncovered
Confirm that the thread surface is clean, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. See below for correct tightening torque of each type of low-pressure-hose clamp.
SM0187
T-Bolt Type
Worm Gear Type
T-Bolt Type Band Clamp: 4.4 Nm (0.45 kgf m) Worm Gear Type Band Clamp: 5.9 a 6.9 Nm (0.6 a 0.7 kgf m)
SM0188
W1-2-6
SM0189
TIGHTENING TORQUE
E215B-E245B
Connecting Hose 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.
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 when installing hoses to prevent hose from being installed kinked.
3.
WRONG
RIGHT
SM0190
WRONG
RIGHT
Rubbing Against Each Other
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 with moving parts or sharp objects.
SM0191
WRONG
Clamp
RIGHT
Clamp
Rubbing SM0192
WRONG
RIGHT
Rubbing Clamp SM0193
W1-2-7
