SM E215B EN

SAFETY PRECAUTIONS
M0103
SAFETY PRECAUTIONS
E215B-E245B
INDEX
Section 1
GENERALITIES
Section 2
SAFETY PRECAUTIONS
Section 3
SAFETY PLATES
GENERALITIES
E215B-E245B
SAFETY PRECAUTIONS
GENERALITIES
Do not leave the machine until it has come to a
complete stop.
Read the Operation and Maintenance Instruction

Manual carefully before starting,
operating,
maintaining, fuelling or servicing the machine.
Always check height, width and weight limitations

which may be encountered in the working site and
ensure the machine does not exceed them.
Carefully read the explanation to each and all safety

signs in the special section of this Manual before
starting, operating, maintaining, fuelling or servicing
the machine.
Assess exact paths of gas ducts, water mains,

telephone lines, sewers, overhead and underground
electric lines and all other possible obstacles.
Machine-mounted safety plates are colour coded

yellow with black borders when they refer to points
where special ATTENTION must be paid and failure
to observe them may cause a serious DANGER to
the integrity of machine operators. They are white
with red borders and black lettering when they refer
to a FORBIDDEN practice.
Such paths should be opportunely defined by

competent Authorities. If necessary, require that the
service is interrupted or said installations are moved
prior to starting the work.
You must know the working capacity of the machine.
Define the rear upperstructure swing area and
provide for opportune barriers to prevent access into
it.
It is fundamental that all machine operators know

very well the meaning of each safety plate as this
considerably decreases operating hazards and
accidents.
Never exceed machine lifting capacity.

Remain within the limits shown in the loading
capacity chart which located on the machine.
Do not allow unauthorised personnel to operate or

service this machine.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get
caught in moving parts. Wear certified safety clothes
such as: hard hat, no-slip footwear, heavy gloves, ear
protection, safety glasses, reflector vests, respirators
every time the job requires it. Ask your employer
about safety regulations in force and protective
equipment.
STARTING
Never start or operate a failed machine. Walk all
around the machine before mounting.
Before operating the machine, make sure that any
possible dangerous condition has been properly
removed. Before starting machine, check that
steering and attachment controls are in the neutral
position and the safety lever is in the LOCK position.
Immediately report any malfunction of parts or
systems to the maintenance managers for proper
action.
Always keep the operators 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

drivers seat for maximum riding comfort and control
accessibility. Prior to operating the machine and/or
its attachments, check that bystanders are outside
the machine operating range. Sound the horn.
Do not jump on or off the machine. Always keep both

hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Do not use controls or hoses as hand holds. Hoses
and controls are movable parts and do not provide
solid support. Besides, controls may be inadvertently
moved and cause unexpected movement of the
machine or its attachments.
Obey all hand signals, safety indications and signs.
Never operate the machine or its attachments from

any position other than sitting in the drivers seat.
Keep head, body, limbs, hands and feet inside the
operators compartment at all times to reduce
exposure to external hazards.
Ensure that nobody is within the excavator operating

area before starting the machine, swinging the upper
structure or moving in any direction.
Be careful of possible slippery conditions of the steps

and hand rails as well as of the ground around the
machine. Wear protective boots or shoes with the
soles made of highly no-slip rubber
Ensure that engine speed is appropriate to the job to

be carried out.
Due to the presence of flammable fluids, never

check fuel level, refuel, charge the batteries in the
presence of smoking materials, open flames or
sparks.
Adjust all rear-view mirrors for maximum visibility of

the area behind the machine.
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GENERALITIES
If any hydraulic control or system exhibits erratic

performance or responds abnormally, have the
machine checked for air in the system.
properly protected against possible backlash in

case of cable or chain failure or detachment.
Be alert of soft ground conditions close to newly
constructed walls. The fill material and machine
weight may cause the wall to collapse under the
machine.
Air in these circuits may cause incorrect movements

with consequent accident hazard. Refer to the
Operation and Maintenance Instruction Manual
about corrective action to be taken.
In darkness, check area of operation carefully before

moving in with the machine. Use all lights provided.
Do not move into low visibility areas.
If the engine tends to slow down and stall for
whatever reason under load or at idle, immediately
report this problem to the maintenance managers for
proper action.
OPERATING
Do not run the engine of this machine in closed
buildings without proper ventilation capable to
remove harmful exhaust gases which concentrate in
the air.
Do not operate the machine until this condition is

corrected. Regularly check all exhaust system
components, as exhaust fumes are toxic for the
operator.
Keep the operators compartment free of foreign

objects, especially if not firmly secured. Never use
the machine to transport objects, unless proper
securing points are provided.
Operators must know the performance of the

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

familiarise with escape routes alternative to normal
exit routes. For your personal safety, do not climb on
or off the machine while it is in motion.
If noise level is high and exceeds 90 dB (A) over 8

hours at the operators ear, wear approved ear
protection in compliance with local regulations.
Make sure that bystanders are clear of the machine

operating range before starting the engine and
operating the attachment. Sound the horn.
Obey all hand signals, safety indications and signs.
Do not operate the machine if you are extremely tired

or feel ill. Be especially careful towards the end of the
working shift.
When backing, always look to where the machine is

to be moved.
Where removable counterweights are provided, do

not operate the machine if they have been removed.
Be alert of the position of bystanders. Should

someone enter the work area, stop the machine.
Maintain a safe distance from other machines or
obstacles to ensure required visibility conditions.
When operating the machine, keep in mind height

limits of overhead doors, arches, overhead cables
and lines as well as width limits of corridors, roads
and narrow passages.
Always give way to loaded machines.
Also, get to know load limits of the ground and

paving type of the ramps you are to work on.
Maintain a clear vision of the surroundings of the

travel or work area at all times. Keep cab windows
clean and repaired.
Beware of fog, smoke or dust that obscure visibility.

Always inspect the working area to identify potential
risks such as: inclines, overhangs, trees, demolition
rubble, fires, ravines, steep slopes, rough terrain,
ditches, crowns, ridge trenches,diggings in traffic
areas, crowded parking lots, crowded service areas,
fenced zones. In such conditions, proceed with
extreme care.
When pulling loads or towing through a cable or

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

such as very rough terrain, rocks, logs, steps,
ditches, railroad tracks.
Always wear heavy gloves when handling chains or

cables.
When obstructions must be crossed, do so with

extreme care and at a square angle, if possible. Slow
down.
Chains and cables should be securely anchored

using suitable hooks. Anchor points should be strong
enough to withstand the expected load.
Ease up to the break-over point, pass the balance

point slowly and ease down the other side also using
the attachment, if necessary.
Keep anyone clear of anchor points and cables or

chains.
To overcome deep trenches or sinking ground, place

the machine perpendicular to the obstacle, drastically
reduce ground speed and start crossing using also
Do not pull or tow unless the operators

compartments of the machines involved are
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GENERALITIES
E215B-E245B
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.
- Nobody should be allowed to remain under the

raised load or within the excavator operating range
for any reason whatever.
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).
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.
Position the machine dependent upon the loading

and unloading areas in order to swing leftwards to
load to obtain best visibility.
All loading capacities are referred to the machine

on a level surface and should be disregarded
when working on a slope.
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).
Avoid travelling across slopes. Proceed from uphill

downhill and vice-versa. If machine starts slipping
sideways when on a slope, lower the bucket and
thrust bucket teeth into the ground.
Working on slopes is dangerous. Grade the working
area if possible. Reduce work cycle time if it is not
possible to grade the working area.
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.
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
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E215B-E245B
GENERALITIES
- Look up the in the telephone directory.
motors be positioned at the front with regard to the

actual travel direction. Remind relative to travel
direction that controls are reversed.
- 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 Operators. 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 Operators.
This signal man (flag-man) must be in direct
communication with the Operator and the Operator
must pay undivided attention to the signals
supplied.
When working in or near pits, in ditches or very high

walls, check that the walls are sufficiently propped up
to avoid cave-in hazards.
Pay the utmost attention when working near
overhang walls or where landslides may take place.
Make sure that the support surface is strong enough
to prevent landslides.
- 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 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.

- Digging trenches subject to vibration from
railroads, working machines or highway traffic.
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.
STOPPING
To work without risks, keep maximum possible

distance from electric lines and never trespass
minimum safety distance.
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.
- Contact the Company owner of the electric lines or

its nearest branch before starting the work.
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GENERALITIES
E215B-E245B
Read all safety plates mounted on the machine and

observe instructions they contain before starting,
operating, repairing, fuelling or servicing the
machine.
Never leave the machine unattended with the engine

running.
Prior to leaving the drivers 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.
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.
If parking in traffic lanes cannot be avoided, provide

appropriate flags, barriers, flares and other signals as
required to adequately warn the oncoming drivers.
Always switch off the key-start switch before
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 operators 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 drivers 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 operators 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
operators seat.
Align the upperstructure to the tracks in order to allow

to easily get on and off the drivers compartment.
Keep the drivers seat free from foreign objects,

especially if these are not secured.
Move all controls to the position specified for machine

stopping. Refer the Operation and Maintenance
Instruction Manual.
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
operators 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.

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.
MAINTENANCE
GENERALITIES
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.
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GENERALITIES
flammable fluids to clean parts. Use proprietary
certified non-flammable, non-toxic solvents only.
Never lubricate, repair or adjust the machine with the

engine running, except when this is specifically
required by the Operation and Maintenance
Instruction Manual.
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.
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.
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 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.
In case of attachment tests during which the engine

should be kept running, a qualified operator must sit
in the drivers seat at all times while the mechanic is
at work.
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.
Keep hands and clothes far off moving parts.
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.
Stop the engine and move the safey lever to the lock
position before starting adjusting or repairing an
assembly.
Do not carry out any work on the attachment without
prior authorisation. Observe maintenance and repair
procedures.
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.
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.
Never align holes or slots using your fingers;

alwaysuse appropriate aligning tools.
Remove all sharp edges and burrs from re-worked
parts.
Keep all bystanders clear of the anchor point, cables

or chains. Do not pull or tow unless the operators
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.
Before starting the machine or its attachment, check,

adjust and lock the operators seat. Also ensure that
nobody is within the machine or attachment
Never pour gasoline or diesel fuel into open

containers. Never use gasoline, solvents or other
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GENERALITIES
E215B-E245B
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.
operating range before starting or operating the

machine and/or its attachments.
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 welders 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.
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.
Metal cables produce steel splinters. Always wear

certified protection clothes such as safety gloves and
glasses while handling them.
Check distance between boom/arm and dimensional

limits during transfer or transportation.
Do not use makeshift jacks to adjust track sag. Follow

instructions given in the Repair Manual.
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.
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.
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.
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.
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
E215B-E245B
GENERALITIES
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.
Tow the machine following the instructions contained

in the Operation and Maintenance Instruction
Manual.
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.
Always use gauges of adequate capacity for

pressure testing. Refer to the Operation and
Maintenance Instruction Manual or Repair Manual.
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.
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.
TOOLS
Always keep head, body, limbs, feet, hands, and
fingers away from the bucket and attachments, when
in the raised position.
ELECTRICAL SYSTEM
Prior to any maintenance or repair work, install all

supports necessary to this aim according to local and
national safety regulations.
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.
In case the attachment is to be operated for

maintenance or repair purposes, do so exclusively
while sitting in the drivers 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
SAFETY PRECAUTIONS
E215B-E245B
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 a potential hazardous

situation which, if not avoided, could result in death
or serious injury.
CAUTION
IMPORTANT
CAUTION: indicates a potential hazardous situation

which, if not avoided, may result in minor or
moderate injury.
NOTE
IMPORTANT: indicates a situation which, if not

avoided, may cause damage to the machine.
NOTE: indicates an additional explanation for
information purposes.
ENVIRONMENTAL PROTECTION
This Manual also contains this symbol
accompanying instructions for correct behaviour
as regards environmental protection.
S2 - 1
E215B-E245B
SAFETY PRECAUTIONS
FOLLOW SAFETY PRECAUTIONS

Carefully read and observe all safety signs on the
machine and read all safety precautions in this
Manual.
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.
S2 - 2
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.
S2 - 3
E215B-E245B
E215B-E245B
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 the 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.
S2 - 4
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.
S2 - 5
E215B-E245B
E215B-E245B
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 operators 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 operators
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.
S2 - 6
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.
S2 - 7
E215B-E245B
E215B-E245B
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.
S2 - 8
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.
S2 - 9
E215B-E245B
E215B-E245B
SAFETY PRECAUTIONS
INVESTIGATE JOB SITE BEFORE

OPERATING THE MACHINE
Explore the working area to identify potential risks
before starting and operating the machine. 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.
S2 - 10
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.
S2 - 11
E215B-E245B
E215B-E245B
SAFETY PRECAUTIONS
KEEP PERSONNEL CLEAR FROM

WORKING AREA
A person may be hit severely by the swinging front
attachment or counterweight and/or may be
crushed against an other object, 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.
S2 - 12
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.
S2 - 13
E215B-E245B
E215B-E245B
SAFETY PRECAUTIONS
AVOID EXCESSIVE DIGGING EFFORTS

Operate the machine complying with the load
limits in accordance with the "table of lifting loads"
located inside the cab.
- Do not 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.
S2 - 14
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
persons 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.
S2 - 15
E215B-E245B
E215B-E245B
SAFETY PRECAUTIONS
SAFE MAINTENANCE
To avoid accidents:
- Understand maintenance procedure before
starting the work.
- 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.
S2 - 16
SAFETY PRECAUTIONS
WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause
serious injury.
- Before performing any work on the machine,
attach a maintenance in progress tag (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.
S2 - 17
E215B-E245B
E215B-E245B
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.
S2 - 18
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.
S2 - 19
E215B-E245B
E215B-E245B
SAFETY PRECAUTIONS
STARTING THE ENGINE WITH BOOSTER

BATTERIES
If the engine is to be started using booster
batteries, ensure to comply with all procedures
detailed
in
the
chapter
OPERATING
INSTRUCTIONS.
- The operator should be sitting in the drivers
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.
S2 - 20
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.
S2 - 21
E215B-E245B
E215B-E245B
SAFETY PRECAUTIONS
AVOID HIGH-PRESSURE FLUIDS

Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing
serious injury, 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.

- 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.
S2 - 22
SP0047
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.
S2 - 23
E215B-E245B
E215B-E245B
SAFETY PRECAUTIONS
PREVENT FIRES
Check for Oil Leaks:
- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts
which may cause oil leaks.
- Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and 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.
S2 - 24
SAFETY PRECAUTIONS
E215B-E245B
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).
S2 - 25
E215B-E245B
SAFETY PRECAUTIONS
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install
temporary fire resistant guards to protect hoses or
other materials when welding, soldering, etc.
AVOID APPLYING HEAT TO LINES

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.
S2 - 26
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.
S2 - 27
E215B-E245B
E215B-E245B
SAFETY PRECAUTIONS
NOTE:
S2 - 28
SAFETY PLATES
SAFETY PLATES
Triple articulation version
Triple articulation version
1. Attachment operating range safety plate.

2. Track adjuster plate.
S3 - 1
E215B-E245B
E215B-E245B
SAFETY PLATES
9. Controls lock/unlock plate (safety lever).
3. Counterweight operating range safety plate.

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
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
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
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
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
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
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
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
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
11 - Burns danger plate

It indicates that a burns danger exists, since
the zone is characterised by high temperature.
Background: yellow
12 - Safety distance plate

It instructs to keep at a safe distance from a
zone dangerous for personal safety.
Background: yellow
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
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
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 2
Group 3
Group 4
Mechatro Control System

Mechatro Controller
Hydraulic System
Electrical System
Section 3
COMPONENT OPERATION
Group 1
Group 2
Group 3
Group 4
Group 5
Group 6
Group 7
Group 8
Hydraulic Pump Assy

Pilot Valve
Control Valve
Swing Device
Travel Device
Swing Joint
Cylinders
Air Conditioner
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
Bucket applications as a function
of the arms E215B ............................. T1-1-13
Digging data E245B
Digging data E245B
Bucket applications as a function
of the arms E245B ............................. T1-1-18
E215B-E245B
SPECIFICATIONS
E215B-E245B
MAIN COMPONENTS
12345678910 -
Bucket
Bucket link
Idler link
Bucket cylinder
Arm
Arm cylinder
Boom
Boom cylinder
Cab
Swivel joint
11 12 13 14 15 16 17 18 19 20 -
Swing motor
Fuel tank
Hydraulic oil tank
Control valve
Engine muffler
Hydraulic pump
Engine
Counterweight
Engine radiator
Travel motor
T1-1-1
21 22 23 24 25 26 27 28 29 -
Track link
Batteries
Upper roller
Track guide
Lower roller
Air cleaner
Crawler adjuster
Front idler
Shoe plate
E215B-E245B
SPECIFICATIONS
Main Components Upper Structure
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
section A - A
SM0013
1-
Right Travel Motor Unit
4-
Swing Gear
2-
Left Travel Motor Unit
5-
Front Idler Assy
3-
Center joint
T1-1-3
E215B-E245B
SPECIFICATIONS
Main Components Front Attachment
1
3
SM0014
1-
Boom cylinder
5-
Monoblock Boom
2-
Arm cylinder
6-
Boom (Triple Articulation Version)
3-
Bucket Cylinder
7-
Arm
4-
Positioning Cylinder (Triple Articulation

Version)
8-
Positioner (Triple Articulation Version)
T1-1-4
SPECIFICATIONS
E215B-E245B
HYDRAULIC COMPONENTS
HYDRAULIC PUMP
Main pump
Gear pump for pilot
Pump
Item
K3V112DTP1KMR-YTOK-HV
ZX10LPRZ7-07G
Type
Variable displacement plunger

pump: regulator attached type
Fixed displacement type gear

pump
110 x 2
10
2000
Max. displacement capacity
cm3
Revolution
rpm
(Clockwise
seen from
shaft end)
Pressure
Rated
Rated
ATT boost
34.3
MPa
Max. flow
L/min
Max. input Power

(at 2000 rpm)
Max. input torque
(at 1200 rpm)
220 x 2 at 7.8 MPa
20
kW
118
3.4
Nm
665
14.7
Model
Regulator
Mass
5.0
37.8
KR3G-YTOK-HV
Control
function
Electric flow control, positive flow control, total power control at

emergency mode and power shift control
Others
With solenoid proportional reducing valve (KDRDE5K-31/

30C50)
kg
143
NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump.
CONTROL VALVE
Item
STD VALVE
Model
KMX15YD / B44041
Max. flow rate

Main relief valve set pressure
L/min
220 x 2
MPa
34.3 at 70 x 2 L/min
When power boost pressure

Over load relief valve set pressure
37.8 at 60 x 2 L/min
MPa
Boom H, Bucket H, Arm R
39.7 at 30 L/min
Boom R, Bucket R, Arm H

Mass
37.8 at 30 L/min
kg
Item
OPT VALVE
Model
Over load relief valve set pressure
KADV22Y / 501103A03
MPa
Positioner R
39.7 at 30 L/min
Positioner H
Mass
232
37.7 at 30 L/min
kg
T1-1-5
2.8
E215B-E245B
SPECIFICATIONS
PILOT VALVE
ATTACHMENT
TRAVEL
PV48K2004
6TH6NRZ
5.0 MPa
4.9 MPa
0.6 ~ 3.2 MPa
0.54 ~ 2.35 MPa
Model
Primary pressure
Secondary pressure
Rated flow
Mass
20 L/min
25 L/min
Approx. 2 kg
Approx. 8 kg
Hydraylic motor
SWING MOTOR UNIT
Antireaction
valve block
Model
M5X130CHB10A41C/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
Planetary 2-stage
Reduction unit
Reduction ratio
Total mass
15.38
Lubicate oil
Lubicate oil volume
Gear oil SAE90 (API class GL4 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
Displacement
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
Max. flow
Max. gearbox
torque
1 : 43.2
output
Parking brake torque
Min. pressure parking brake release

Relief valve set pressure
11 bar
cracking
311 bar at 1.2 L/min
total flow
353 bar at 40 L/min
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
120 / 85
1345
3200 / 1855
Arm
135 / 95
1558
3637 / 2079
Bucket
120 / 80
1080
2684 / 1604
Positioning
145 / 90
992
2662 / 1670
Use
T1-1-7
Cushion
Mass
(kg)
With cushion
on rod side
With cushion
on both sides
With cushion
on rod side
Without cushion
176
255
153
220
E215B-E245B
SPECIFICATIONS
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 cm3
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
9185
9446
9929
10366
8991
9258
9750
10195
5840
6160
6700
7260
5620
5954
6519
7082
9440
9519
9733
9749
6737
6793
7037
7149
3679
3559
3544
3478
4268
3955
3503
2942
5005
5346
5879
6588
T1-1-9
E215B
SPECIFICATIONS
DIGGING DATA E215B

(Triple Articulation Version)
(Dimensions in mm)
Arm
2080
2400
2 940
3500
9322
9598
10098
10555
9131
9413
9922
10387
5590
5891
6417
6932
5467
5775
6310
6832
10682
10882
11280
11544
7755
7952
8351
8632
2929
2742
2524
2695
5016
4575
3724
3196
2470
2747
3151
3818
T1-1-10
SPECIFICATIONS
E215B
TRANSPORTING DIMENSIONS E215B

(Monoblock Version)
VERSIONS
E215BEL
E215BL
E215BLC
3656
3656
3656
4451
4451
4451
1035
1035
1035
2800
2800
2800
(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
2503
3027
948
471
2503
3027
948
471
2503
3027
948
471
Arm:
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 mm
(dimensions in mm)
E215BEL
E215BL
E215BLC
M Track shoe width
(mm)
500
600
700
600
700
800
900
600
700
800
900
N Gauge
(mm) 2490
2590
2690
2800
2900
3000
3100
2990
3090
3190
3290
(*) Working weight

Spec. 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
E215B
SPECIFICATIONS

G
D
H
I
F
C
A
B
VERSIONS
E215BEL
E215BL
E215BLC
3656
3656
3656
4451
4451
4451
1035
1035
1035
2800
2800
2800
NH0148
(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
2503
3027
948
471
2503
3027
948
471
2503
3027
948
471
Arm:
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 mm
(dimensions in mm)
E215BEL
E215BL
E215BLC
M Track shoe width
(mm)
500
600
700
600
700
800
900
600
700
800
900
N Gauge
(mm) 2490
2590
2690
2800
2900
3000
3100
2990
3090
3190
3290
(*) Working weight

Spec. ground pres.
(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 m3
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
Width
(mm)
Capacity
(dm3)
SAE J296
(ISO 7451)
Mass
(kg)
750
525
503
850
625
537
1000
789
634
1200
1000
651
1300
1105
698
1500
1315
760
E215BEL
E215BL
E215BLC
Arm (mm)
Arm (mm)
Arm (mm)
2080 2400 2940 3500 2080 2400 2940 3500 2080 2400 2940 3500
E215B Triple Articulation

BUCKETS
Width
(mm)
Capacity
(dm3)
SAE J296
(ISO 7451)
Mass
(kg)
750
525
503
850
625
537
1000
789
634
1200
1000
651
1300
1105
698
1500
1315
760
E215BEL
E215BL
E215BLC
Arm (mm)
Arm (mm)
Arm (mm)
2080 2400 2940 3500 2080 2400 2940 3500 2080 2400 2940 3500
General digging work (specific weight of material < 1.8 t/m3)

Slightly heavy digging work (specific weight of material < 1.5 t/m3)
Loading work (specific weight of material < 1.2 t/m3)
T1-1-13
E245B
SPECIFICATIONS
DIGGING DATA E245B

(Monoblock Version)
(Dimensions in mm)
Arm
2080
2400
2940
3500
9185
9446
9929
10366
8991
9258
9750
10195
5822
6142
6682
7242
5602
5936
6501
7064
9458
9537
9751
9767
6755
6811
7055
7167
3679
3559
3544
3478
4286
3973
3521
2960
5005
5346
5879
6588
T1-1-14
SPECIFICATIONS
E245B
DIGGING DATA E245B

(Dimensions in mm)
Arm
2080
2400
2940
3500
9322
9598
10098
10555
9131
9413
9922
10387
5572
5873
6399
6914
5449
5757
6292
6814
10700
10900
11298
11562
7773
7970
8369
8650
2929
2742
2524
2695
5034
4593
3742
3214
2470
2749
3151
3818
T1-1-15
E245B
SPECIFICATIONS

(Monoblock Version)
VERSIONS
E245B
3840
4645
1053
2800
(1) 9617
(1) 3141
(2) 9577
(2) 3050
(3) 9487
(3) 2886
(4) 9564
(4) 3044
Arm:
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 mm
2503
3045
970
486
(dimensions in mm)
E245B
M Track shoe width
(mm)
550(*)
700
800(*)
N Gauge
(mm)
2490
2690
2890
(**) Working weight
(kg)
22000
22500
22850
Spec. ground pres.
(bar)
0.51
0.41
0.37
(**) With arm 2940 mm and bucket 1.3 m3

(*) Asymmetric type shoes
T1-1-16
SPECIFICATIONS
E245B

G
D
H
I
F
C
A
B
VERSIONS
E245B
3840
4645
1053
2800
NH0148
(1) 9684
(1) 3067
(2) 9665
(2) 3014
(3) 9641
(3) 2957
(4) 9634
(4) 3235
Arm:
(1) 2080 mm
(2) 2400 mm
(3) 2940 mm
(4) 3500 mm
2503
3045
970
486
(dimensions in mm)
E245B
M Track shoe width
(mm)
550(*)
700
800(*)
N Gauge
(mm)
2490
2690
2890
(**) Working weight
(kg)
22600
23100
23450
Spec. ground pres.
(bar)
0.53
0.42
0.38
(**) With arm 2940 mm and bucket 1.3 m3

(*) Asymmetric type shoes
T1-1-17
E245B
SPECIFICATIONS
BUCKET APPLICATIONS AS A FUNCTION

OF THE ARMS E245B
E245B Monoblock
BUCKETS
E245B
Arm(mm)
Width (mm)
Capacity (dm3)
SAE J296
(ISO 7451)
Mass (kg)
750
525
503
850
625
537
1000
789
634
1200
1000
651
1300
1105
698
1500
1315
760
2080
2400
2940
3500
E245B Triple Articolation

BUCKETS
Capacity (dm3)
Width (mm)
SAE J296
(ISO 7451)
E245B
Mass
(kg)
750
525
503
850
625
537
1000
789
634
1200
1000
651
1300
1105
698
1500
1315
760
Arm (mm)
2080
2400
2940
3500
General digging work (specific weight of material < 1.8 t/m3)

Slightly heavy digging work (specific weight of material < 1.5 t/m3)
T1-1-18
MECHATRO CONTROL SYSTEM
E215B-E245B
1. 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
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)
GAUGE CLUSTER
LCD DISPLAY
FOR SELECTION
FUEL GAUGE
COOLANT TEMP. GAUGE
SWITCH
SENSOR BLOCK
SE-3
SE-7
SCREEN CHANGE
BUZZER STOP
(1)
(8)
(7)
L4
(6)
WASHER
SE-5
WIPER
ACCEL DIAL
SE-16
SERIAL COMMUNICATION
TRAVEL
AUTO-IDLE
(5)
OUTPUT VOLTAGE
MODE
(2)
SE-1
SE-8
L2
L3
(3)
SE-2
PSV-R
SHORT-CIRCUIT
VALVE
PROPORTIONAL
VALVE
SE-23
HIGH PRESSURE SENSOR
C-1
SE-22
MECHATRO CONTROLLER
ENGINE
GOVERNOR
MOTOR
M-2
A1
L5
A2
A3
SPEED SENSOR
SE-13
PSV -P1
P1 PUMP PROPORTIONAL VALVE
: HIGH PRESSURE SENSOR

(FOR P1,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
L1
E215B-E245B
MAIN CONTROL VALVE

SE-29
(3)
UP
REVERSE
REVERSE
L2
L3
LEFT ARM OUT
(5)
(7)
SV-13
N&B
SELECTOR VALVE
(8)
OPTION
(6)
BOOM UP
CONFLUX
P2 UNLOAD
TRAVEL LEFT
PL1
ATTACHMENT BOOST
P1 P2
(3)
ARM 1 SPEED
DIGGING
FORWARD
(4)
SWING
(1)
DOWN FORWARD
TRAVEL
P1 UNLOAD
STRAIGHT
BUCKET
ARM 2 SPEED
(2)
TRAVEL RIGHT
DUMP
(8)
BOOM LOW SPEED
ARM OUT
SOL
RIGHT ARM IN
SOLENOID VALVE
L4
SWING MOTOR PARKING RELEASE
PSV
-A
PSV PSV PSV

-D
-C
-B
SV
-2
SV
-3
SV
-1
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SAFETY LOCK LEVER
SWING PARKING BRAKE
TRAVEL 1,2 SPEED
ATTACHMENT BOOST
P2 UNLOAD
TRAVEL STRAIGHT
P1 UNLOAD
L5
ARM IN 2 SPEED
TRAVEL MOTOR 1,2 SPEED SELECT
SV
-4
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
(7)
ARM IN
L6
BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
PROPORTIONAL VALVE
SOLENOID VALVE
) BLOCK
SM0117
T2-1-3
E215B-E245B
P2
(LEFT)
(RIGHT)
OPTIONAL
PILOT VALVE
PILOT
VALVE
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL
STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
P2 UNLOAD
SOLENOID
SWING
N&B
SELECTOR
VALVE
ARM 1 SPEED
UNLOAD VALVE CONTROL
OPTION
2.2
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

pi
PILOT SIGNAL
PROCESS
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0118
1. On starting any one of operations, the control pilot secondary pressure switches spools and enters in
respective low pressure sensors.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3. Each unload pressure proportional valves output pilot secondary pressure according to the command
output by mechatro controller and switches each unload spools.
4. With this operation, the bleed opening according to lever manipulated movement is obtained, consequently
the pump pressure which is used to actuate each actuators are delivered and makes each actuator start
operating.
T2-1-4
P2
SE-23
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL
STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
OPTIONAL
PILOT VALVE
P2 UNLOAD
SOLENOID
SWING
N&B
SELECTOR
VALVE
ARM 1 SPEED
POSITIVE CONTROL & P-Q CONTROL
OPTION
2.3
E215B-E245B
P1
SE-22
SE-11
(LEFT)
(RIGHT)
PILOT
VALVE
PILOT
VALVE
PILOT VALVE
FOR TRAVEL
SE-10
SE-9
LOW
LOW
PRESSURE PRESSURE
SENSOR
SENSOR
SE-1~4
SE-5,7,8
pi
PILOT SIGNAL
PROCESS
P2 PUMP
PROPORTIONAL
VALVE COMMAND
P2 PUMP
PROPORTIONAL
VALVE PSV-P2
pi
pi
PILOT SIGNAL
PROCESS
P1 PUMP
PROPORTIONAL
VALVE COMMAND
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0119
T2-1-5
E215B-E245B
1. Positive control
1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each
low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator,
and consequently the working speed according to the lever manipulated movement will be obtained.
2. P-Q control
1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller
and the mechatro controller processes pilot signal and operates the command according to the input
voltage (load pressure).
2) The lower value between command values calculated by positive control and operated value found by
P-Q control {operated value found in item 1)} is selected and is output to each pump proportional valve
as command value.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator and
consequently working speed will be obtained according to lever movement.
P-Q CONTROL
PILOT SIGNAL PROCESS
PUMP PROPORTIONAL
SECONDARY PRESSURE
PUMP PROPORTIONAL
SECONDARY PRESSURE
POSITIVE CONTROL
PILOT PRESSURE
PILOT SIGNAL PROCESS
PUMP DELIVERY PRESSURE
SM0120
T2-1-6
P2
PILOT
VALVE
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL
STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
P2 UNLOAD
SOLENOID
SWING
N&B
SELECTOR
VALVE
ARM 1 SPEED
BOOM UP CONFLUX CONTROL
OPTION
2.4
E215B-E245B
P1
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS
BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS

pi
PILOT SIGNAL
PROCESS

pi
PILOT SIGNAL
PROCESS
MECHATRO
CONTROLLER
P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P2 UNLOAD
PROPORTIONAL
VALVE PSV-D
pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0121
1. On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux
spool and is input to low pressure sensor.
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control
valve.
4. With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and
also with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are
switched and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during
boom up operation.
T2-1-7
E215B-E245B
P2
LOW
PRESSURE
SENSOR
SE-1~6
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL
STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
PILOT
VALVE
P2 UNLOAD
SOLENOID
SWING
N&B
SELECTOR
VALVE
ARM 1 SPEED
ARM IN RECIRCULATION & CONFLUX CONTROL
OPTION
2.5
P1
LOW
PRESSURE
SENSOR
SE-7
CONTROL PROCESS
FOR 2 SPEED
pi
PILOT SIGNAL
PROCESS
P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM IN PILOT SECONDARY PRESSURE

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SIGNAL
PROCESS
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
pi
pi
ARM PILOT SECONDARY

PRESSURE
P2 PUMP PRESSURE
REVERSE PROPORTIONAL
VALVE CONTROL
PROCESS FOR ARM
2 SPOOL
MECHATRO
CONTROLLER
VALVE FOR ARM
2 SPOOL PSV-A
SECONDARY PRESSURE
SM0122
T2-1-8
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
P2
LOW
PRESSURE
SENSOR
SE-7
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL LEFT
TRAVEL
STRAIGHT
PILOT
VALVE
P2 UNLOAD
SWING
SOLENOID
ARM 1 SPEED
N&B
SELECTOR
VALVE
BOOM UP CONFLUX
ARM-IN ANTI-CAVITATION CONTROL
OPTION
2.6
P1
ACCEL
POTENTIO
pi
PILOT SIGNAL
PROCESS

pi
PILOT SIGNAL
PROCESS
pi
P2 PUMP
PROPORTIONAL
VALVE PSV-P2
VALVE CONTROL PROCESS
FOR ARM 2 SPOOL PSV-Bpi
pi
VALVE FOR ARM
2 SPOOL COMMAND
ENGINE SPEED (COMMAND VALUE)
MECHATRO
CONTROLLER
VALVE FOR ARM 2 SPOOL
PSV-A
pi
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
PILOT
VALVE
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL
STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
P2 UNLOAD
SOLENOID
SWING
N&B
SELECTOR
VALVE
ARM 1 SPEED
ARM-OUT CONFLUX CONTROL
OPTION
2.7
E215B-E245B
P1
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS
P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM OUT PILOT SECONDARY PRESSURE

pi
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
MECHATRO
CONTROLLER
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
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.
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
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
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
BOOM UP CONFLUX
TRAVEL LEFT
TRAVEL
STRAIGHT
PILOT
VALVE
P2 UNLOAD
SOLENOID
SWING
N&B
SELECTOR
VALVE
ARM 1 SPEED
BUCKET DIGGING (DUMP) CONFLUX CONTROL
OPTION
2.8
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
pi
PILOT SIGNAL
PROCESS
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
pi
PILOT SIGNAL
PROCESS
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
pi
PILOT SIGNAL
PROCESS
TRAVELSTRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE 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.
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.
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
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL
STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
PILOT
VALVE
P2 UNLOAD
SOLENOID
SWING
N&B
SELECTOR
VALVE
ARM 1 SPEED
BUCKET DIGGING ANTI-CAVITATION CONTROL
OPTION
2.9
E215B-E245B
P1
LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS
BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS

pi
PILOT SIGNAL
PROCESS
ACCEL
POTENTIO
P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS

pi
PILOT SIGNAL
PROCESS
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C
pi
PILOT SIGNAL
PROCESS
BUCKET
ANTI-CAVITATION
PROCESS
ATT BOOST
SOLENOID VALVE
SV-2
ENGINE SPEED (COMMAND VALUE)
MECHATRO
CONTROLLER
SECONDARY PRESSURE
P1 PUMP PRESSURE
T2-1-13
SM0126
E215B-E245B
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.
valves, P1 and P2 unload proportional valves and travel straight proportional valve.
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
E215B-E245B
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL
STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
P2 UNLOAD
SOLENOID
SWING
N&B
SELECTOR
VALVE
ARM 1 SPEED
PILOT
VALVE
OPTION
2.10 SWING PRIORITY CONTROL
P1
LOW
PRESSURE
SENSOR
SE-5
SE-7
pi
pi
PILOT SIGNAL
PROCESS
PILOT SIGNAL
PROCESS
pi
pi
SWING PILOT SECONDARY PRESSURE
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
SWING PILOT SECONDARY PRESSURE
P2 PUMP
PROPORTIONAL
VALVE PSV-P2
TRAVEL STRAIGHT
PROPORTIONAL
VALVE COMMAND
TRAVEL STRAIGHT
COMMAND
PROPORTIONAL
VALVE PSV-C
VALVE CONTROL
PROCESS FOR ARM
2 SPOOL
VALVE FOR ARM
2 SPOOL PSV-A
MECHATRO
CONTROLLER
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.
valves, P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve
for arm 2 spool.
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
(RIGHT)
PILOT
VALVE
P2
PILOT VALVE
FOR TRAVEL
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL LEFT
BOOM UP CONFLUX
PILOT
VALVE
TRAVEL
STRAIGHT
(LEFT)
P2 UNLOAD
SOLENOID
SWING
N&B
SELECTOR
VALVE
ARM 1 SPEED
OPTIONAL
PILOT VALVE
OPTION
2.11 TRAVEL STRAIGHT CONTROL
P1
SOLENOID SHORT CIRCUIT

VALVE
SE-10
SE-9
SE-11
LOW
PRESSURE
SENSOR
VALVE SIGNAL
TRAVEL STRAIGHT SIGNAL
pi
PILOT SIGNAL
PROCESS
PROPORTIONAL
VALVE PSV-R
IN SHORT-CIRCUIT
VALVE
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

pi
PILOT SIGNAL
PROCESS
PILOT
SECONDARY PRESSURE
T2-1-16
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
SM0128
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 operation
Boom
Arm
Right travel operation (P1)

Left travel operation (P2)
T2-1-17
Bucket
Swing
Option
E215B-E245B
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL
STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
PILOT
VALVE
P2 UNLOAD
GAUGE CLUSTER
SWING
SOLENOID
ARM 1 SPEED
N&B
SELECTOR
VALVE
OPTION
2.12 PRESSURE RELEASE CONTROL
P1
SE-23
SE-22
ENGINE
(M-2)
PRESSURE
RELEASE
CONTROL
ENGINE SPEED
CONTROL
pi
pi
pi
pi
PILOT SIGNAL
PROCESS
PILOT SIGNAL
PROCESS
PILOT SIGNAL
PROCESS
PILOT SIGNAL
PROCESS
MECHATRO
CONTROLLER
P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
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
E215B-E245B
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL
STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
P2 UNLOAD
SWING
SOLENOID
OPTION
PRESSURE SENSOR N&B

FOR BREAKER
SELECTOR
SE-29
VALVE
ARM 1 SPEED
2.13 N&B SWITCH CONTROL (OPTION)
P1
A MODE
B MODE
GAUGE CLUSTER
pi
B MODE SWITCH
MECHATRO
CONTROLLER
pi : OUTPUT OF N&B SELECTOR SOLENOID
SM0131
1. 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
P2
LOW
PRESSURE
SENSOR
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL
STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
P2 UNLOAD
SOLENOID
SWING
PILOT VALVE
ARM 1 SPEED
N&B
SELECTOR
VALVE
OPTION
2.14 OPTION CONFLUX CONTROL (OPTION)
P1
SINGLE / CONFLUX
SWITCH
SE-11
pi
PILOT SIGNAL
PROCESS
OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS
P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
PILOT SIGNAL
PROCESS

pi
PILOT SIGNAL
PROCESS

pi
PILOT SIGNAL
PROCESS
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO
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.
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

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
2. Gauge cluster
11
22:00
H
1
2
3
10
4
No.
Name
Engine coolant temperature gauge
Fuel level gauge
Screen change switch
Buzzer stop switch
Work mode select switch
Washer switch
Wiper switch
Travel high speed, low speed select switch
Auto accel switch
10
Select switch
11
Multi display (LCD)
SM0134
T2-1-21
E215B-E245B
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
S mode
10:25
Contents
"S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.
10:25
H mode
"H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.
B mode
10:25
For the work with breaker, select "B mode" without fail.
10:25
For the work with crusher (nibbler), select "A mode".
A mode
T2-1-22

1) Pump flow rate adjustment (A mode /B mode)
No. Switches
1
Buzzer stop switch
KPSS work mode select switch
Washer switch
Wiper switch
Travel speed select switch
Auto accel switch
Select switch
E215B-E245B
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 rate 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
130 L/m
Flow
rate
Enter
(a)
Flow
rate
100 L/m
(b)
(d)
100 L/m
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
100 L/m
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
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
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
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
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
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
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 information like pressure sensor sensed value,
proportional valve command, etc. output by mechatro controller
6) Failure diagnosis mode display function .......Specifies failed section automatically for failures which are not
detected by self diagnosis and displays the results.
T2-1-25
E215B-E245B
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)
CLOGGED AIR FILTER
CHANGE ENG OIL
NOTE: Error codes were stored as trouble history, and displayed on the monitor by the
trouble history display function.
T2-1-26
E215B-E245B
Warning Condition
Level
Priority
(*)
Screen
DATA COMMUCATION ERROR
SWING BRAKE DISENGAGED
ENGINE STOP
FAIL DRAIN HYD. PRESSURE
DRAINING HYD. PRESS.
Condition
Engine
Only
Key ON
Run
Data from Mechatro controller

is not received
The swing parking brake
switch is turned ON
Engine is stopped after engine
oil pressare low warning
Impossible to drain hyd.
Pressure
Auto
Stop
Possible to drain hyd. Pressure
CAUTION ATTACHMENT
The selector valve (OPT) is

malfunction
POWER BOOST ON
The power boost switchis turn ON
FINISH WARM-UP
After finishing warming up

control
Low engine oil pressure
W005
LOW ENG OIL PRESS.
W006
W010
W008
O
O
W001
W009
The engine water is more than

105 C
Water in water separator filter
is increased
HIGH ENG. WATER TEMP.
DRAIN WATER SEPA
CLOGGED AIR FLTR
(SELF DIAGNOSIS SCREENS)
PREHEAT
CHARGE ERROR
No signal from the alternator
LOW FUEL LEVEL
The fuel level is less than 10 %
LOW ENG WATER LEVEL
AUTO WARMING UP
CHANGE ENG OIL
The air filter is clogged

According to the self diagnosis
control
The heater relay contact is
faulty
The warter engine coolant

reservoir is low
The auto warming up control is
activated
The remaining time is reached
zero Huors
(*) 1: these extremely influence safety and the machine

performance
2: these warn the machine control mode is switched
3: fatal failure
4: normal priority warning
5: low priority message
3.2
Type
(**)
Disconnection
Trouble
History
Manual Code
Stop
Buzzer sounds
W011
W004
(**) 1: Continuation
2: Beep ON 0.2 sec. OFF 0.3 sec.
SELF DIAGNOSIS DISPLAY
CONTROL
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
Pressure sensor, Governor motor
INPUT Proportional valve, Battery relay
Selector valve (SOL)
Gauge cluster
(Buzzer sound)
SM0147
T2-1-27
E215B-E245B
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
Low pressure
sensor
High pressure
sensor
D
Proportional
valve for
Proportional
valve for
nd
Solenoid valve
G
Speed sensor
Throttle
Boom up
P1 pump
P1 unload
P1 pump
ATT boost
Step motor
02
Torque adjust
data
Boom down
P2 pump
P2 unload
P2 pump
Swing parking
brake
Step motor
03
Unload
adjust data
Arm out
Boom head
Travel straight
05
Bucket
digging
06
Bucket dump
07
Swing
09
Travel right
10
Travel left
11
Selector
position
Communication
Battery relay
Relay output
Battery relay
Wiper ark
prevention
AND 3 DIGIT
01
Arm in
rd
Engine
adjust data
04
H
Potentiometer
etc.
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
1
Larger than
normal range
Transistor
OFF failure/
Wrong output
Wrong output
Disconnection
Disconnection
Power source
short circuit
Power source
short circuit
Transistor ON
failure
Disconnection
Transistor ON
failure
Disconnection
Over run
Transistor ON
failure /
Disconnection
Disconnection
Power source
short circuit
Obnormal
data
T2-1-28
Time is over
Contact point
is melted and
adhered
Power source
short circuit

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.2No.3No.4...)
Wiper switch: Screen loses by 1 in order. (No.24No.23No.22...)
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns
to No.1. (No.1No.2No.3No.1...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then
returns to No.3. (No.3No.2No.1No.3...)
4) Turn key switch OFF and the display of service diagnosis mode is closed.
T2-1-29
E215B-E245B
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
Service diagnosis mode
MODE
H-1 ACCEL VOLT.
POS.
G-1 MOTOR STEP
POS.
COIL A
COIL B
G-2 LIMIT SW.
NO.3 SOL.VALVE
F-1 POWER BOOST
COMP.
MEAS.
SWITCH
F-2 SWING-BRAKE
COMP.
MEAS.
RELEASE SW
F-3 1/2-TRAVEL
COMP.
MEAS.
SWITCH
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

Measured value
Switch
OFF
OFF
OFF

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
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


SM0149
T2-1-30
No.
7
10
11
Displays
Contents
NO.7 P.SENSOR PROPO-V

C-1 PUMP P1
0.4 V 0.3 M
C-2 PUMP 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

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

1.0 M
1.0 M
0 mA
30 L

1.0 M
1.0 M
0 mA
30 L

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.
16
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

Measured value (Feed back value)
Spool position
Mode of selector valve
Measured value
Measured value
22
0.0 M
0.0 M

0.0 M
0.0 M

0.6 M
0.6M

0.0 M
0.0 M

Displays
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
E215B-E245B
Contents

NO.18 DIGITAL INPUT

DI1
OFF
DI2
ON
DI3
OFF
DI4
OFF
DI5
OFF
DI6
OFF
DI7
--DI8
OFF
DI9
OFF
DI10 OFF
DI11 --DI12 --DI13 ON
DI14 ---
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
NO.19 DIGITAL INPUT

DI15 --DI16 ON
DI17 ON
DI18 OFF
DI19 --DI20 OFF
DI21 --DI22 --DI23 ON
DI24 OFF
DI25 ON
DI26 --DI27 OFF
DI28 ---
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
NO.20 DIGITAL INPUT

DI29 OFF
DI30 --DI31 --DI32 --DI33 ON
DI34 --DI35 --DI36 OFF
DI37 --DI38 OFF
DI39 --DI40 OFF
DI41 --DI42 ---
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
NO.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

Measured value
Measured value
Measured value
Measured value
Measured value
Measured value
Measured value

DO8 COMP. ON
MEAS. ON
DO9 COMP. OFF
MEAS. OFF
DO10 COMP. --MEAS. --DO11 COMP. OFF
MEAS. OFF
DO12 COMP. --MEAS. --DO13 COMP. --MEAS. --DO14 COMP. --MEAS. ---

Measured value
Measured value
Measured value
Measured value
Measured value
Measured value
Measured value
See
Mechatro
controller
connector
SM0150
T2-1-31
E215B-E245B
No.
23
24
25
Displays
Contents

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

Measured value
Measured value
Measured value
Measured value
Measured value
Measured value
Measured value

DO22 COMP. --MEAS. --DO23 COMP. OFF
MEAS. ON
DO24 COMP. --MEAS. --DO25 COMP. --MEAS. --DO26 COMP. --MEAS. --DO27 COMP. --MEAS. --DO28 COMP. --MEAS. ---

Measured value
Measured value
Measured value
Measured value
Measured value
Measured value
Measured value
NO.25 WIPER SYSTEM

WIPER SW
RISEUP SW
REVERSE SW
PREVENT ARC
CW MOTOR RLY
CCW MOTOR RLY
WASHER SW
MOTOR RELAY
OFF
ON
ON
OFF
OFF
OFF
OFF
OFF
Wiper switch
Wiper rise-up switch
Wiper reverse rotation switch
Wiper motor ark prevention
relay
Wiper normal rotation relay
Wiper reverse rotation relay
Washer switch
Washer motor relay
SM0151
T2-1-32
E215B-E245B
No.
1
Displays
Contents
NO.1
MAIN CONT. P/N
YN22E00207F1
PROGRAM VERSION
1-VER 2.00
2-VER 0.00
P/No. indication
MERIT controller program version
SERVICE DIAG 2
31
32
No.
33
Service diagnosis mode 2
34
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

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

Command current
Command current
Command current
Command current
Command current
Command current
Arm out pressure sensor
Arm in pressure sensor
Boom up pressure sensor
Swing pressure sensor
Engine actual speed
Power shift current
35
Displays
Contents
NO.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

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

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

Command current
Command current
Command current
Command current
Command current
Command current
P1 side option pressure sensor
Optional selector SOL (Nibbler line)
Conflux/ Single selector switch
Engine actual rpm
Power shift current
SM0152

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
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
WATER TEMP.
TOTAL 10Hr
LEVEL1 24% 22%
LEVEL2 50% 50%
LEVEL3 25% 25%
LEVEL4 1 %
3%
Coolant temperature distribution (%)

SM0153
T2-1-33
E215B-E245B
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
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
600~617 mA
E-2 P2-PSV
350 mA
D-1 P1-UL(BPC)
427~477 mA
D-2 P2-UL(BPC)
750 mA
B-1 BOOM RAISE
0.0 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 lever operation & relief

H mode Hi idle
Operation No.7 : Arm-in in full lever operation & in operation
No.32 ARM, SWING
No.32 ARM, SWING
H mode Hi idle
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
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

after release of low temperature mode
* Measure the values after a lapse of 5 minutes or

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
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-2 P2-PSV
415~525 mA
E-1 P1-PSV
650~750 mA
E-2 P2-PSV
540~563 mA
D-1 P1-UL(BPC)
360 mA
D-1 P1-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-2 P2-UL(BPC)
360 mA
D-3 S-TRAVEL
720 mA
D-3 S-TRAVEL
720 mA
B-5 BUCKET DIG
3.0 M
B-5 BUCKET DIG
3.0 M
B-6 BUCKET DUMP
0.0 M
B-6 BUCKET DUMP
0.0 M
G-3 ENG SPEED
1970~2060
POWER SHIFT
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
C-2 P2-PRES
33.0~35.8 M
6.0~15.0 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 BUCKET DUMP
3.0 M
G-3 ENG SPEED

POWER SHIFT
1970~2060
G-3 ENG SPEED
0 mA
POWER SHIFT
T2-1-37
1970~2060
0 mA
E215B-E245B
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

DOUBLE FLOW SW.
G-3 ENG SPEED
POWER SHIFT
NIB
F-4 OPT SELECT
ON
DOUBLE FLOW SW.
1970~2060
G-3 ENG SPEED
0 mA
POWER SHIFT
BRK
OFF
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

3.4
E215B-E245B
TROUBLE HISTORY DIAGNOSIS
The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as
one of history. And the errors are able to be indicated on the multi display.
A part of warning contents is stored (the stored items are listed in warning table).
The error code for self diagnosis is stored.
1. How to display
1) Turn starter switch on.
2) Press buzzer stop switch continuously 5 times and the trouble history screen is displayed.
(Example)
No errors
NO ERROR
Error detected in the past
SM0154
3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
Hour meter and 4 failure data are displayed on screen.
In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
Press washer switch ( ) A, and the item moves upward.
Press wiper switch ( ), and the item moves downward.
5) Turn starter switch off, and the display is disappeared.
2. How to delete contents of trouble history
1)
2)
3)
4)
Display trouble history screen.

Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
When "NO ERROR" is displayed, the deletion is completed.
Turn starter switch off.
NOTE: all the stored items are erased. It is impossible to erase data partially.
T2-1-39
E215B-E245B
3.5
TROUBLE DIAGNOSIS MODE
The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be
detected through the use of self diagnosis function (the failure can be specified through the use of error code)
like disconnection and abnormal output. This is useful to save the time for troubleshooting.
1. Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are
automatically actuated, the sensor detects the machine status and the mechatro controller identifies
the normal condition or failed condition of the system.
For details of how to use, refer to Chapter: TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".
T2-1-40

3.6
E215B-E245B
SET PROCEDURE OF MAINTENANCE SCHEDULE
This machine is equipped with multi-display which allows confirmation of remaining time to the coming
replacement/change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the
remaining time reaches to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc.
and perform the initial setting by the following order.
NOTE: interval of replacement of parts is mentioned
below.
Screen change
switch
Buzzer stop
switch
KPSS work mode

select switch
Washer
switch
Engine oil : 500 Hr

Fuel filter : 500 Hr
Hydraulic filter : 1,000 Hr
Hydraulic oil : 5,000 Hr
Select
switch
Auto accel
switch
Travel speed
select switch
Wiper
switch
SM0155
Procedure
Operating Procedure
Display on Multidisplay
NEW HOLLAND
Turn starter key switch on.
KOBELCO
Press "
" switch press once display
change switch on the switch panel once. And
the clock display changes to the display of
remaining time for coming engine oil change.
Press "
" switch press once select
switch once and the display for the engine
oil change reverses.
When required to adjust the interval to the coming
change time by 10 hours, press "
" switch
and the time to the coming engine oil change is
added. Press "
" switch and the time to the
coming engine oil change is reduced.
When desired to return to the initial set time,
press "
" buzzer stop switch once.
Press "
" select switch once and the set
time is stored.
10:25
H
250 Hr
ENGINE OIL
250 Hr
ENGINE OIL
500 Hr
ENGINE OIL
After several seconds,

display is changed to
clock autmatically.
Press screen change

switch
once more.
Press select switch

once more.
Replacing interval is
changed with each
pressing of switch.
To set the desired interval,

press the select switch
10:25
H
250 Hr
ENGINE OIL
250 Hr
ENGINE OIL
500 Hr
ENGINE OIL
500 Hr
ENGINE OIL
H
SM0156
NOTE:
1. After displaying the display for setting by pressing the display change switch, set the respective
maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does
not sound.
T2-1-41
E215B-E245B
3.7
ADJUSTING PROCEDURE OF DISPLAY
1. For operator
1) Clock Adjustment Switches
No.
Switches
Screen Change Switch
Buzzer Stop Switch
Work Mode Select Switch
Washer Switch
Wiper Switch
Travel Speed Select Switch
Auto Accel Switch
Select Switch
Main screen
10:25
SM0140
(a)
SWITCH STATUS
CLOCK/CONTRAST
13:15
H
(a)
H
(b)
(c)
SWITCH STATUS
CLOCK/CONTRAST
(d)
(e)
ADJUST CLOCK
ADJ CONTRAST
Y M D H M
06 04 01 13 15
Select Year/Month/Day/Hour/Minute
Enter
Increase/Decrese
SM0157
1) Turn starter key switch on and display main screen (a) for operator, and then press select switch (8)
and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2) In operations of FEED
(4) and FEED
(5), move cursor to "CLOCK/CONTRAST" screen (c) and
then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4) Select any of "YMDHM" in operation of FEED
operations of FEED (6) and FEED (7).
(4) and FEED
(5) and vary the values in
5) After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting
is completed, and then the screen returns to main screen (a).
T2-1-42
2) Contrast Adjustment Switches

No.
E215B-E245B
Switches
Screen Change Switch
Buzzer Stop Switch
Work Mode Select Switch
Washer Switch
Wiper Switch
Travel Speed Select Switch
Auto Accel Switch
Select Switch
Main screen
10:25
SM0140
SWITCH STATUS
CLOCK/CONTRAST
H
(a)
(b)
(c)
SWITCH STATUS
CLOCK/CONTRAST
(d)
(a)
ADJUST CLOCK
ADJ CONTRAST
10:25
H
(e)
ADJUST CLOCK
ADJ CONTRAST
(f)
Enter
ADJ CONTRAST
55555
Adjustable range
11111~99999
(Default 55555)
Increase/Decrease
SM0158
1) Turn starter key switch on and display main screen (a), and press select switch (8) and display
"SWITCH STATUS CLOCK CONTRAST" select screen (b).
2) In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.
3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and
then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4) Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5) Vary the values by pressing the desired figure in operations of FEED (4) and FEED
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) 99999 (clear) * The initial set value is 55555.
(5).
6) Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).
T2-1-43
E215B-E245B
2. Function for service

Following items are provided for adjustment of service function.
LANGUAGE/LOGO
Function
Explanation
Range
All language data is stored in 15

one gauge cluster
languages
LANGUAGE
To change language
LOGO
To change Company Logo
Note
5 Logos
Default
ISO
NHK
ADJUSTING MODE 1
Function
Explanation
RISE-UP WIPER
Note
To change wiper control, when special

CAB is installed on demolition OFF is for special CAB
machine
Range
ON/OFF
Default
ON
P1 OPT SENSOR To activate the self-diagnosis when P1 Switch to ON when 2PB is

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

ON/OFF
ACTIVE
OPT pressure sensor is failed
option is installed
OFF (*)
PRIORITY MODE
Only for EU, to activate the priority

valve
ON/OFF
OFF
LEFT
ACTIVE
To use P1 option pedal for P4-rotation

circuit, releasing auto accel. And not
activating unload valve
ON/OFF
OFF
PEDAL
SELECT
SYSTEM
OPT
1:No selector valve

Switch to ON when N&B
2:Selector Valve + Mechanical relief
1 or 3
option is installed
3:Selector Valve + Electrical relief
1 or 3 (*)
ADJ
OVERLOAD To change the pressure for overload
PRESS
alarm in EU
10 - 27
18
ENG
DISPLAY
ON/OFF
OFF
SPEED To activate the engine

information for customer
speed
AUTO ACCEL
To change auto accel control type
START MODE
To change
(S,H,B,A)
the
starting
6, 8, 10, 12,
18
14, 16, 18
MODE X: return to default MODE

S, H, B, A, X S
when key sw is ON
To cancel the low temp. mode to

CANCEL
LOW
OFF = Low Temp. Mode
prevent hydraulic hunching at low
ON/OFF
TEMP MODE
ACTIVE
temp.
OFF
DRAIN
PRESS
OFF
HYD. To activate the

pressure function
drain
hydraulic When switch is ON, this

ON/OFF
function starts.
To adjust Pressure and Flow for

ADJ OPT HAMMER
Follow setting procedure
Hammer (9set)
20
35
15 Mpa (at
Pressure
220 L/min)
30 - 220
220 L/min
Flow rate
To adjust Pressure and Flow for

Follow setting procedure
Nibbler (9set)
20
35
15 Mpa (at
Pressure
220 L/min)
30 - 220
220 L/min
Flow rate
ADJ OPT NIBBLER
(*) Autodetect
T2-1-44
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).
1
4
5
3
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
EU (ISO icons only)
ITA
(B)
USA
LANGUAGE/LOGO
ADJUSTING MODE 1
PRESET BY FACTORY
CHN
IDN
THA
SELECT LANGUAGE
ESP
(C)
FRA
ENG
FEED
DEU
VNM
MYS
MMR
TAM
SELECT LANGUAGE
POR
(D)
ENG
FRA
FEED
JPN
SELECT LANGUAGE
(E)
FRA
FEED
SM0070
T2-1-45
E215B-E245B
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)
LANGUAGE/LOGO
ADJUSTING MODE 1
PRESET BY FACTORY
(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
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
2. Press SELECT button (2) to choose the number

relative to the setting pressure, display (F).
18 = 180 bar
63
(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
ADJ OVERLOAD PRESS

18
FEED
63
(F)
ADJ OVERLOAD PRESS

18
FEED
4
63
(G)
ADJ OVERLOAD PRESS

11
FEED
63
ADJ OVERLOAD PRESS
11
FEED
5
SM0073
T2-1-46
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).
(C)
LANGUAGE/LOGO
ADJUSTING MODE 1
PRESET BY FACTORY
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.
(L)
DRAIN HYD PRESS

ON
FEED
10:25
(M)
PR
S
SM0072
T2-1-47
E215B-E245B
3.8
MECHATRO CONTROL EQUIPMENT
1. C-1 Mechatro controller

1) Outside view
2 1
10
2 1
22
18
4 2 1 8
16
26
34
27
CN101
CN105
CN102
16 12
CN103
28
22
CN104
CN106
CN107
CN108
CN109
21 7
2 16
21 9
21 7
21
21
10
31
22
16
24
17
12
17
28
10 22
13 19
20
15 16
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
Down load
Transmission
Reception
Reception
Spare
Spare
Safety relay
Spare
Extra pressure release
Spare
Heavy lift
Output
Output
Output
Output
Output
Input
Signal level
0V
0.5~4.5V
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
0V
Shield GND
EARTH / OPEN(5V
0V
CAN communication
CAN communication
EARTH/OPEN
EARTH/OPEN
EARTH/OPEN
EARTH/OPEN
EARTH/OPEN
EARTH/OPEN
SM0160
T2-1-48
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
Travel right
Input
Travel left
Input
Accelation
Input
P1 option
Input
P2 option
Input
Spare
Input
Spare
Input
Spare
Input
Function
Input/putput
Swing
Input
P1 pump
Input
P2 pump
Input
Boom angle
Input
Arm angle
Input
Reserved
Signal level
0V
0.5~4.5V
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
GND / OPEN
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
SM0161
T2-1-49
E215B-E245B
Connector No.
CN104
Connector No.
CN105
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
Output
Swing P/B select valve
Output
Travel 1,2 speed select valve Output
Attachment boost select valve Output
Battery (-)
Battery (-)
OPT changeable relief 1
Output
P1 unload
Output
Travel 1,2 speed select valve
P2 unload
Output
Travel straight
Output
Arm in
Output
P1 pump
Output
Battery (-)
P2 pump
Output
Output
Spare
Output
Spare
Output
Spare
Output
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
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
Oil level (spare)
Output
Output
Output
Output
0
Output
Spare
Output
Bypass valve
Output
Spare
Output
Battery (-)
Spare
Output
Accel motor A phase

Accel motor A phase
Accel motor B phase
Accel motor B phase
E/G speed sensor
Input
Proportional vlave expand unit
Input/putput
Function
Grid heater feedback
Input
Engine coolant temperature
Input
Input
E/G oil pressure
Air filter
Input
Spare
Input
Spare
Input
E/G coolant level
Input
Spare
Input
Spare
Input
Heater temperature of fuel filter
Input
Spare
Input
Hand control nibbler
Input
Quick coupler
Input
Spare
Input
Heater temperature
Input
Spare
Input
Reserved
Signal level
20~32V
Shield GND
1.5A
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
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
Port name
DI 2
DI 4
DI 5
DI 6
DI 7
DI 16
DI 17
DI 18
DI 19
DI 21
DI 22
DI 23
DI 24
DI
DI
DI
DI
DI
25
26
27
29
30
GP
DI 33
DI 34
DI 35
H1+
H2H2+
H2Port name
DO 1
DO 2
DO 3
DO 4
DO 5
DO 6
DO 12
DO 13
DO 14
DO 15
DO 16
DO 17
DO 18
DO 19
GP
TXD2
RXD2
RTS
CTS
SHG2
DO 10
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Signal level
+24V / OPEN
+24V / OPEN
GND / OPEN
+24V / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
+24V / OPEN
+24V / OPEN
+24V / OPEN
GND / OPEN
Front window open or close

Spare
Conflux/single select
Overload select
Spare
Reserved
Input
Input
Input
Input
Input
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
Charge
Spare
Spare
Reserved
Spare
Input
Input
Input
~12V / 12V~
+24V / OPEN
+24V / OPEN
Function
Key switch (ON)
Water separator
Swing P/B release
E/G start
Spare
Wiper rise up
Wiper reverse
ATT boost
Spare
Spare
Spare
Lever lock
Hand control rotation
Input/putput
0~5V
0V
0~5V
0V
Spare
Function
Wiper arc prevention
Wiper normal moving
Wiper reserve moving
Washer motor
Spare
Reserved
Spare
Swing flasher (RH)
Swing flasher (LH)
Travel alarm
Auto idle stop relay
Engine stop
Lever lock
Grid heater
Reserved
Input/putput
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Signal level
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
0V
Tranmission RS232C communication
Spare
Spare
Reception RS232C communication

Shiled GND
24V/OPEN
SV
SM0164
T2-1-52
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
Gauge cluster Mechatro

controller
(RS232C
communication)
White
GND source (+24V Battery

direct connection)
Yellow /
Black
Mechatro controller Gauge

cluster
(RS232C
communication)
Red
GND
Black
Source (+24V starter switch

ON)
White
GND
communication)
Black
(RS232C
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
Monitor display
LCD dot 120168
Gauge display (Coolant temp., Fuel level)
Stepping motor
Buzzer
Buzzer stop switch
Work mode select switch
Piezo-electricity type
T2-1-53
E215B-E245B
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
CN2-1
20
14
12
CN2-2
20
CN4-1
17
11
22
10
CN5
15
26
13
13
CN3-2
12
16
24
12
CN8
17
CN3-1
26
13
1
CN9
20
12
1
CN2-3
3
CN15
3 CN12
CN1
CN14
CN4-2
1
CN17
CN16
CN13
6
2
1
6
2
CN10
LOCATION OF CONNECTORS (Seen from backside)
LOCATION OF RELAY & FUSE
LABEL OF RELAY & FUSE BOX

No. CODE IN CIRCUIT
PARTS NAME
SM0166
T2-1-54
E215B-E245B
2) Circuit diagram
SM0167
T2-1-55
E215B-E245B
SM0168
T2-1-56
E215B-E245B
SM0169
T2-1-57
E215B-E245B
4) High pressure sensor : YN52S00048P1
SPECIFICATION :
ECONOSEAL SERIES MARK(+)>

3POLES CAP
MATING HOUSING174357-2
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 (+)
INSURANCE RESISTANCE : 100M
POWER SOURCE (+)
PLASTIC POTTING
(BETWEEN CASING AND ALL IN/OUT
TERMINAL
TERMINALS AT 50V DC MEGGER)
CONDENSER
DIE
ELECTRIC CONNECTING DIAGRAM
CASING
FLEXIBLE BOARD
CIRCUIT
OR MORE
HOUSING
COVER
(Ex. Construction of internal controller)
DIAPHRAGM
O-RING P14
JIS B2401 CLASS1B
PF 3/8
Tightening torgue
73.5N.m (54.2lbf.ft)
4.5V DC)
PIPE
THREAD
STRUCTURE
SM0170
5) Low pressure sensor : YX52S00013P1

Tightening torgue
Vout
29.434.3N.m (21.725.3lbf.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
HYDRAULIC SYSTEM
E215B-E245B
1. SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety, mass
volume handling and low fuel consumption.
Device
Attachment
Function
Features
Performance
Device
Function
Features
Electric flow controlled variable displacement

pump
Pump delivery rate control by a current

command to the solenoid proportional valve
of the variable displacement pump
Positive flow rate control
Flow control by positive pilot control pressure
Hydraulics backup control
Backup control by hydraulic when the electric

flow controlled variable displacement pump
fails.
Boom up conflux circuit
Speed up of boom up operation
Arm conflux circuit
Speed up of arm operation
Bucket conflux circuit
For speed-up of bucket operation (digging &

dump)
Travel 2-speed change & Auto 1st (low)

speed return
1-2 travel speed change and low speed / high

torque at heavy duty
Auto parking brake
Automatic braking when parking
Motor overrun protection
Prevents overrunning of travel motor on the
Travel pilot operation
Prevents hunting by the built in travel
Reverse rotation protective function
Easy positioning to protect it from swinging

back when stops swinging.
Swing priority circuit

(simultaneous operation of arm in and swing
Easy operation of stable swing speed, arm

slanted leveling, swing press digging
Optimum operation by work mode select

(H,S,A,B)
Efficient operation in all work modes
Automatic swing parking brake
Swing parking brake when operating at on a

slope
Auto accel
Reduce fuel consumption and noise by

lowering engine speed when control lever is
in neutral position.
Hydraulic pilot control system
Light action with operating lever
Pilot safety lock system
Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm)
Protect boom and arm from unexpected drop

(Natural fall).
Holding valve for boom (Option)
Prevention of boom falling when boom head

side piping breaks
manual
valve
for
lowering
Attachment
Micro
computer
Low fuel
consumption
Pump
Travel straight at combined operation
Mass handling capability
Travel straight
Emergency
attachment
Others
Easy operability and safety
Swing
Travel
Performance
For safety, this valve lowers risen attachment

to the ground, if the machine stops with
engine trouble, and the pressure in the
cylinder of attachment can be released.
Pressurized hydraulic oil tank
To prevent hydraulic oil from entering dust

and to promote self suction ability of pump
Suction strainer
Remove dust on suction side.
Line filter; pilot circuit
To prevent pilot
malfunctioning
Return circuit oil filter
To prevent hydraulic oil from contamination
Cooling hydraulic oil by oil cooler
To prevent hydraulic oil from being deteriorated.
Pressure draining circuit
To release the main circuit pressure for piping

repair work.
Main control valve with optional valve
Optional piping and additional work are easy
Switching of return line for N&B machine in

the cab (Option)
Switching of return line for N&B machine is

able to change with a switch in the cab
operating
circuit
from
T2-2-1
E215B-E245B
HYDRAULIC SYSTEM
2. HYDRAULIC CIRCUITS AND COMPONENTS

HYDRAULIC DIAGRAM READING KEY
Item
T2-2-2
Component name
Hyd. pump assy
Control valve (main)
Swing motor unit
Travel motor unit
Boom cylinder (RH & LH)
Arm cylider
Bucket cylinder
Swivel joint
Pilot valve (ATT)
10
Pilot valve (travel)
11
Inline filter
12
Suction strainer
13
Solenoid valve assy
14
Return filter
15
Air breather
16
Restrictor
17
Shuttle valve
18
Short-circuit valve
19
Low pressure sensor block
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
Conflux OFF
Conflux OFF
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
58
59
56
SM0080
T2-2-9
E215B-E245B
6. COLOR CODING STANDARD FOR

HYDRAULIC CIRCUITS
Blue
Feed, drain circuit
less than 0.44 MPa (64 psi)
Green
Return, make up circuit,
0.44~0.59 MPa (64~86 psi)
Purple
Secondary pilot pressure,
(including proportional vlave)
0.59~5 MPa (86~725 psi)
Red
Primary pilot pressure,
(including proportional vlave)
5 MPa (725 psi)
Orange
Main pump drive pressure,
5~34.3 MPa (725~4970 psi)
Blue tone
At valve operation
Red valve
When solenoid proportional valve (reducing) is
operating
Red solenoid
In active and exciting
Displaying the flow circuit and standby circuit when
operating.
Regarding the electrical symbols in this manual,
refer to the electric circuit diagram.
HYDRAULIC SYSTEM
7. NEUTRAL CIRCUIT
7.3 PUMP POSITIVE FLOW CONTROL
This section describes the following.

7.1 Bypass cut valve and unload valve control
7.2 Safety lock lever and pilot circuit
7.3 Pump positive flow control
7.4 Pump P-Q (Pressure-Quantity) curve control
(1) Type:
Electric flow controlled variable displacement
pump.
7.1 OPERATION OF BY-PASS CUT VALVE AND

UNLOADING VALVE HOUSED IN CONTROL
VALVE
(3) Operation:
(1) By-pass cut valve

On starting engine, P1 and P2 unloading
proportional valves (PSV-D, PSV-B) output
secondary pressure according to the command
output by mechatro controller, and this pressure
exerts on PBp1 and PBp2 ports, and
consequently the by-pass cut spool is switched
to CLOSE side.
The by-pass cut spool is usually held on CLOSE
side after the engine started. And it is switched
to OPEN side only when failure occurred on
pump proportional valve and mechatro
controller.
(2) Unloading valve
On starting engine, like by-pass cut valve, the
secondary pressures output by P1 and P2
unloading proportional valves (PSV-D, PSV-B)
exert on PCb and PCa ports, consequently the
P1 and P2 unloading valves are switched to
OPEN side.
7.2 SAFETY LOCK LEVER AND PILOT CIRCUIT
(1) Purpose:
To protect attachment
movement for safety.
from
unexpected
(2) Principle:
Cut pressure source of pilot valve for operation.
(3) Operation:
If the safety lock lever (red) is pushed forward
after the engine starts, the limit switch (SW-11)
is turned on. The timer relay is actuated one
second later which causes the solenoid (SV-4)
of the solenoid valve block (13) to be energized
and makes the pilot operating circuit to stand by.
T2-2-10
(2) Principle:
The current command I to the pumps solenoid
proportional valve controls the delivery rate of
the pump.
1) Flow rate rise operation (Eg. P1 pump)
By operating any of control levers, the
operating secondary pressure of pilot valve
rises, and the rising pressure is transformed
to the rise of output voltage corresponding
to the pressure input by the low pressure
sensor.
Mechatro
controller
signalprocesses this change of voltage, resulting
in rise of command current value I to the
pump proportional solenoid valve and
consequently the pump flow rate rises. This
is called "Positive Control System".
As the pump command current value rises,
the secondary pressure of proportional
solenoid valve also rises. On the regulator
attached on the pump, the spool (652)
through piston (643) is pushed leftward, and
stops at the position where being in
proportion to the force of pilot spring (646).
The tank port connected to the large bore of
servo piston (532) opens, and the piston
moves leftward by delivery pressure P1 of
the small bore resulting in the increase of tilt
angle ( ).
The servo piston and spool (652) are
connected to feedback lever (611).
Therefore when servo piston moves
leftward, the spool (652) also moves
rightward by means of feedback lever. With
this movement, the opening of spool sleeve
closes gradually, and the servo piston stops
at the position the opening closed
completely.
2) Flow rate reduction operation
As the current value I of mechtro controller
reduces, the secondary pressure of
solenoid proportional valve reduces, and
spool (652) is moved rightward by the force
of pilot spring (646). With the movement of
spool, the delivery pressure P1 usually flows
into the large bore of piston through the
spool.
The delivery pressure P1 flows in the small
bore of servo piston, but the servo piston
moves rightward due to the difference of
area, resulting in the reduction of tilt angle.
Similarly, when the servo piston moves
rightward, the spool (652) is moved leftward
by the feedback lever.
The operation is maintained until the

opening of spool sleeve is closed.
7.4 PUMP P-Q CURVE CONTROL OPERATION

(1) Type:
Electrical flow control type variable pump
(2) Principle:
Perform an operation of the value from pump
high pressure sensor to P-Q curve control value,
and send a command to the pump solenoid
proportional valve.
(3) Operation:
The pump high pressure sensor converts the
pressure to the output voltage corresponding to
the pump delivery pressure.
The mechatro controller converts the voltage
output by the high pressure sensor to the P-Q
curve control value. On the other hand, select
the pump positive control command current
value from the low pressure sensor in lower
order, and the values are output to respective
pump proportional valve as a command current.
With this operation, the pump power is
controlled so as not to be exceed the engine
power, therefore engine dose not stall.
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
E215B-E245B
HYDRAULIC SYSTEM
8. TRAVEL CIRCUIT
8.1 Travel forward pilot simultaneous operation
circuit
8.2 2 speed travel solenoid command circuit and
auto 1-speed return function
8.3 Travel main circuit
8.4 Travel motor function
8.1 TRAVEL FORWARD PILOT
SIMULTANEOUS OPERATION CIRCUIT
(1) Purpose:
Light operating force and shockless operation
(2) Mechatronics :
1) If the travel lever with damping mechanism
is operated for travel right, left and forward
motions, the secondary pilot proportional
pressure comes out of the 3, 1 ports of P/V
(10). The higher of the pressures is
selected, comes out of the 6, 5 ports and
acts upon the low pressure sensors (SE9)
(SE-10).
2) The pilot secondary pressure flows to PAr
and PAL ports of the control valve (2),
moves the travel spool, and switches the
main circuit.
3) The low pressure sensor output voltage is
input into mechatro controller. The mechatro
controller performs signal processing and
outputs current corresponding to the
increase of flow rate to P1 pump
proportional valve (PSV-P1) and P2 pump
proportional valve (PSV-P2), and at the
same time the command current is output to
P1 unloading valve (PSV-D) and P2
unloading valve (PSV-B).
4) The secondary pressures output by P1
pump proportional valve (PSV-P1) and P2
pump proportional valve (PSV-P2) exert on
pump regulator, actuating the pump on the
delivery flow rate increase side.
5) The secondary pressure delivered in P1
unloading valve (PSV-D) and P2 unloading
valve (PSV-B) is fed to PBp1, PCb, PBp2
and PCa ports provided in control valve (2).
The secondary pressure from proportional
valve which has exerted on PBp1 and PBp2
ports holds the by-pass cut spool on CLOSE
side, like the operation in the lever neutral
position.
valve which has exerted on PCb and PCa
ports switches the unloading spool in
CLOSE side.
T2-2-12
8.2 2-SPEED TRAVEL SOLENOID COMMAND

CIRCUIT AND AUTO 1st SPEED RETURN
FUNCTION
1) Purpose:
Change travel motor speed with switch.
(2) Principle:
If the switch is turned, an electric signal is
issued. It excites the 2-speed travel solenoid
which in turn converts the primary pilot pressure
and the self pressure to a tilting angle of the
variable displacement motor.
(3) Operation:
If the rabbit marked switch on the gauge cluster
is pressed, the solenoid (SV-3) of the
proportional valve block (13) is excited and
changes the proportional valve. Then the
solenoid command pressure is issued from port
A3, enters the P port of the travel motor (4),
opens the oil passage to the 2nd speed select
piston, and causes the motor to run in the 2nd
speed tilting mode by its self pressure. However,
when the main circuit pressure rises above 28
MPa (4060 psi), the motors self pressure
pushes the 2nd speed select piston back to the
1st speed.
8.3 TRAVEL MAIN CIRCUIT
(1) Operation:
The delivery oil from Pump A1 and A2 ports by
changing the travel spool with the operation of
travel pilot flows in each VA port on the left side
of travel motor (4) through C,D ports of swivel
joint (8) from AL, AR ports of C/V, and rotates
the travel motor.
8.4 TRAVEL MOTOR FUNCTION
(1) Function:
1) Prevents the motor from over running on a
slope.
2) Check valve that prevents cavitation of the
hydraulic motor.
3) Shockless relief valve and anti cavitation
valve when inertia force stops.
4) High/Low 2 step speed change mechanism
and auto 1st speed return at high load.
5) Travel parking brake.
HYDRAULIC SYSTEM
E215B-E245B
TRAVEL CIRCUIT: Travel 2nd speed, RH & LH simultaneous operation.
SM0082
T2-2-13
E215B-E245B
HYDRAULIC SYSTEM
9. BUCKET CIRCUIT
9.1
9.2
9.3
9.4
9.5
Bucket digging pilot circuit

Auto accel operation
Flow control in the work mode
Bucket digging travel priority main circuit
Bucket spool stroke limiter
9.1 PILOT CIRCUIT FOR BUCKET DIGGING

(1) Mechatronics :
1) When the operation for bucket digging is
performed, the pilot proportional secondary
pressure is delivered through port 1 of the
right pilot V (9), flows to PAc port, and acts
on the low pressure sensor (SE-1), and at
the same time the bucket spool is switched.
2) The voltage output by low pressure sensor
(SE-1) inputs in mechatro controller. The
mechatro controller performs signal
processing
and
outputs
current
corresponding to the increase of pump flow
rate to pump proportional valves (PSV-P1)
and (PSV-P2) on the P1 and P2 pump sides,
and at the same time the command current
is output to P1 unloading valve (PSV-D), P2
unloading valve (PSV-B) and travel priority
proportional valve (PSV-C).
In the following pages, the relation of
operation of low pressure sensor to both the
increase of pump flow rate and unloading
proportional valve is the same. Therefore
the explanation is omitted.
3) The secondary pressure output by P1 pump
proportional valve (PSV-P1) and P2 pump
proportional valve (PSV-P2) exerts on pump
regulator, actuating the pump onto the
delivery flow increase side.
4) The secondary pressure delivered in P1
unloading valve (PSV-D) and P2 unloading
valve (PSV-B) is led to PBp1, PCb, PBp2
and PCa ports provided in control valve (2).
valve which has exerted on PBp1 and PBp2
ports holds the by-pass cut spool on CLOSE
side, like the operation in the lever neutral
position.
valve which has exerted on PCb and PCa
ports switches the unloading spool in
CLOSE side.
T2-2-14
5) The secondary pressure delivered in travel

priority proportional valve (PSV-C) is led to
PTb port provided in control valve (2) and
shifts the travel priority valve one stage.
9.2 AUTO ACCELERATION OPERATION
(1) Principle:
Auto acceleration actuates according to signals
from low pressure sensor.
(2) Operation:
<When lever is set to neutral position>
In the event where the sensor does not receive
signal for 4 seconds or more even though the
acceleration dial is set to MAX position, the
engine speed should be raised to 1000rpm.
<When lever is operated>
When the pressure 0.6MPa (87psi) is input to
low pressure sensor in STD specification (travel,
bucket, swing, arm), proportional voltage from
low pressure sensor inputs in mechatro
controller, and then the engine speed returns to
the dial set position corresponding to the lever
operation.
9.3 FLOW CONTROL IN THE WORK MODE
(1) Principle:
When the engine speed is intermediate speed
or lower, command current value to have the
pump delivery rate constant is output.
(2) Operation:
Even if the engine speed specified by
acceleration potentiometer is low speed, as the
delivery rate corresponds to the intermediate
speed, the actuator moves earlier than the
movement equivalent to the control lever angle
rate in light load operation.
9.4 BUCKET DIGGING AND TRAVEL PRIORITY
CONFLUENCE (CONFLUX) MAIN CIRCUIT
(1) Operation:
1) The oil delivered through A1 port of P1
pump goes into P1 port of C/V (2), opens
load check valve LCc through parallel circuit
and enters in bucket spool.
2) On the other hand, the oil delivered through
A2 port of P2 pump goes into P2 port of C/V
(2), confluences with oil from P1 pump
through travel priority valve, and goes into
bucket spool. (Confluence of oil from 2
pumps)
3) 3)With the function of pilot circuit, the oil flow
is switched from bucket spool, and is fed into
bucket cylinder head side through Ac port of
C/V (2). On the other hand, the return oil
from cylinder rod (R) side is throttled by
bucket spool and returns to tank circuit from

Bc port of C/V (2).
References:
In bucket dumping operation, the travel
priority valve also switches like digging
operation, resulting in confluence with travel
straight.
When the bucket operation and other
operation are simultaneously performed, the
travel priority valve does not actuate,
resulting in single flow of bucket circuit.
9.5 BUCKET SPOOL STROKE LIMITER
(1) Purpose:
To secure simultaneous operability of boom and
arm on boosting up attachment pressure (Pump
flow rate decreases.) and to prevent cavitations
at low engine speed
(2) Operation:
On boosting up attachment pressure, pilot
primary pressure exerts on PCc port of C/V(2)
through attachment booster solenoid valve,
operates stroke limiter of bucket spool, and
throttle oil path of spool. As a result, P1 pump
pressure increases, making the simultaneous
operation of boom up and bucket digging
possible.
Even though the engine speed is low, similarly
the cavitations can be prevented by actuating
the stroke limiter.
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
E215B-E245B
HYDRAULIC SYSTEM
This section describes boom lower operation.
10.3 Boom down pilot circuit
10.4 Prevention of natural fall by lock valve and
actuation at lowering
10.5 Constant recirculation function of boom down
main circuit
10.3 BOOM DOWN PILOT CIRCUIT
(1) Operation:
1) If the boom down operation is performed,
the secondary pilot proportional pressure
comes out of port 2 of the right pilot valve (9)
and acts upon the low pressure sensor (SE4).
At the same time, the pressure acts upon
the PBb port of C/V (2).
2) The voltage output of the low pressure
sensor (SE-4) enters the mechatro
controller and processed in it.
3) Then, the proportionl secondary pressure
fed into C/V (2) PBb port and branches off in
two lines and switches boom spool and
releases boom lock valve.
10.4 PREVENTION OF NATURAL FALL BY LOCK
VALVE AND ACTUATION AT LOWERING
(1) Purpose:
Prevention of natural fall when the lever is
neutral
(2) Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation:
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line
on the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from
making a natural fall.
T2-2-18
10.5 CONSTANT RECIRCULATION FUNCTION

OF BOOM DOWN MAIN CIRCUIT
(1) Purpose:
Prevention of cavitation during boom lowering
motion.
(2) Principle:
The oil returning from the boom cylinder head
(H) is recirculated to the rod (R).
(3) Operation:
When the oil is supplied to the boom cylinder rod
(R) side during boom down operation, the boom
moves faster than it should do in some cases by
the self weight of the attachment.
On that occasion, the circuit pressure on the rod
(R) side is on the negative side.
The oil supplied to the boom cylinder rod (R)
flows into the A1 port of the P1 pump and the P1
port of C/V. The oil then passes through the
boom spool and goes out of the Bb port.
On that occasion, the oil returning from the head
(H) goes through the recirculation path in the
boom spool, pushes the check valve in the spool
open, is recirculated to the Bb port and is
supplied to the rod (R). When the (R) pressure
is larger than the head (H) pressure, the check
valve in spool closes.
Thereupon, the recirculation is stopped.
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
E215B-E245B
HYDRAULIC SYSTEM
12. ARM CIRCUIT

12.1 Arm in, light-load operating pilot circuit
12.2 Arm in, light-load variable normal recirculation
main circuit / internal conflux main circuit
12.1 ARM IN, LIGHT-LOAD OPERATING PILOT
CIRCUIT
(1) Purpose:
Speed-up and Anticavitation when the arm is at
light loaded.
(2) Principle:
The oil returning from the arm cylinder rod (R) is
recirculated variably to the head (H) at arm 2
spool in C/V.
(3) Operation:
1) When the arm in operation is performed, the
secondary pilot proportional pressure gets
out of port 4 of the left pilot valve (9) and acts
upon the low pressure sensor (SE-7).
At the same time, the pressure is branched
off in two flows, acts upon the PAa1 port and
the PLc2 port, changes over the arm spool
and the arm lock valve CRar releases.
2) The output voltage by the low pressure
sensor is input into mechatro controller, and
is pilot signal-processed, and is output to
P1, P2 pump proportional valve (PSV-P1),
(PSV-P2) and arm 2 inverse proportional
valve (PSV-A).
3) The secondary pressure from pilot
proportional valve, which is reduced by arm
2 inverse proportional valve (PSV-A)
switches arm 2 spool.
3) The return oil from arm cylinder (R) side

flows in Ba port of C/V (2) and passes
through the Ba port because the arm lock
valve CRar is open, and is flowed into arm 2
spool through arm 1 spool.
4) Because arm 2 spool is switched to normal
recirculation position, causing restriction of
passage to tank, the return oil from arm
cylinder (R) side flows into arm cylinder (H)
side.
Because, at light load, the pressure in
cylinder rod (R) side is higher than that in
the head (H) side, it opens the check valve
housed-in arm 2 spool and is recirculated
in the head (H) side, resulting in the speed
up of arm-in operation at light load.
5) Cavitations prevention control in arm-in
operation.
Command current is output to arm 2
solenoid proportional valve by signal
processing of E/G speed and arm-in pilot
pressure, accordingly the arm 2 spool is
switched to neutral (cavitations prevention)
position, resulting in cavitations prevention.
Position of arm 2 spool
Neutral position
(Anticavitation position)
Normal recirculation position

Recirculation
From arm out

P/V
From arm 2 inverse
proportional valve
SM0195
12.2 ARM-IN, LIGHT-LOAD VARIABLE NORMAL

RECIRCULATION, INTERNAL CONFLUX
MAIN CIRCUIT
(1) Operation:
1) The P2 pump delivery oil flows in travel left
section through P2 port of C/V (2) and is
branched off in by-pass circuit and parallel
circuit, but because arm 1 spool is switched,
the delivery oil which goes through parallel
circuit opens load check valve LCa and is
flowed into arm 1 spool.
2) On the other hand, P1 pump delivery oil
flows in P1 port of C/V (2), and the flows in
travel straight section and travel right
tandem path. Then because arm 2 spool
was switched, the delivery oil opens load
check valve LCAT2, goes through arm 2
spool, and confluences with P2 pump
delivery oil in the valve section, and then is
flowed into arm cylinder head (H) side
through Aa port of C/V (2).
T2-2-22
Reference:
In light-load arm-in operation (normal
recirculation, conflux), when the attachment
to which the circuit in P1 pump side is
applied is operated, the meter-in path of arm
2 spool is closed, resulting in single flow
operation.
Spool position at arm in,
light load and combined operation
(This position is not shown in hydraulic diagram)
Neutral position
Arm 2 spool
Meter-in passage
(Close)
Normal recirculation opsition

SM0196
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
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.
Neutral position
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
From
arm out
P/V
Recirculation cut position
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
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:
<Operation: Different point of pilot circuit from
independent operation >
1) The mechatro controller outputs command
current
to
travel
priority
solenoid
proportional valve (PSV-C) and to shortcircuit solenoid proportional valve (PSV-R)
after signal processing.
And 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
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
Position of forced recirculation

Neutral position
From
arm out
P/V
Meter-in passage
(Close)
From arm 2
inverse
proportional valve
Arm 2 spool
Normal recirculation position

SM0198
HYDRAULIC SYSTEM
E215B-E245B
COMBINED CIRCUIT: Swing / Arm in operation, swing priority function
SM0091
T2-2-31
E215B-E245B
HYDRAULIC SYSTEM
14. PRESSURE DRAINING (RELEASING)

CIRCUIT
14.1 Pressure releasing pilot circuit
14.2 Pressure releasing main circuit
14.1 PRESSURE RELEASING PILOT CIRCUIT
(1) Purpose:
To release the pressure in main circuit for piping
repair works.
(2) Principle:
After the mode is switched to "Pressure Relief
Mode" with switch on gauge cluster, mechatro
controller outputs the following commands.
1) Minimum tilting command value to pump
proportional valve (PSV-P1, PSV-P2).
2) Output "Pressure relief control speed
command value" at engine governor motor
(M2).
3) Stand-by command value to P1, P2
unloading proportional valves.
How to switch to "Pressure release
mode"
1) Select the service diagnosis mode 1.
(Keeping pressing of the "BUZZER STOP
SWITCH" [
] on gauge cluster, turn
the starter key ON.)
2) Select the service Adjustment Mode 1.
(Under the condition that "Screen No.1"
of "Service diagnosis mode 1" is
indicated, keeping pressing of the
"BUZZER STOP SWITCH", press the
SELECT switch [
] 3 times.
When
"LANGUAGE/LOGO",
"ADJUSTING MODE 1" and "PRESET
BY FACTORY" are displayed, press [ ]
or [ ] switch, and highlight "ADJUSTING
MODE 1", and then press "SELECT
Switch" again.)
3) When "ADJUSTING MODE 1" screen is
displayed, press [
] or [ ] switch,
several times and "DRAIN HYD. PRESS.
OFF " screen appears.
4) Press "SELECT Switch" and highlight
"OFF", and press [
] switch to change
to "DRAIN HYD. PRESS. ON", and then
press " SELECT Switch" again.
(3) Operation:
1) Pump proportional valve reduces the pump
flow rate to the minimum.
2) Unloading proportional valves (PSV-D,
PSV-B) output secondary pressure and the
secondary pressure flows in PCb, PCa ports
of C/V(2) and switches the P1, P2 unloading
valves to OPEN position.
T2-2-32
14.2 PRESSURE RELEASING MAIN CIRCUIT

(1) Operation:
CAUTION:
before to perform the hydraulic pressure releasing,
make sure to place bucket on the ground.
When the operating lever is shifted to neutral
during engine running, "DRAINING HYD.
PRESS." is
displayed on the gauge cluster
while the mode switch is changed to pressure
relieving mode.
In this time the intermittent buzzer sounds
continuously. When right and left operating
levers are operated 4 or 5 times to their full
stroke, pressure is relieved.
After draining pressure is completed, turn off the
starter key and buzzer sound stops. If the pump
pressure is determined to be more than 1 MPa
(145 psi) by the output value of the high
pressure sensor
(SE 22, SE 23) (or the high
pressure sensors are broken) "FAIL DRAIN
HYD. PRESS" is displayed and the buzzer
sounds continuously. In that case, also the
buzzer is not stopped unless the engine key is
turned to OFF. Repeat the pressure releasing
procedure once again.
(2) Hydraulics:
If the Unloading valves are turned to the
pressure release position, the oil delivered by
each pump is unloaded to the tank passage. If
the spools are switched by pilot operation, the
remaining pressure from the actuators may be
relieved to the tank circuit, i.e. the main circuit
pressure may be released.
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
E215B-E245B
AUTO AIR CONDITIONER SYSTEM OUTLINE
AIR CONDITIONER CONTROL PANEL
25.0
COMPRESSOR
COMPRESSOR DRIVE SOURCE
SOLAR RADIATION SENSOR
REFRIGERANT
PRESSURE SWITCH
AIR MIXED DAMPER SIGNAL

AIR-CON
AIR OUTLET SWITCHING SIGNAL
BLOWER REVOLUTION SIGNAL
CONTROLLER
INNER AIR SENSOR
EVAPORATION SENSOR
INNER AIR AND OUTER AIR

SWITCHING SIGNAL
MOTOR
ACTUATOR
VENT
OUTER AIR INTAKE

INNER AIR
MOTOR
ACTUATOR
AIR CONDITIONER UNIT
FACE
FOOT
MOTOR BLOWER
ACTUATOR CONTROLLER
SM0024
T3-8-2
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
32
Compressor
35-6
D hose
27-1
Air conditioner unit
33
Pulley
35-7
L hose
27-2
Hose
34
Condenser
35-8
L hose: 15.5
27-3
Clamp
35
Air dryer assy
35-9
S tube: 16
27-5
Filter
35-1
Receiver dryer
35-10 L tube: 8.5
27-6
Tube assy
35-2
Bracket
39
Filter
30
Panel assy
35-5
S hose: 24.5
40
Solar radiation sensor
T3-8-3
E215B-E245B
CONSTRUCTION
(1) Air conditioner unit
49
48
6
47
46
44
42
31
31
41
50
45
1
43
32
28
39
37
38
36
27
H
9
40
A
I
2
33
SM0022
Air conditioner unit (1/2)
T3-8-4
1
1
31
E215B-E245B
14
16
15
31
61
C
D
7
G
1
1
26
20
13
59
29
11
21
22
23
1
24
60
17
18 A
I
C
10
31
19
12
3
31
1
25
52
SM0021
Air conditioner unit (2/2)
T3-8-5
E215B-E245B
No.
Q.ty
No.
Q.ty
No.
Parts
Q.ty
Screw M516
Parts
23
19
Relay
Parts
40
KK-box lower packing
Main harness
20
Evaporator
41
Vent lever
MA air mix
21
Expansion valve
42
Face lever
Blower controller
22
O-ring
43
Foot joint lever
Upper casing
23
O-ring
44
MA mode lever
Air mix door
24
Screw M540
45
Foot lever
Air mix lever
25
Thermistor
46
Face lever cam
Lower casing
26
Thermistor holder
47
Vent lever cam
Air mix door sub
27
Heater core
48
Face rod
10
Air mix lever sub
28
Pipe holder
49
Vent rod
11
Blower
29
Thermistor
50
Foot rod
12
Lever MA air mix
31
Screw M430
52
Inner air filter
13
Intake door
32
Upper casing
55
Screw M625
10
14
MA intake lever
33
Lower casing
56
Screw M825
10
15
Intake lever
36
Foot door
59
Evaporator packing
16
Intake rod
37
Vent door
60
Casing packing A
17
Air mix rod
38
Face door
61
Casing packing B
18
Air mix rod sub
39
KK box upper packing
Receiver dryer
1 - Pressure switch
2 - Sight glass
3 - Desiccant
4 - Suction pipe
5 - Filter
6 - Receiver tank
A - Refrigerant INLET
B - Refrigerant OUTLET
2 -M6
1
3
4
5
SM0037
T3-8-6
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)
CH2FCF3
Chemical formula
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
P (MPa)
R134a
3
LIQUID
GAS
1
15 18
35
50
T (C)
SM0038
E215B-E245B
2.
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
6
4
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
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
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
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.
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
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.
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
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.
2
3
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.
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.
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.
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
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 (8.2cuin) 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: Nm (lbfft)
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: Nm (lbfft)
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 (2.4cuin)
CONDENSER
40 cc (2.4cuin)
COMPRESSOR
Drain out the volume of oil left in

the compressor to be replaced,
from the new compressor.
RECEIVER DRYER
20 cc (1.2cuin)
HOSES
20 cc (1.2cuin)
T3-8-13
E215B-E245B
DISASSEMBLY AND ASSEMBLY OF UNIT

1.
Removing inner air filter

Slide the inner air filter (1) leftward and remove
it from the unit (2).
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).
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).
4
6
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
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
SM0032
T3-8-15
E215B-E245B
4) Remove 2 socket bolts M540 (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 M540 (2 pcs.) Tightening torque:
6.9Nm (5.1lbfft)
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
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
29
28
30
31
27
SM0034
33
36
32
34
T3-8-16
26
35
SM0035

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
E215B-E245B
40
39
41
37
38
T3-8-17
SM0036
E215B-E245B
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. -26C (-15F)]. 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 40C (104F). 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 40C (104F).
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 40C (104F 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
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
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.
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.
3.
5
4
S
8
Connect the central valve of the gauge manifold

with charging pipe (4) of the vacuum pump (7).
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
9
SM0017
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).
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
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
E215B-E245B
ELECTRIC CIRCUIT
WIRING DIAGRAM AND CONNECTORS
Wiring Diagram
(A)(B)
2
(C)
12
(R)
(N)
155(BR)
(D)
150(BP)
FUSE 20A
15
85E(WB)
(E)
18(RG)
13
25(WG)
FUSE 5A
26(RL)
FUSE 15A
E24(B)
FUSE 5A
(Q)
(M)
FUSE BOX
(P)
(F)
(L)
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
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)

HOUSING No. : 7123-2249
TERMINAL : 17111
(J)
(L)

HOUSING No. : 7123-2249
TERMINAL : 17111
(D)

HOUSING No. : 7123-2228
TERMINAL : 17111
JAE IL-AG5-7S-S3C1

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
(K)

HOUSING No. : 7123-6020
(N) MAKER : YAZAKI CORP.
HOUSING No. : 7123-6060-40

26
25 85E
150 E24 18
(P)
(Q)

7120-8019
CP3.96MA
NIPPON AMP KK
170889-1
170003-5
(R)
MAKER : SUMITOMO
HOUSING No. : 6189-0094
HARNESS SEAL : 7160-8234
150 155
SM0045
JAE : JAPAN AVIATION ELECTRONICS

INDUSTRY, LTD.
Br Lg O
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE
T3-8-24
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
+
TESTER
SM0047
CONTINUITY
3
-
CONTINUED
(4.7 k
5%)
NOT CONTINUED
CONTINUED (DIODE
PARALLEL AND
FORWARD DIRECTION
FLOW)
Lg
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.
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 ONOFF 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

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
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.

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
Cool air flowing into inner

air sensor
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.
Refer to Troubleshooting for
refrigeration cycle.
NO
Controller is faulty
or inner air sensor
is faulty.
Inspect and replace.
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.
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.

NO
YES
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.
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 switch before work.
T3-8-30
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.
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).
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.
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
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
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.

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
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
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
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
SM0063
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
EVAPORATOR SENSOR
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
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
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.

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
THIRD SEGMENT
SOLAR RADIATION SENSOR SHORT-CIRCUITING
EACH SENSOR IS NORMAL
SOLAR RADIATION SENSOR 5V SIDE SHORT-CIRCUITING

INNER AIR SENSOR SHORT-CIRCUITING
EVAPORATOR SENSOR SHORT-CIRCUITING
SM0068
T3-8-38
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
2. CLASSIFICATION OF FAILURE AND TROUBLESHOOTING

Classify failures into the following 3 types and carry out the troubleshooting.
No.
Classes of failure
Troubleshooting
When error code after self-diagnosis is displayed Carry out troubleshooting according to the error
on gauge cluster
code.
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.
When error code after self diagnosis is not Carry out troubleshooting according to
displayed or is not remained in the history
instructions
in
Chapter
T5-2
"TROUBLESHOOTING BY TROUBLE".
Carry out troubleshooting according to
instructions in Chapter T5-3 "TROUBLE
DIAGNOSIS MODE".
3. 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
E215B-E245B
Error
Code
Trouble
B023
Disconnection of boom down pressure sensor
T5-1-11
B024
Short-circuit of boom down pressure sensor
T5-1-11
B032
Incorrect output of arm out pressure sensor
T5-1-12
B033
Disconnection of arm out pressure sensor
T5-1-12
B034
Short-circuit of arm out pressure sensor
T5-1-13
B042
Incorrect output of arm in pressure sensor
T5-1-13
B043
Disconnection of arm in pressure sensor
T5-1-14
B044
Short-circuit of arm in pressure sensor
T5-1-15
B052
Incorrect output of bucket digging pressure sensor
T5-1-16
B053
Disconnection of bucket digging pressure sensor
T5-1-16
B054
Short-circuit of bucket digging pressure sensor
T5-1-17
B062
Incorrect output of bucket dump pressure sensor
T5-1-17
B063
Disconnection of bucket dump pressure sensor
T5-1-18
B064
Short-circuit of bucket dump pressure sensor
T5-1-18
B072
Incorrect output of swing pressure sensor
T5-1-19
B073
Disconnection of swing pressure sensor
T5-1-19
B074
Short-circuit of swing pressure sensor
T5-1-20
B092
Incorrect output of travel right pressure sensor
T5-1-20
B093
Disconnection of travel right pressure sensor
T5-1-21
B094
Short-circuit of travel right pressure sensor
T5-1-22
B102
Incorrect output of travel left pressure sensor
T5-1-23
B103
Disconnection of travel left pressure sensor
T5-1-23
B104
Short-circuit of travel left pressure sensor
T5-1-24
B113
Disconnection of pressure sensor of optional selector positioning
T5-1-25
B114
Short-circuit of pressure sensor of optional selector positioning
T5-1-26
B162
Incorrect output of P1 optional side pressure sensor
T5-1-26
B163
Disconnection of P1 side optional pressure sensor
T5-1-27
B164
Short-circuit of P1 side optional pressure sensor
T5-1-28
B172
Incorrect output of P2 optional side pressure sensor
T5-1-28
B173
Disconnection of P2 side optional pressure sensor
T5-1-29
B174
Short-circuit of P2 side optional pressure sensor
T5-1-29
C012
Incorrect output of P1 pump pressure sensor
T5-1-30
C013
Disconnection of P1 pump pressure sensor
T5-1-30
C014
Short-circuit of P1 pump pressure sensor
T5-1-31
C022
Incorrect output of P2 pump pressure sensor
T5-1-31
C023
Disconnection of P2 pump pressure sensor
T5-1-32
C024
Short-circuit of P2 pump pressure sensor
T5-1-32
C033
Disconnection of boom head pressure sensor
T5-1-33
C034
Short-circuit of boom head pressure sensor
T5-1-33
D012
Failure of output transistor ON at P1 unload proportional valve
T5-1-34
D013
Disconnection of P1 unload proportional valve
T5-1-34
D022
Failure of output transistor ON at P2 unload proportional valve
T5-1-35
D023
Disconnection of P2 unload proportional valve
T5-1-36
D032
Failure of output transistor ON at travel straight proportional valve
T5-1-36
D033
Disconnection of travel straight proportional valve
T5-1-37
D062
Failure of output transistor ON at arm in high speed proportional valve
T5-1-38
T5-1-3
Described
page
E215B-E245B
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
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
G-3 SPEED SET
Screen No.
Checking object
Checking contents and remedy
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"
Mechatro controller
Check that the error is corrected after replacement of controller.
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
E-1 P1 PUMP
E-2 P2 PUMP
Screen No.
Checking object
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"
Mechatro controller
T5-1-5
E215B-E245B
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.
D-1 P1 UN-LOAD (BP-CUT)
Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
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"
Mechatro controller
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.
checking screen
No.
Screen
No.
Checking object
1
Mechatro controller

2
3
T5-1-6
E215B-E245B
Table 5
Error code
A225
Trouble
Judging condition
Check adjustment data, and judge the data is correct or not.
Symptom
Control in the
Control can be done by default value.
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
Mechatro controller

2
3
Table 6
Error code
A235
Trouble
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
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
Mechatro controller

2
3
T5-1-7
E215B-E245B
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
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
Mechatro 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
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
Mechatro controller

2
3
T5-1-8
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.
B-1 BOOM RAISE

checking screen
No.
Screen
No.
Checking object
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.
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.
Mechatro controller
Table 10
Error code
B013
Trouble
Boom up pressure sensors 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 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.
B-1 BOOM RAISE

checking screen
No.
Screen
No.
Checking object
Boom up pressure sensor SE-3 When B013 is cancelled and other error occurs after exchanging the connector
with other sensor.

When B013 is displayed after the connector is exchanged with other sensor.
CN-126F
CN-101F
Mechatro controller
T5-1-9
E215B-E245B
Table 11
Error code
B014
Trouble
Boom up pressure sensors 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
Returned
in
normal condition
Screen
No.
B-1 BOOM RAISE

checking screen
No.
Screen
No.
Checking object
Boom up pressure sensor SE-3 When B014 is cancelled and other error occurs after exchanging the connector
with other sensor.

CN-126F
CN-101F
Mechatro controller
Table 12
Error code
B022
Trouble
Boom down pressure sensor outputs error.
Judging condition
Symptom
The boom down operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-2 BOOM LOWER

checking screen
No.
Screen
No.
Checking object
Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on after
SE-4
Wiring between boom down

CN-127F
CN-101F
Mechatro controller
T5-1-10
E215B-E245B
Table 13
Error code
B023
Trouble
Boom down pressure sensors wiring is disconnecting.
Judging condition
The input voltage from boom down pressure sensor is 0.1 V or less.
Symptom

Control in the
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
normal condition
Screen
No.
B-2 BOOM LOWER

checking screen
No.
Screen
No.
Checking object
Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the connector
with other sensor.
SE-4

CN-127F
CN-101F
Mechatro controller
Table 14
Error code
B024
Trouble
Boom down pressure sensors power source is shortcut.
Judging condition
The input voltage from boom down pressure sensor is 4.7 V or more.
Symptom

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-2 BOOM LOWER

checking screen
No.
Screen
No.
Checking object
Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on after
SE-4

CN-127F
CN-101F
Mechatro controller
T5-1-11
E215B-E245B
Table 15
Error code
B032
Trouble
Arm-in pressure sensor outputs error.
Judging condition
Symptom
The arm-out operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-3 ARM OUT

checking screen
No.
Screen
No.
Checking object
Arm-out pressure sensor SE-8
When B032 is cancelled and other error occurs by turning starter switch on after
Wiring between arm-out pressure

sensor and controller
CN-131F
CN-101F
Mechatro controller
Table 16
Error code
B033
Trouble
Arm-out pressure sensors 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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-3 ARM OUT

checking screen
No.
Screen
No.
Checking object
When B033 is cancelled and other error occurs after exchanging the connector
with other sensor.
Wiring between arm-out pressure

CN-131F
CN-101F
Mechatro controller
T5-1-12
E215B-E245B
Table 17
Error code
B034
Trouble
Arm-out pressure sensors 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.

Control in the
event of failure
Set output of P1, P2 unload proportional valves to 0 mA. (Valve emergency mode)
Returned
in
normal condition
Screen
No.
B-3 ARM OUT

checking screen
No.
Screen
No.
Checking object
Wiring
between
arm-out
CN-131F
CN-101F
Mechatro 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
normal condition
Screen
No.
B-4 ARM IN

checking screen
No.
Screen
No.
Checking object
1
Arm-in pressure sensor

SE-7

Wiring between arm-in pressure

CN-130F
CN-101F
Mechatro controller
T5-1-13
E215B-E245B
Table 19
Error code
B043
Trouble
Arm-in pressure sensors 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
normal condition
Screen
No.
B-4 ARM IN

checking screen
No.
Screen
No.
Checking object

SE-7
When B043 is cancelled and other error occurs after exchanging the connector
with other sensor.
Wiring between arm-in pressure

CN-130F
and repair it if necessary..
CN-101F
Mechatro controller
T5-1-14
E215B-E245B
Table 20
Error code
B044
Trouble
Arm-in pressure sensors 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
normal condition
Screen No.
Service diagnosis
Screen No.
checking screen
Screen No.
B-4 ARM IN
Checking object

SE-7
When B044 is cancelled and other error occurs by turning starter switch on
after exchanging the connector with other sensor.
Wiring between arm-in pressure When B044 is displayed after turning the starter switch on after the connector
CN-130F
CN-101F
Mechatro controller
T5-1-15
E215B-E245B
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
normal condition
Screen
No.
B-5 BUCKET DIG

checking screen
No.
Screen
No.
Checking object
Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on after
SE-1
Wiring between bucket digging

CN-124F
CN-101F
Mechatro controller
Table 22
Error code
B053
Trouble
Bucket digging pressure sensors 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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-5 BUCKET DIG

checking screen
No.
Screen
No.
Checking object
SE-1

CN-124F
CN-101F
Mechatro controller
T5-1-16
E215B-E245B
Table 23
Error code
B054
Trouble
Bucket digging pressure sensors 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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-5 BUCKET DIG

checking screen
No.
Screen
No.
Checking object
SE-1

CN-124F
CN-101F
Mechatro 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
Symptom
The bucket dump operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-6 BUCKET DUMP

checking screen
No.
Screen
No.
Checking object
SE-2

CN-125F
CN-101F
Mechatro controller
T5-1-17
E215B-E245B
Table 25
Error code
B063
Trouble
Bucket dump pressure sensors 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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-6 BUCKET DUMP

checking screen
No.
Screen
No.
Checking object
SE-2

CN-125F
CN-101F
Mechatro controller
Table 26
Error code
B064
Trouble
Bucket dump pressure sensors 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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-6 BUCKET DUMP

checking screen
No.
Screen
No.
Checking object
SE-2

CN-125F
CN-101F
Mechatro controller
T5-1-18
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
normal condition
Screen
No.
B-7 SWING

checking screen
No.
Screen
No.
Checking object
1
SE-5
2
Wiring between swing pressure When B072 is displayed after turning the starter switch on after the connector
CN-169F
CN-103F
Mechatro controller
Table 28
Error code
B073
Trouble
Swing pressure sensors wiring is disconnected.
Judging condition
The input voltage from swing pressure sensor is 0.1 V or less.
Symptom

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-7 SWING

checking screen
No.
Screen
No.
Checking object
1

SE-5

CN-169F
CN-103F
Mechatro controller
T5-1-19
E215B-E245B
Table 29
Error code
B074
Trouble
Swing pressure sensors power source is shortcut.
Judging condition
The input voltage from swing pressure sensor is 4.7 V or more.
Symptom

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-7 SWING

checking screen
No.
Screen
No.
Checking object
1
SE-5
2
CN-169F
CN-103F
Mechatro 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
Symptom
The travel right operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-9 TRAVEL (R)

checking screen
No.
Screen
No.
Checking object
1

SE-9

Wiring between travel right

CN-301F
CN-102F
Mechatro controller
T5-1-20
E215B-E245B
Table 31
Error code
B093
Trouble
Travel right pressure sensors 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.

Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
normal condition
Screen
No.
B-9 TRAVEL (R)

checking screen
No.
Screen
No.
Checking object
1

SE-9


CN-301F
CN-102F
Mechatro controller
T5-1-21
E215B-E245B
Table 32
Error code
B094
Trouble
Travel right pressure sensors 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.

Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
normal condition
Screen
No.
B-9 TRAVEL (R)

checking screen
No.
Screen
No.
Checking object
1

SE-9


CN-301F
CN-102F
Mechatro controller
T5-1-22
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
Symptom
The travel left operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-10 TRAVEL (L)

checking screen
No.
Screen
No.
1
Checking object
SE-10
2
Wiring between travel left

CN-302F
CN-102F
Mechatro controller
Table 34
Error code
B103
Trouble
Travel left pressure sensors 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.

Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
normal condition
Screen
No.
B-10 TRAVEL (L)

checking screen
No.
Screen
No.
1
Checking object
SE-10
2

CN-302F
CN-102F
Mechatro controller
T5-1-23
E215B-E245B
Table 35
Error code
B104
Trouble
Travel left pressure sensors 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.

Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
normal condition
Screen
No.
B-10 TRAVEL (L)

checking screen
No.
Screen
No.
1
Checking object
SE-10
2

CN-302F
CN-102F
Mechatro controller
T5-1-24
E215B-E245B
Table 36
Error code
B113
Trouble
Option selector position detect pressure sensors 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
normal condition
Screen
No.
16
B-11

checking screen
No.
Screen
No.
Checking object
Option selector position detect When B113 is cancelled and other error occurs by turning starter switch on after
pressure sensor
SE-29
Wiring between option selector

position detect pressure sensor
and controller
CN-162F
CN-104F
Mechatro controller
T5-1-25
E215B-E245B
Table 37
Error code
B114
Trouble
Option selector position detect pressure sensors 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
normal condition
Screen
No.
16
B-11

checking screen
No.
Screen
No.
Checking object
Option selector position detect When B114 is cancelled and other error occurs by turning starter switch on after
pressure sensor
SE-29

position detect pressure sensor
and controller
CN-162F
CN-104F
Mechatro 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
Symptom
The P1 side option operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-16 P1 OPT.

checking screen
No.
Screen
No.
Checking object
1

SE-20

Wiring between P1 side option

CN-304F
CN-102F
Mechatro controller
T5-1-26
E215B-E245B
Table 39
Error code
B163
Trouble
P1 side option pressure sensors 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.

Control in the (Hydraulic pump emergency mode)
event of failure
But normal control is done when the left control pedal selection is ON.
Returned
in
normal condition
Screen
No.
B-16 P1 OPT.

checking screen
No.
Screen
No.
Checking object
1

SE-20


CN-304F
CN-102F
Mechatro controller
T5-1-27
E215B-E245B
Table 40
Error code
B164
Trouble
Judging condition
The input voltage from P1 side option pressure sensor is 4.7 or more.
Symptom
The P1 side option does not work.

Control in the (Hydraulic pump emergency mode)
event of failure
But normal control is done when the left control pedal selection is ON.
Returned
in
normal condition
Screen
No.
B-16 P1 OPT.

checking screen
No.
Screen
No.
Checking object
1

SE-20

CN-304F
CN-102F
Mechatro 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
Symptom
The P2 side option operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-17 P2 OPT.

checking screen
No.
Screen
No.
Checking object
1

SE-11


CN-304F
CN-102F
Mechatro controller
T5-1-28
E215B-E245B
Table 42
Error code
B173
Trouble
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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-17 P2 OPT.

checking screen
No.
Screen
No.
Checking object
1

SE-11

CN-303F
CN-102F
Mechatro controller
Table 43
Error code
B174
Trouble
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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-17 P2 OPT.

checking screen
No.
Screen
No.
Checking object
1

SE-11


CN-303F
CN-102F
Mechatro controller
T5-1-29
E215B-E245B
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
Symptom
The P1 pump operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
C-1 PUMP P1

checking screen
No.
Screen
No.
1
Checking object
P1 pump pressure sensor
When C012 is cancelled and other error occurs by turning starter switch on after
SE-22
2
Wiring between P1 pump

CN-139F
CN-103F
When C012 is displayed after turning the starter switch on after the connector
Mechatro controller
Table 45
Error code
C013
Trouble
P1 pump pressure sensors 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
Returned
in
normal condition
Screen
No.
C-1 PUMP P1

checking screen
No.
Screen
No.
1
Checking object
SE-22
2

CN-139F
CN-103F
Mechatro controller
T5-1-30
E215B-E245B
Table 46
Error code
C014
Trouble
P1 pump pressure sensors power source is shortcut.
Judging condition
The input voltage from P1 pump pressure sensor is 4.7 V or more.
Symptom
event of failure
Returned
in
normal condition
Screen
No.
C-1 PUMP P1

checking screen
No.
Screen
No.
1
Checking object
SE-22
2

CN-139F
CN-103F
Mechatro 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
Symptom
The P2 pump operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
C-2 PUMP P2

checking screen
No.
Screen
No.
1
Checking object
SE-23
2

CN-140F
CN-103F
Mechatro controller
T5-1-31
E215B-E245B
Table 48
Error code
C023
Trouble
P2 pump pressure sensors wiring is disconnected.
Judging condition
The input voltage from P2 pump pressure sensor is 0.1 V or less.
Symptom
event of failure
Returned
in
normal condition
Screen
No.
C-2 PUMP P2

checking screen
No.
Screen
No.
1
Checking object
SE-23
2

CN-140F
CN-103F
Mechatro controller
Table 49
Error code
C024
Trouble
P2 pump pressure sensors power source is shortcut.
Judging condition
The input voltage from P2 pump pressure sensor is 4.7 V or more.
Symptom
event of failure
Returned
in
normal condition
Screen
No.
C-2 PUMP P2

checking screen
No.
Screen
No.
1
Checking object
SE-23
2

CN-140F
CN-103F
Mechatro controller
T5-1-32
E215B-E245B
Table 50
Error code
C033
Trouble
Boom head pressure sensors 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
normal condition
Screen
No.
C-3 BOOM-HEAD

checking screen
No.
Screen
No.
Checking object
1
Boom head pressure sensor

SE-24
Wiring between boom head

CN-140F
CN-103F
Mechatro controller
Table 51
Error code
C034
Trouble
Boom head pressure sensors 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
normal condition
Screen
No.
C-3 BOOM-HEAD

checking screen
No.
Screen
No.
Checking object
1
Boom head pressure sensor

SE-24

Wiring between boom head

CN-706F
CN-104F
Mechatro controller
T5-1-33
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.

checking screen
No.
Screen
No.
Checking object
1
P1 unload proportional valve

PSV-D
When D012 is cancelled and other error occurs by turning starter switch on after
Wiring between P1 unload

proportional valve and controller
CN-120F
CN-105F
When D012 is displayed after turning the starter switch on after the connector
Mechatro controller
Table 53
Error code
D013
Trouble
P1 unload proportional valves 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
normal condition
Screen
No.

checking screen
No.
Screen
No.
Checking object
1

PSV-D


CN-120F
CN-105F
Mechatro controller
T5-1-34
E215B-E245B
Table 54
Error code
D022
Trouble
P2 unload proportional valve and output transistor ON are failure.
Judging condition
Symptom
Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned
in
normal condition
Screen
No.

checking screen
No.
Screen
No.
Checking object
1

PSV-B


CN-118F
CN-105F
Mechatro controller
T5-1-35
E215B-E245B
Table 55
Error code
D023
Trouble
P2 unload proportional valves wiring is disconnected.
Judging condition

Symptom
Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned
in
normal condition
Screen
No.

checking screen
No.
Screen
No.
Checking object
1

PSV-B

CN-118F
CN-105F
Mechatro 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
normal condition
Screen
No.
D-3 S-TRAVEL

checking screen
No.
Screen
No.
Checking object
straight
Travel
valve
Wiring between Travel straight

CN-119F
CN-105F
Mechatro controller
PSV-C
proportional When D032 is cancelled and other error occurs by turning starter switch on after
T5-1-36
E215B-E245B
Table 57
Error code
D033
Trouble
Travel straight proportional valves wiring is disconnected.
Judging condition

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
normal condition
Screen
No.
D-3 S-TRAVEL

checking screen
No.
Screen
No.
Checking object
straight
Travel
valve
Wiring between Travel straight

CN-119F
CN-105F
Mechatro controller
PSV-C
proportional When D033 is cancelled and other error occurs by turning starter switch on after
T5-1-37
E215B-E245B
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
normal condition
Screen
No.
D-4 ARM IN-2-SPEED

checking screen
No.
Screen
No.
Checking object
Arm-in spool 2 proportional When D062 is cancelled and other error occurs by turning starter switch on after
valve
PSV-A
Wiring between Arm-in spool 2

CN-121F
CN-105F
Mechatro controller
T5-1-38
E215B-E245B
Table 59
Error code
D063
Trouble
Arm-in spool 2 proportional valves wiring is disconnected.
Judging condition

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
normal condition
Screen
No.
D-4 ARM IN-2-SPEED

checking screen
No.
Screen
No.
Checking object
Arm-in spool 2 proportional When D063 is cancelled and other error occurs by turning starter switch on after
valve
PSV-A
Wiring between Arm-in spool 2

CN-121F
CN-105F
Mechatro controller
Table 60
Error code
D152
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
2
3
T5-1-39
E215B-E245B
Table 61
Error code
D153
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
2
3
Table 62
Error code
E012
Trouble
P1 pump proportional valve and output transistor ON are failure.
Judging condition
Symptom
event of failure
Returned
in
normal condition
Screen
No.
E-1 PUMP P1

checking screen
No.
Screen
No.
1
Checking object
P1 pump proportional valve
When E012 is cancelled and other error occurs by turning starter switch on after
When replacing of connector is executed, turn off power source once.
PSV-P1

CN-141F
CN-105F
When E012 is displayed after turning the starter switch on after the connector
Mechatro controller
T5-1-40
E215B-E245B
Table 63
Error code
E013
Trouble
P1 pump proportional valves wiring is disconnected.
Judging condition

(If output is 100mA or less, judging is not done.)
Symptom
event of failure
Returned
in
normal condition
Screen
No.
E-1 PUMP P1

checking screen
No.
Screen
No.
1
Checking object
PSV-P1

CN-141F
CN-105F
Mechatro controller
T5-1-41
E215B-E245B
Table 64
Error code
E022
Trouble
P2 pump proportional valve and output transistor ON are failure.
Judging condition
Symptom
event of failure
Returned
in
normal condition
Screen
No.
E-2 PUMP P2

checking screen
No.
Screen
No.
1
Checking object
PSV-P2

CN-142F
CN-105F
Mechatro controller
Table 65
Error code
E023
Trouble
P2 pump proportional valves wiring is disconnected.
Judging condition

Symptom
event of failure
Returned
in
normal condition
Screen
No.
E-2 PUMP P2

checking screen
No.
Screen
No.
1
Checking object
PSV-P2

CN-142F
CN-105F
Mechatro controller
T5-1-42
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.
F-1 POWER BOOST

checking screen
No.
Screen
No.
1
Checking object
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.
Mechatro controller
T5-1-43
E215B-E245B
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.
F-1 POWER BOOST

checking screen
No.
Screen
No.
1
Checking object
ATT boost solenoid valve
When F013 is cancelled and other error occurs by exchanging the connector
for other solenoid valve.
SV-2
2
Wiring between ATT boost

CN-117F
CN-105F
valve.
Mechatro controller
T5-1-44
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
Symptom
Swing parking is not available.
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.
F-2 SWING-BRAKE

checking screen
No.
Screen
No.
Checking object
1
Swing parking solenoid valve

SV-1
for other solenoid valve. Check solenoid valve unit for possible failure. If failure
found, replace it.
Wiring between swing parking

CN-123F
CN-105F
valve.
Mechatro controller
Table 69
Error code
F023
Trouble
Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
Symptom
Swing parking is not available or is leaving available.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
F-1 POWER BOOST

checking screen
No.
Screen
No.
Checking object
1
Swing parking solenoid valve

SV-1

Wiring between swing parking

CN-123F
CN-105F
valve.
Mechatro controller
T5-1-45
E215B-E245B
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
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.
F-3 1/2-TRAVEL

checking screen
No.
Screen
No.
Checking object
Travel 1, 2 speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
SV-3
Wiring between travel 1, 2

speed solenoid valve and
controller
CN-123F
CN-105F
valve.
Mechatro controller
T5-1-46
E215B-E245B
Table 71
Error code
F033
Trouble
Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
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.
F-3 1/2-TRAVEL

checking screen
No.
Screen
No.
Checking object
Travel 1, 2 speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
SV-3
Wiring between travel 1, 2

speed solenoid valve and
controller
CN-122F
CN-105F
valve.
Mechatro controller
Table 72
Error code
F041
Trouble
Option selector solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition
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

checking screen
No.
Screen
No.
Checking object
1
Option selector solenoid valve

SV-13


CN-251F
CN-105F
valve.
Mechatro controller
T5-1-47
E215B-E245B
Table 73
Error code
F043
Trouble
Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
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

checking screen
No.
Screen
No.
Checking object
1
Option selector solenoid valve

SV-13


CN-251F
CN-105F
valve.
Mechatro controller
Table 74
Error code
G011
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
2
3
T5-1-48
Table 75
Error code
G013
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
2
3
Table 76
Error code
G023
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
2
3
T5-1-49
E215B-E245B
E215B-E245B
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
normal condition
Screen
No.
G-3 MEAS 1 (for mechatro controller)

checking screen
No.
G-3 MEAS 2 (receive from engine controller)
Screen
No.
Checking object
Engine speed sensor
Measure the resistance between terminals of speed sensor.

Check wiring for possible failure according to the wiring checking
procedure and repair it if necessary.
CN-251F
Especially check wiring for false disconnection and noise included.
CN-105F
Mechatro controller
SV-13
Normal value: 1.6~2.0k
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
normal condition
Screen
No.
G-3 MEAS 1 (for mechatro controller)

checking screen
No.
G-3 MEAS 2 (receive from engine controller)
Screen
No.
Checking object
1
Engine speed sensor

SE-13

Measure the resistance between terminals of speed sensor.
Normal value: 1.6~2.0k
Wiring between engine speed

CN-136F
CN-106F
Mechatro controller

(Controller is broken by only applying power to grounding of signal.).
T5-1-50
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
event of failure
Returned
in
normal condition
Screen
No.
H-1 ACCEL VOLT.

checking screen
No.
Screen
No.
Checking object
1
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
CN-402F
CN-102F
Mechatro controller
Table 80
Error code
H014
Trouble
Accel potentiometers power source is shortcut.
Judging condition
The input voltage from accel potentiometer is 4.7 V or more.
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
H-1 ACCEL VOLT.

checking screen
No.
Screen
No.
Checking object
1
Accel potentiometer
SE-16

Measure the resistance between terminals of accel potentiometer.
1.6~2.0k .
Wiring
between
accel
CN-402F
CN-102F
Mechatro controller
T5-1-51
E215B-E245B
Table 81
Error code
H023
Trouble
Boom angle potentiometers 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
normal condition
Screen
No.
12
H-2 BOOM

checking screen
No.
Screen
No.
Checking object
1
Boom angle potentiometer

SE-17

Measure the resistance between terminals of boom angle potentiometer.
4.0~6.0k .
Normal value: 0 to all resistance (4.0~6.0)k
Wiring between boom angle

CN-702F
CN-103F
Mechatro controller
T5-1-52
E215B-E245B
Table 82
Error code
H024
Trouble
Boom angle potentiometers power source is shortcut.
Judging condition
The input voltage from boom angle potentiometer is 0.1 V or less.
Symptom
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
12
H-2 BOOM

checking screen
No.
Screen
No.
Checking object
1
Boom angle potentiometer

SE-17

Measure the resistance between terminals of boom angle potentiometer.
4.0~6.0k .
Wiring between boom angle

CN-702F
CN-103F
Mechatro controller
T5-1-53
E215B-E245B
Table 83
Error code
H033
Trouble
Arm angle potentiometers wiring is disconnected.
Judging condition
The input voltage from arm angle potentiometer is 0.1 V or less.
Symptom
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
12
H-3 ARM

checking screen
No.
Screen
No.
Checking object
1
Arm angle potentiometer

SE-18

Measure the resistance between terminals of arm angle potentiometer.
4.0~6.0k .
Wiring between arm angle

CN-703F
CN-103F
Mechatro controller
T5-1-54
E215B-E245B
Table 84
Error code
H034
Trouble
Arm angle potentiometers power source is shortcut.
Judging condition
The input voltage from arm angle potentiometer is 0.1 V or less.
Symptom
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
12
H-3 ARM

checking screen
No.
Screen
No.
Checking object
1
Arm angle potentiometer

SE-18

Measure the resistance between terminals of arm angle potentiometer.
4.0~6.0k .
Wiring between arm angle

CN-703F
CN-103F
Mechatro controller
T5-1-55
E215B-E245B
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
normal condition
Screen
No.
10
H-9 FUEL LEVEL

checking screen
No.
Screen
No.
1
Checking object
Fuel sensor potentiometer
Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15
EMPTY 95
.~ FULL 5
Wiring between fuel sensor and

controller
CN-152F
CN-104F
Mechatro controller
Table 86
Error code
H093
Trouble
Fuel sensors 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
normal condition
Screen
No.
10
H-9 FUEL LEVEL

checking screen
No.
Screen
No.
1
Checking object
Fuel sensor potentiometer
Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15
EMPTY 95
.~ FULL 5
Wiring between fuel sensor and

controller
CN-152F
CN-104F
Mechatro controller
T5-1-56
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
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
Wiring between gauge cluster

and controller
CN-600F
CN-101F
Mechatro controller
T5-1-57
E215B-E245B
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.
K-1 AIS RELAY 2

checking screen
No.
K-3 KEY SWITCH OFF
Screen
No.
Checking object
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.
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
Mechatro controller
T5-1-58
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

checking screen
No.
Screen
No.
Checking object
Wiper motor arc prevention When error is cancelled after removing wiper motor arc prevention relay, check
relay unit for failure, replace it with new one if failed.
relay
R-31
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
Wiring between wiper motor arc

prevention relay and controller
CN-109F, CN2-1
Fuse& relay box
E-1
Mechatro controller
When R014 is left displayed with the relay removed.

When no failure found after checking on wiring and R014 is left displayed.
T5-1-59
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
25
CW MOTOR RLY

checking screen
No.
Screen
No.
Checking object
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
Wiring between wiper motor

forward rotation relay and When R024 is left displayed with the relay removed.
controller
CN-109F, CN2-1
Fuse& relay box
E-1
Mechatro controller
T5-1-60
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
event of failure
Returned
in
normal condition
Screen
No.
25
CCW MOTOR RLY

checking screen
No.
Screen
No.
Checking object
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
Wiring between wiper motor

forward rotation relay and When R034 is left displayed with the relay removed
controller
CN-109F, CN2-1
When no failure found after checking on wiring and R034 is left displayed
Fuse& relay box
E-1
Mechatro controller
T5-1-61
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
25
MOTOR RELAY

checking screen
No.
Screen
No.
Checking object
1
Washer motor relay

R-32

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.
Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller
CN-112F, CN2-1
Fuse& relay box
When no failure found after checking on wiring and R044 is left displayed
E-1
Mechatro controller
T5-1-62
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
event of failure
Returned
in
normal condition
Screen
No.
22
D13

checking screen
No.
Screen
No.
Checking object
1
Swing flasher relay

R-19

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
Wiring between swing flasher

When R134 is left displayed with the relay removed
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.
Mechatro controller
T5-1-63
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
22
D14

checking screen
No.
Screen
No.
Checking object
1
Swing flasher relay

R-19

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
Wiring between swing flasher

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.
Mechatro controller
T5-1-64
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
event of failure
Returned
in
normal condition
Screen
No.
23
D15

checking screen
No.
Screen
No.
Checking object
1
Travel alarm relay

R-8

When error is cancelled after removing of travel alarm relay, check relay unit for
Wiring between travel alarm When R154 is left displayed with the relay removed
CN-109F, CN2-2
Fuse & relay box
E-1
Mechatro controller
T5-1-65
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
K-1 AIS RELAY 2

checking screen
No.
Screen
No.
1
Checking object
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.
Wiring between auto idle stop When R164 is left displayed with the relay removed
relay 2 and controller
CN-109F, CN2-2
Fuse & relay box
E-1
Mechatro controller
T5-1-66
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
event of failure
Returned
in
normal condition
Screen
No.
K-3 ENG STOP

checking screen
No.
Screen
No.
1
Checking object
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.
Wiring between engine forcibly When R174 is left displayed with the relay removed
stop relay and controller
CN-109F, CN2-2
Fuse & relay box
E-1
Mechatro controller
T5-1-67
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
K-4 LOCK LEVER

checking screen
No.
Screen
No.
Checking object
1
Safety lock lever relay

R-26

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
Wiring between safety lock lever

CN-109F, CN2-2
Fuse & relay box
E-1
Mechatro controller

T5-1-68
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
event of failure
Returned
in
normal condition
Screen
No.
K-2 SAFETY RLY

checking screen
No.
Screen
No.
Checking object
1
Safety lock lever relay

R-26

When error R214 is cancelled after removing of safety relay, check relay unit for
Wiring between safety lock lever

CN-109F, CN2-2
Fuse & relay box
Mechatro controller
E-1

Check that no power 24V is produced on relay (-) line according to the wiring
T5-1-69
E215B-E245B
[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.
All controls do not function/slow
2.
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.
All controls do not function/slow
No.
Sections
Contents/normal value
Corrective action, others
Fuse
Check fuse No.4

(10 A)
If the fuse is blown out, check

on the short-circuited section.
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.
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
Safety lever lock

relay
Carry out service

diagnosis
Pilot pressure sensor
Solenoid valve for

safety lock lever
Check solenoid unit for

possible failure.
Check harness for possible
failure.
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.
Check 5 V power for controller
Measure pressure
of solenoid A1 port
About 0 MPa by pushing the lever up,

and 4 MPa or more by push it down.
Replace solenoid valve
Pilot line filter
Disassemble and
check it visually
Check filter for clogging
Clean filter
Pilot gear pump
Measure pilot
Check that it is 4 MPa or more in high
primary pressure at idling
gear pump
Multi control valve (in Change position

case that travel is
operable)
Since all are blocked due to poor

switching performance, check that the
lever select pattern is set to the proper
position.
10
Actual measuring
current value of P1/
P2 unload
proportional valve
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
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
P2 pump
proportional valve
Carry out service

diagnosis
Carry out service

diagnosis.
Check gear pump and the

relief valve for possible failure
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
Operation No.18 Travel right full lever
& idling
Operation No.19 Travel left full lever &
idling
T5-2-2

No.
Sections
E215B-E245B
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

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

Measure the relief pressure
Operation No.3 Boom up full lever & relief actually
15
Check set pressure Check that P1 and P2 pump pressures

are 32 MPa in boom up full lever, high
idling and H mode operation.
Reset or replace
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
No.
Sections
Actual measuring
P2 pump
proportional valve
Carry out service
diagnosis
No.9 E-1 P1 pump

E-2 P2 pump
Operation No. 1 Operation is nil


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.
Pressure sensor of
P1, P2 pump
Check pressure

relief
Check pressure sensor and

replace it if necessary
Pump regulator
Visual check

resistance against sliding
Free from abnormal damage, etc on outside
surface
Replace
Pump
Visual check
Replace
When removing, inside parts (cylinder
T5-2-3
E215B-E245B
3.
Move at lever neutral position
No. Sections
Pilot pressure
sensor
Carry out service

diagnosis
Check that targeted pilot pressure of

sensor is 0MPa in high idling
Check remote control valve
Remote control
valve
Check targeted
remote control
valve
Check that spool is free from abnormal

damage and spring is free from
breakage
Replace
Main spool
Check targeted
spool visually

breakage
Replace
Over load relief

valve
Check targeted
spool visually
Free from dust entered in port relief

valve. Seat is free from abnormality
Replace
Lock valve poppet

Check targeted
(in case of boom and poppet visually
arm)
Seat is free from abnormality
Replace
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
Holding valve spool

for boom
(in case of boom)
Check that smooth

sliding of spool in
sleeve
Free from abnormal resistance against

sliding
Replace
Do not pull spool out of sleeve
forcibly.
Holding valve relief

valve for boom
(in case of boom)
Check targeted
spool visually
Filter free from abnormal contamination Replace
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
Pressure sensor
Carry out service

diagnosis

Replace pressure sensor
All low pressure sensors are 0MPa to
0.1 MPa
Actual measuring
P2 unload
proportional valve
Carry out service

diagnosis


of unload
proportional valve
proportional valve
secondary pressure
A7 and A8 of 8
sections solenoid
block

Check that P1/P2 unloads secondary

pressures is within the range of 2.7 MPa
or more in control lever neutral and high
idling operation
T5-2-4
No. Sections
E215B-E245B
Carry out service

diagnosis
No.9 E-1 P1 pump

E-2 P2 pump

Actual measuring
P2 pump
proportional valve

of P1, P2 pump
proportional valve
proportional valve
secondary pressure
directly. (Ports a3,
a4)

0.5 to 1.0 MPa in control lever neutral
and high idling operation

Check regulator
Command current
Carry out service
value of short-circuit diagnosis.
No.15 D-15
Operation No. 1 Operation is nil.


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.
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
Short-circuit valve
spool.

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
Boom up pressure
sensor
Carry out service

diagnosis

Check and replace pressure
Operation No.3 boom up full lever and sensor
relief
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
Pump pressure
sensor
Carry out service

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.
Actual measuring
P2 unload
proportional valve
Carry out service

diagnosis


relief
T5-2-5
E215B-E245B
No. Sections

of P1, P2 unload
proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block

pressures are within the range of
0.5~1.2 MPa in boom up full lever and
high idling operation
Actual measuring
P2 pump
proportional valve
No.9 E-1 P1 pump

E-2 P2 pump
Operation No.4 boom up full lever & in
operation


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

1.8 to 3.0 MPa in boom up full lever and
P2 by-pass cut valve Visual check

<Trouble>
Only P2 pressure is
low.
No problem for sliding ability of main

poppet and no contamination on orifice
No problem for sliding ability of internal
piston (Check it through PBp2 port.)
Clean and replace
Remote control
valve
Check targeted
remote control
valve

breakage
Replace
10
Lock valve poppet

<Trouble>
Both P1 and P2
pressures are low.
Visual check

outside surface
Replace
(Check on the casing side for
damage)
11
Conflux check valve Visual check

<Trouble>
Only P2 pressure is
high.

outside surface
Replace
damage)
12
Holding valve for

boom (poppet)
<Trouble>
Both P1 and P2
pressures are high.
Visual check

outside surface
Replace
damage)
13
Boom spool
<Trouble>
Only P1 pressure is
high.
Visual check

Spring is free from breakage.
Replace
damage)
14
Check boom spool

and recirculation
<Trouble>
Only P1 pressure is
low.
Disassembly and
investigation

sliding
Replace spool assembly
15
Conflux spool
<Trouble>
Only P2 pressure is
high.
Visual check

outside surface
Replace
damage)
Carry out service

diagnosis
T5-2-6
E215B-E245B
No. Sections
16
Main relief valve

<Trouble>
Relief pressure is
low.
Check set pressure See Service Diagnosis Data List

Reset or replace
relief
17
Over load relief

valve
<Trouble>
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.
Slow boom down, insufficient power for lifting up body
No. Sections
Boom down
pressure sensor
Carry out service

diagnosis

sensor.
Check remote control valve.
Remote control
valve
Measure remote
control pressure of in boom down full lever and high idling When equipped with multi
boom down directly operation
changing lever pattern.
Actual measuring
current value of P1
unload proportional
valve
Carry out service

diagnosis

of P1 unload
proportional valve
proportional valve
secondary pressure
A7 of 8 sections
solenoid block.
Check that P1 unload secondary

1.2 MPa in boom down full lever and
Actual measuring
current value of P1
pump proportional
valve
No.9 E-1 P1 pump

Operation No.5 boom down full lever
& in operation

of P1 pump
proportional valve
proportional valve
secondary pressure
directly (Ports a3,
a4)
Check that P1 pump proportional valve Replace proportional valve

2.5 MPa in boom down full lever and
Actual measuring
current value of
travel straight
proportional valve
Check that the value is not change

Check pressure sensor of
regardless of operation
travel
& idling
check proportional valve
and controller for possible
idling
failure.
Carry out service

diagnosis
Carry out service

diagnosis

& in operation
P1 unload valve (cut valve)

& in operation
T5-2-7


E215B-E245B
No. Sections
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
Actual measuring
current value of
short-circuit valve.

regardless of operation No 15 D-15
travel.
Operation No.18 travel right full lever
& idling. Operation No.19 travel left full
lever & idling
failure.
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
11
Remote control
valve
Check targeted
remote control
valve

breakage
Replace
12
Lock valve poppet

<Trouble>
Boom down is low.
Visual check

outside surface
Replace
damage)
13
Holding valve
Visual check
(poppet)
<Trouble>
Boom down is slow.

resistance against sliding Free from
abnormal damage, etc on outside
surface
Replace
damage)
14
Boom spool
Visual check
<Trouble>
Boom down is slow.

outside surface
Replace
damage)
15
Check boom spool

and recirculation
<Trouble>
Machine can not be
lifted by supporting
with boom.
Disassembly and
investigation

sliding
16
short-circuit valve
spool.
Visual check.

resistance against free from abnormal
is free from breakage.
Replace (Check on the casing

site for damage).
Carry out service

diagnosis
T5-2-8
E215B-E245B
No. Sections
17
Main relief valve

<Trouble>
Relief pressure is
low.

Reset or replace
relief
18
Over load relief

valve
<Trouble>
Machine can not be
lifted by supporting
with boom.
Visual check
7.
No.
Free from dust entered in port relief

valve.
Replace
Slow arm in, insufficient power

Sections
Arm in pressure
sensor
Carry out service

diagnosis

Operation No.6 arm in full lever and
relief
Remote control
valve pressure
Measure directly
remote control
pressure of arm in
in arm in full lever and high idling
operation
Pump pressure
sensor
Carry out service

Operation No.7 arm in full lever and in
pump pressures in
operation
operation.

pressure sensor
Actual measuring
P2 unload
proportional valve
Carry out service

diagnosis


of P1, P2 unload
proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block.

1.2 MPa in arm in full lever and high
idling operation.
Actual measuring
P2 pump
proportional valve
No.9 E-1 P1 pump

E-2 P2 pump
Operation No.7 Arm in full lever & in
operation
Carry out service

diagnosis

Operation No.6 Arm in full lever &
relief
T5-2-9

sensor

E215B-E245B
No.
Sections

of P1, P2 pump
proportional valve
proportional valve
secondary pressure
directly. (Ports a3,
a4)

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)
Actual measuring
Carry out service
current value of arm diagnosis
in spool 2
proportional valve

Operation No.6 Arm in full lever &
relief
Operation No.7 Arm in full lever & in
operation

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

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

travel
& idling
idling
failure.
11

of travel straight
the proportional
proportional valve
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
12
Remote control
valve
Check targeted
remote control
valve

breakage
Replace
13
Main relief valve

<Trouble>
Relief pressure is
low.

Reset or replace
relief
14
Over load relief

valve
<Trouble>
P1, P2 pressure is
low.
When only relief pressure of

Visual check (Head Pressure is 32 MPa or more in arm in
arm in is low, replace valve
side)
and relief.
Free from dust entered in over load relief
valve.
Carry out service

diagnosis
T5-2-10

No.
Sections
E215B-E245B
15
Over load relief

valve
<Trouble>
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
valve.
Seat is free from abnormality.
16
Arm 1 spool
<Trouble>
P1, P2 pressure is
high.
Visual check

outside surface
Replace
damage)
17
Arm 2 spool
<Trouble>
P1, P2 pressure is
high or low.
Visual check

outside surface
Replace
damage)
18
Check arm 2 spool

and recirculation
<Trouble>
Arm in power is
poor.
Disassembly and
investigation

sliding
19
Check lock valve

poppet
<Trouble>
Both P1, P2
pressures are high.
Visual check

sliding
outside surface
Replace
damage)
8.
No
.
Slow independent arm out (in the air)

Sections
Arm out pressure

sensor
Carry out service

diagnosis

Operation No.8 arm out full lever and sensor
relief
Remote control
valve
Measure directly
remote control
in arm out full lever and high idling
pressure of arm out operation
Pump pressure
sensor
Carry out service

Operation No.9 arm out full lever and
pump pressures in
in operation
operation.

pressure sensor
Actual measuring
P2 unload
proportional valve
Carry out service

diagnosis


Operation No.8 Arm out full lever &
relief
T5-2-11
E215B-E245B
No
.
Sections

of P1, P2 unload
proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block

1.2 MPa in arm out full lever and high
idling operation
Actual measuring
P2 pump
proportional valve
No.9 E-1 P1 pump

E-2 P2 pump
Operation No.9 Arm out full lever & in
operation


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

1.5 to 2.7 MPa in arm out full lever and
(Secondary pressure is affected by oil
temperature and attachment weight)
Actual measuring
current value of
travel straight
proportional valve

travel
& idling
idling
failure.

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

10
Remote control
valve
Check targeted
remote control
valve

breakage
Replace
11
Main relief valve

<Trouble>
Relief pressure is
low.

Reset or replace
relief
12
Over load relief

valve
<Trouble>
P1, P2 pressure is
low.
Visual check (Rod

side)
13
Visual check
Arm 1 spool
<Trouble>
P2 pressure is high.
Carry out service

diagnosis
Carry out service

diagnosis
Pressure is 32 MPa or more in arm out When only relief pressure of

and relief.
arm out is low, replace valve
valve. Seat is free from abnormality

outside surface
T5-2-12
Replace
damage)
No
.
Sections
E215B-E245B
14
Arm 2 spool
Visual check
<Trouble>

outside surface
Replace
damage)
15
Check arm 2 spool

and recirculation
<Trouble>
Both P1, P2
pressures are low.
Disassembly and
investigation
(spring side)

sliding
16
Check lock valve

poppet
<Trouble>
Both P1, P2
pressures are high.
Visual check

sliding
outside surface
Replace
damage)
9.
Slow bucket digging
No. Sections
Bucket digging
pressure sensor
Carry out service

diagnosis

Operation No.12 bucket digging full
lever and relief

sensor
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
idling operation
Pump pressure
sensor
Carry out service

Operation No.13 Bucket digging full
pump pressures in
lever and in operation
operation.

pressure sensor
Actual measuring
P2 unload
proportional valve
Carry out service

diagnosis


of P1, P2 unload
proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block

1.2 MPa in bucket digging full lever and
Actual measuring
P2 pump
proportional valve
No.9 E-1 P1 pump

E-2 P2 pump
lever & in operation

of P1, P2 pump
proportional valve
proportional valve
secondary pressure
directly (Ports a3,
a4)
Carry out service

diagnosis

lever & relief


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
No. Sections
Attachment boost
solenoid command
Carry out service

diagnosis
No.3 POWER BOOST

Check harness
Bucket digging COMP OFF, MEAS OFF Replace solenoid valve
Attachment boost
solenoid secondary
pressure
Measure switching
valve secondary
pressure
Check that pressure is 0 MPa in bucket Replace solenoid valve

digging full lever and high idling
operation
10
Actual measuring
current value of
travel straight
proportional valve
Carry out service

diagnosis

lever & relief

11

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
12

<Trouble>
Only P2 pressure is
low.

Clean or replace
13
Check stroke limiter Visual check

<Trouble>
Both P1, P2
pressures are high.
When piston is removed from cover, it is Replace

sliding
damage.)
outside surface
14
Remote control
valve
Check targeted
remote control
valve

breakage
15
Main relief valve

Reset or replace
Operation No.3 Boom up full lever and
relief
16
Travel straight spool Visual check

<Trouble>

outside surface
Replace
damage)
17
Bucket spool
<Trouble>
Both P1, P2
pressures are high.
Visual check

outside surface
Replace
damage)
18
Over load relief

valve
Check targeted
spool visually
Free from dust entered in over load relief Replace

valve.
T5-2-14
Replace
E215B-E245B
10. Slow bucket dump

No.
Sections
Bucket dump
pressure sensor
Carry out service

diagnosis

Operation No.14 Bucket dump full
lever and relief
Remote control
valve
Measure directly
remote control
pressure of bucket
dump
in bucket dump full lever and high idling When equipped with multi
operation
Pump pressure
sensor
Carry out service

pump pressures in
lever and in operation
operation.

pressure sensor
Actual measuring
P2 unload
proportional valve
Carry out service

diagnosis

lever & relief


of P1, P2 unload
proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block

0.5~1.2 MPa in bucket dump full lever
and high idling operation. Replace
proportional valve
Actual measuring
P2 pump
proportional valve.
No.9 E-1 P1 pump

E-2 P2 pump
lever & in operation


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

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.
Actual measuring
current value of
travel straight
proportional valve

lever & relief

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

sensor

Check that travel straight secondary

pressure is 2.7 MPa or more in bucket
dump full lever and high idling operation
T5-2-15
E215B-E245B
No.
Sections
10

<Trouble>
Only P2 pressure is
low.

piston (Check it through PBP2 port.)
Clean and replace
11
Check stroke limiter Visual check

<Trouble>
Pilot pressure is low.
Free from abnormal damage and wear

on outside of piston inside cover
Replace
damage.)
12
Remote control
valve
Check targeted
remote control
valve

breakage
Replace
13
Main relief valve

<Trouble>
Relief pressure is
low.

Reset or replace
Operation No.3 Boom up full lever and
relief
14

<Trouble>

outside surface
Replace
damage)
15
Bucket spool
<Trouble>
Both P1, P2
pressures are high.
Visual check

outside surface
Replace
damage)
16
Over load relief

valve
Check targeted
spool visually
Free from dust entered in over load relief Replace

valve.
11. Swing operation not functioned/slow

No. Sections
Swing pressure
sensor
Carry out service

diagnosis

Operation No.11 Swing full lever and
in operation

sensor
Remote control
valve
Measure directly
remote control
pressure of swing
in boom up full lever and high idling
operation
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
Swing parking brake Measurement of

solenoid
solenoid valve A2
port
Lever neutral: 0 MPa

In operation: 4 MPa or more
T5-2-16
No. Sections
E215B-E245B
Shuttle valve
Visual check
<Trouble>
Pilot pressure is low.
No contamination on spool cover (short Clean or replace

side) and orifice
No damage on spool cover (long side)
and shuttle
Pump pressure
sensor
Carry out service

diagnosis for P2
pump pressures in
operation

in operation
Check high pressure sensor
Actual measuring
current value of P2
unload proportional
valve
Carry out service

diagnosis

Operation No.11 Swing full lever & in
operation


of P2 unload
proportional valve
proportional valve
secondary pressure
A5 of 8 sections
solenoid block
Check that P2 unload secondary

1.2 MPa in swing full lever and high
idling operation
Actual measuring
current value of P2
pump proportional
valve
No.9 E-2 P2 pump

Operation No.11 Swing full lever & in
operation
10
Secondary pressure Measure the pump Check that P2 pump proportional valve Replace proportional valve
of P2 pump
proportional valve
pressure is 2.7 MPa or more in swing full
proportional valve
secondary pressure lever and high idling operation
directly (Ports a3,
a4)
11
Actual measuring
current value of
travel straight
proportional valve
(Check this trouble
by only swing
operation)
Carry out service

diagnosis

travel
& idling
idling
failure.
12
Secondary pressure
of travel straight
proportional valve
(Check this trouble
by only swing
operation)
Measure directly
the proportional
valve secondary
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block

Carry out service

diagnosis
T5-2-17

E215B-E245B
No. Sections
13
Command current
Carry out service
value of short-circuit. diagnosis

travel.
lever & idling
failure.
14

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

regardless of neutral/operation.
Replace proportional valve.
15
Remote control
valve

breakage
Replace
16

<Trouble>
P2 pressure is low.

outside surface
Replace
damage)
17
Swing spool
Visual check
<Trouble>

outside surface
Replace
damage)
18
Short-circuit valve
spool.
Visual check.
When removing, free from abnormal Replace (Check on the casing

resistance against free from abnormal site for damage).
damage, etc on outside surface
19
Swing relief valve

<Trouble>
Relief pressure is
low.

relief
20
Swing motor
Visual check
21
Swing reduction
gear oil
Take sample oil

Sampling oil does not include a lot of
from swing
metal powder.
reduction gear drain
Disassemble and inspect

reduction gear
22
Swing reduction
Visual check
Replace
Check targeted
remote control
valve
Reset or replace
Inner parts (cylinder block, piston, valve Replace

brake etc) are to be free from abnormal
resistance against sliding.
outside surface (brake plate etc)
Tooth surface is not worn abnormally

and is not chipped.
T5-2-18
E215B-E245B
12. Noise during swing operation

No. Sections
Carry out service No.3 F-2 SWING-BRAKE

diagnosis
Lever neutral: COMP ON, MEAS
ON
Check swing pressure

sensor
Check harness
Measurement of Lever neutral: 0 MPa

solenoid valve A2 In operation: 4 MPa or more
port
Swing parking
brake solenoid
Boost check valve Visual check

(Sound of
cavitation at
stopping)
When removing, free from abnormal Replace

By-pass check
valve
(Sound of
cavitation at
stopping)
Visual check

Swing motor
(Brake valve/
friction plate)
Visual check
Disassemble and inspect abnormal Replace

wear and scuffing
Swing motor
piston
Visual check

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
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
Swing
sensor
Remote
valve
Swing parking brake Carry out service No.3 F-2 SWING-BRAKE

solenoid
diagnosis
Lever neutral: COMP ON, MEAS ON
pressure Carry out service Engine stop & starter key ON

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
E215B-E245B
No.
Sections
Swing motor
Visual check
(Brake valve/friction
plate)
Disassemble and inspect abnormal Replace

wear and scuffing
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
Visual check
Shuttle valve
<Trouble>
Pilot pressure is
low
Swing
sensor
Swing relief valve Check

pressure
<Trouble>
Relief pressure is
low.
Anti-reaction valve Visual check
Remote
valve
Swing motor
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.
control Check
remote
valve
set See Service Diagnosis Data List Reset or replace

Operation No.10 Swing full lever
and relief
Clean or replace
Free from dirt entering
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.
15. Slow travel speed/weak

No.
Sections
Travel right and left Carry out service See Service Diagnosis Data List
pressure sensor
diagnosis
Operation No.18 Travel right full lever sensor
and idling
Operation No.19 Travel left full lever
and idling
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
No.
Sections
E215B-E245B
Actual
measuring Carry out service No.9 D-1 P1 unload valve (cut valve)
current value of P1/ diagnosis
P2
unload
proportional valve
& idling
idling

Secondary pressure Measure

the
of P1, P2 unload proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block
Actual
measuring Carry out service No.9 E-1 P1 pump
E-2 P2 pump
P2
pump
proportional valve
& idling
idling

of P1, P2 pump proportional valve
proportional valve
secondary pressure
directly (Ports a3,
a4)
Actual
measuring Carry out service Check that the value is not change Check voltage of low
current value of diagnosis
pressure sensor other than
travel
straight
sensor for travel
proportional valve
& idling
idling
failure

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
Command current Carry out service Check that the value is not change Check pressure sensor of
value of short-circuit diagnosis
travel.
lever & idling
failure.
Check that P1/P2 unload secondary Replace proportional valve

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

operation
Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more
directly 0.8 MPa or less in high idling operation Replace proportional valve.
10 Secondary pressure Measure
secondary regardless of neutral/operation.
of proportional valve the
in short-circuit valve. pressure of the
proportional valve
in
short-circuit
valve. (G Port)
T5-2-21
E215B-E245B
No.
Sections
11 Remote
valve
control Check
remote
valve

breakage
Check sealing ability of shuttle valve and
entry of dust in orifice
12 Travel straight spool Visual check

<Trouble>
13 Travel spool
Visual check
<Trouble>
targeted spool
Pump pressure is
high.
14 short-circuit
spool.
valve Visual check.

Free from abnormal damage, etc on damage)
outside surface
of When removing, free from abnormal Replace
outside surface
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
If P1 is low, right travel

motorfs relief valve is failed.
If P2 is low, left travel
Visual check
Inner parts (piston, cylinder block, valve Replace

plate, brake valve spool) are to be free
from abnormal resistance against
sliding.
in Visual check

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
19 Travel reduction
Visual check
Tooth surface is not worn abnormally Replace

and is not chipped.
T5-2-22
inspect
E215B-E245B
16. Travel deviation

No.
Sections
Travel right and left Carry out service See Service Diagnosis Data List
pressure sensor
diagnosis
Operation No.18 Travel right full lever sensor
and idling
Operation No.19 Travel left full lever
and idling
Remote
valve
Actual
measuring Carry out service Check that the value is not change Check voltage of low
travel
straight
sensor for travel
proportional valve
& idling
idling
failure.

directly 0.8 MPa or less in high idling operation Replace proportional valve
proportional regardless of neutral/operation
proportional valve
valve
secondary
pressure
Actual
measuring Carry out service No.8 D-1 P1 unload valve (cut valve)
P2
unload
proportional valve
& idling
idling

the
of P1, P2 unload proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block
Actual
measuring Carry out service No.9 E-1 P1 pump
E-2 P2 pump
P2
pump
proportional valve
& idling
idling

of P1, P2 pump proportional valve
secondary pressure
proportional valve
directly (Ports a3,
a4)
control Measure
remote
control in travel right (left), forward (reverse) full
pressure of travel lever and high idling operation
right and left


operation
Travel right (P1 unload): 0.5 to 1.0 MPa
Travel left (P2 unload): 0.5 to 1.0 MPa

operation
Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more
T5-2-23
E215B-E245B
No.
9
Sections
Exchange P1 for P2 Exchange delivery Check the direction of deviation

pipe of P1 for P2
10 Remote
valve
control Check
remote
valve
12 Travel spool
Visual check
<Trouble>
targeted spool
Pump pressure is
high.

outside surface
Spring is free from breakage
of When removing, free from abnormal Replace
outside surface
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.

breakage
Check sealing ability of shuttle valve and
entry of dust in orifice

<Trouble>
14 Travel motor
Visual check
If P1 is low, right travel

If P2 is low, left travel
Replace as necessary
Inner parts (piston, cylinder block, valve Replace

plate, brake valve spool) are to be free
from abnormal resistance against
sliding.
reduction Take sample oil Sampling oil does not include a lot of Disassemble and
from
travel metal powder.
reduction gear
16 Travel reduction
Visual check
Tooth surface is not worn abnormally Replace

and is not chipped.
17 Pump regulator
Visual check

outside surface
18 Pump
Visual check
When removing, inside parts (cylinder Replace

T5-2-24
inspect
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
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
Travel 1/2 speed Measure A3 port Lever neutral: 0 MPa

switching solenoid
pressure
on In operation: 4 MPa or more
solenoid valve
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)
1/2 speed switching Visual check

orifice in travel motor
Free from entry of dust
Tilting
piston
travel motor
Free from abnormal wear on piston and Replace

seal
damage)
in Visual check
Remove dust or replace
18. Travel parking on a slope is not held

No.
Sections
Pilot
sensor
Remote
valve
Parking brake
travel motor
Orifice of passage Visual check

for parking brake in
travel motor
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
control Check
remote
valve

breakage
in Visual check

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
Actual
measuring Carry out service No. 8 D-3 S-TRAVEL is should be Check voltage of low
COMP 557 mA and MEAS 55730 mA
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.
Above mentioned values indicate while
boom-up and full lever operation are
performed).
failure.
T5-2-25
E215B-E245B
No.
Sections

directly
proportional
proportional valve
valve
secondary
pressure
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 53030 mA in both travel full
valve
lever and in boom-up full lever at high
travel sensor.
idling
failure.

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)

outside surface
Short-circuit
spool.

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
Pressure sensor for Carry out service See Service Diagnosis Data List
optional attachment diagnosis
Operation No.16 P2 side OPT full sensor
lever and relief
Remote
valve
Actual
measuring Carry out service See Service Diagnosis Data List
Operation No.16 P2 side OPT full largely differed from the
P2
unload
lever and relief
proportional valve
control Measure
remote
control in optional attachment full lever and high
pressure of travel idling operation
right and left
T5-2-26
No.
Sections
E215B-E245B

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
A7 and A5 of 8
sections solenoid
block
Actual
measuring Carry out service See Service Diagnosis Data List
Check voltage of low
Operation No.16 P2 side OPT full
travel
straight
lever & relief
sensor
for
optional
proportional valve
attachment
failure.

directly
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

<Trouble>
Only P1 pressure is
low.
No problem for sliding ability of main Clean or replace

Relief pressure
Remote
valve

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.

<Trouble>

outside surface
11 Spool for optional Visual check

attachment
<Trouble>
P1, P2 pressures
are high.

outside surface
12 Over
valve
load
relief Check
targeted Free from dust entered in over load relief Replace
spool visually
valve
T5-2-27
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 selector solenoid valve")
No.
Sections
Visual check
N&B selector spool

outside surface
N&B
solenoid
selector Screw
emergency
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
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 selector solenoid valve")
No.
Sections
N&B selector spool
N&B
solenoid
Visual check

outside surface
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
E215B-E245B
Table 1 - Action of optional selector solenoid valve

Safety
Engine lock lever
No.
SW's
condition
input
Running
ON
Safety
lock
lever
relay's
output
OFF
Work
mode
Optional
selector
valve
COMP.
MEAS.
OFF
Spool
position
Selector
valve
detecting
pressure
sensor
Warning display
Failure diagnosis
display
Nibbler
Normal
Running
ON
OFF
ON
Breaker
"SELECTOR
Normal
FAILURE"
Running
ON
OFF
OFF
Breaker
Normal
Running
ON
OFF
ON
Nibbler
Normal
[F042] displayed
Running
ON
OFF
ON
Breaker
Normal
Running
ON
OFF
OFF
Nibbler
Normal
"SELECTOR
FAILURE"
VALVE [F043] displayed

simultaneously
Running
ON
OFF
ON
N&B
Normal
"SELECTOR
FAILURE"
VALVE
Running
ON
OFF
OFF
Breaker
Normal
[F043] displayed
Running
ON
OFF
Failure
"SELECTOR
FAILURE"
VALVE [B113] displayed
10 Stopping
"SELECTOR
FAILURE"
VALVE [F042] displayed

simultaneously
VALVE
11
OFF
12
ON
T5-2-29
E215B-E245B
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.
CONNECTOR
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.
WIRE
TESTER
(When both ends measurement is difficult

because of long distance between connectors)
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.
SM0104
JUMPER
WIRE
TESTER
FRAME BODY GROUNDING
SM0105
Checking for presence or absence of shortcircuit with machine body

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.

When the resistance is 1 M
or more, it is in
normal condition.
TESTER
SM0107
T5-2-30

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
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

2.2 TROUBLE
1.
Engine does not stop.
2.
"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
E215B-E245B
1.
Engine does not stop.
No
.
Sections
Starter key switch Check signal of

starter key switch
ON by carrying
out
service
diagnosis.
Check continuity between

No.4 K-3 Key switch
OFF at starter key switch OFF terminals of starter switch
using tester
position
ON at starter key switch ON position
Engine
forcible When
ON
is
stop relay
displayed with the
starter
switch
OFF, then pull out
R-25
engine
forcible stop relay
and carry out the
service diagnosis.
No.4 K-3 Key switch

Check on engine forcible
OFF at starter key switch OFF stop relay
position
ON at starter key switch ON position
Wiring
2.
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
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
Fuse
No.1 fuse (5 A)
Not blown fuse
Check harness
Replace fuse
Mechatro
controller
Accel control
Engine speed varies according to Check mechatro controller

and replace as necessary
accel potentiometer operation.
(Use remote control because the
auto accel function is working.)
Wiring
See
WIRING
Transmission
circuit line No.770 PROCEDURE"
from
mechatro
controller
to
gauge cluster
Gauge cluster
Gauge cluster
CHECKING Repair wiring
Replace gauge cluster
T5-2-34

3.
No
.
Auto accel does not actuate. (The engine speed does not automatically slow down.)
Sections
Engine
coolant Check
engine
temperature
coolant
temperature by
carrying
out
service diagnosis.
Gauge cluster
Low
sensor
4.
No
.
E215B-E245B
Replace engine coolant

No.2 G-5 WATER TEMP
Auto accel does not work in the sensor
temperature -15 C or less.
Warm up and raise the coolant
temperature to 15 C or more
Indication of auto Mark "Display/not display" for auto Replace gauge cluster
accel
accel switches by auto accel switch
operation on gauge cluster.
pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is in the range of 0~0.1 MPa at
control lever neutral position.
Auto accel does not actuate. (The engine speed does not automatically speed up.)
Sections
Low
sensor
pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is raised with control lever
operated.
T5-2-35
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.
Sections
Fuse
Check fuse No.20
Replace fuse
SW-19:
Wiper interlock
switch
Service diagnosis No.19 D125

Check wiper interlock switch
Wiper switch display (D125) is OFF with front window closed. and repair it if necessary
Check according to "WIRING
CHECKING PROCEDURE"
and repair it if necessary
Rise up limit switch Service diagnosis No.25 Wiper system

built-in wiper motor
Reverse limit switch Switch action in operation
Check according to "WIRING

CHECKING PROCEDURE"
Normal condition
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:
Arc prevention relay
OFF
ON
ON
ON
ON
Forward rotation
Forward rotation relay
OFF
ON
ON
ON
ON
Reverse rotation relay
OFF
OFF
OFF
OFF
OFF
relay
Check that the relay is worked as shown in the table.
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)
(STOP)
(REVERSE)
(FORWARD)
OFF
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
ON
ON
OFF
OFF
Check that the relay is excited.

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 condition 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 and 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
No.2
LANGUAGE/LOGO
No.3
8 FAULT DIAG MODE
ADJUSTING MODE 1
PRESET BY FACTORY
SELECT SWITCH
DIAG MODE 1
DIAG MODE 2
BUZZER STOP SWITCH
FEED
SCREEN CHANGE SWITCH
CASE OF DIAG MODE 1

SENSOR CHECK
CHECK
START ENG
ENGINE SPEED
0000 rpm
PRESSURE
C-1 00.0M
PROPO-VALVE
E-1 005mA
D-1 300mA
C-2 00.0M
LOWER BOOM
DIAG MODE 1
RELEASE LOCK
LEVER
TO GROUND
About 15 minutes
E-2 005mA
D-2 300mA
Turn engine on
manually.
BACK TO No.3
RESULT OF DIAGNOSIS
When
not failed,
DIAG MODE 1
END
In diagnosis
operation
START
ENGINE STOP
RESULT OF DETAIL
DIAG MODE 1
1 P1 UNLOAD
OK
O K
DATA END
Engine stops
automatically.
FEED
DIAG MODE 1 RESULT 1

P1 UN-LOAD PSV NG
P1 UN-LOAD SPOOL NG
DATA END
BACK TO No.3
FEED
The data at the time of judgment

can be confirmed with the select
switch.
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,
For
tthediagnosing
Forthe
diagnosingitems,
items,see
seeTable
Table 48-1.
1.
When
Whenrequired
requiredto
tostop
stopin
indiagnosis
diagnosis
operation,
operation,press
pressthe
thebuzzer
buzzerstop
stopswitch
switch
and
andthe
theoperation
operationisisforcedly
forcedlystopped.
stopped.
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 taken, 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
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
Table 1 - Failure diagnosis Mode-1/Diagnosis item

No.
Display
Contents of diagnosis
1 P1 UNLOAD
Is normal pressure generated in the condition that the flow rate at P1 side is minimum
and the unloading valve is in the emergency position?
2 P1 UNLOAD
Is normal pressure generated in the condition that the minimum flow rate is relieved at
P1 side?
3 P1 UNLOAD
Is normal pressure generated in the condition that the unload valve is fully opened,
and P1 side flow rate is minimum?
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?
2 P2 UNLOAD
Is normal pressure generated in the condition that the minimum flow rate is relieved at
P2 side?
3 P2 UNLOAD
Is normal pressure generated in the condition that the unload valve is fully opened,
and P2 side flow rate is minimum?
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?
2 P1 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and
P1 side flow rate is minimum?
3 P1 PUMP
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
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
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 is excessive high

against the command
Check P1 unload proportional valve
P1 UN-LOAD PSV NG
Secondary pressure is excessive low and replace it if necessary
against the command
P1 UN-LOAD SPOOL
NG
Stuck at full-stroke side
Check P1 unload spool and replace it

if necessary
Stuck at neutral side

T5-3-4
E215B-E245B
Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display)
Possible cause
Remedy

against the command
Check P2 unload proportional valve
P2 UN-LOAD PSV NG
against the command
P2 UN-LOAD SPOOL
NG
P1 B-P CUT NG
P2 B-P CUT NG
Check P2 unload spool and replace it

if necessary

Stuck at closing side
Check P1 by-pass cut valve and


Stuck at closing side
Check P2 by-pass cut valve and

P1 PUMP PSV NG

against the command
Check P1 pump proportional valve
against the command
P1 PUMP NG
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
P2 PUMP PSV NG

against the command
Check P2 pump proportional valve
against the command
P2 PUMP NG
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
S-TRAVEL PSV NG

against the command
Check travel straight proportional
Secondary pressure is excessive low valve and replace it if necessary
against the command
S-TRAVEL SPOOL NG
Check travel straight spool and

PUMP 1 PRESS. SENPressure is recognized lower than it is

SOR NG
Check P1 high pressure sensor and

PUMP 2 PRESS. SENPressure is recognized lower than it is

SOR NG
Check P2 high pressure sensor and

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

T5-3-5
E215B-E245B
[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
CCCCC
GGGGGGG
wwwww
Section 3
UNDERCARRIAGE
Group 1
Group 2
Group 3
Group 4
Group 5
Group 6
Group 7
Group 8
AAAAAA
zzzzzz
wwwww
zzzzzz
AAAAAA
zzzzzz
wwwww
zzzzzz
Section 4
FRONT ATTACHMENT
Group 1
Group 2
Group 3
Group 4
Group 5
Group 6
Group 7
Group 8
AAAAAA
zzzzzz
wwwww
zzzzzz
AAAAAA
zzzzzz
wwwww
zzzzzz
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 "Dont operate" tag to control lever, and
begin a meeting before starting the work.
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.
- 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,
dont 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.
- 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
manufactures side, disassembly, assembly and
modification without permission are strictly
prohibited.
W1-1-1
E215B-E245B
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, dont 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
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:
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 tears, breaks,
deformation or hardening.
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
C
B
b
a=b
W1-1-3
ab
SM0174
E215B-E245B
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 scald 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
Bolt Dia.
Wrench
Size
Hexagon
Wrench
Size
T Bolt,
Socket
bolt
(Nm)
M18
13
29.5
M10
17
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
12
14
13
10
11
6
2.3
Tighten from center and diagonally
4
2
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
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.
WRONG
RIGHT
Do not bend it round
Bend along edge sharply
RIGHT
RIGHT
WRONG
Lock Wire
IMPORTANT: apply wire to bolts in the bolttightening direction, not in the bolt-loosening
direction.
Bend along edge sharply
RIGHT
RIGHT
Tighten
SM0180
WRONG
RIGHT
WRONG
Loosen
SM0181
W1-2-3
E215B-E245B
TIGHTENING TORQUE
PIPING JOINT
Pipe Thread Connection / Union
Tightening Torque Specifications
Joint
Union Joint
Metal sealing faces (4) and (5) of adaptor (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
Joint Body
SM0182
IMPORTANT
1.
2.
Do not over-tighten union nut (3). Excessive

force will be applied to metal sealing surfaces
(4) and (5), possibly cracking adaptor (1). Be
sure to tighten union nut (3) to specifications.
37
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
Type
37 Union Joint
Wrench Size
Tightening Torque
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.
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
(8). Tightening union nut (9) with O-Ring (6)
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
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
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.
Leave one to two pitch threads uncovered
Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.
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.
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.
RIGHT
WRONG
SM0190
WRONG
RIGHT
Rubbing Against Each Other
SM0191
RIGHT
WRONG
Clamp
Clamp
Rubbing
SM0192
WRONG
RIGHT
Rubbing
Clamp
SM0193
W1-2-7
E215B-E245B
TIGHTENING TORQUE
NOTE:
W1-2-8

SM E215B EN

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SAFETY PRECAUTIONS

Read the Operation and Maintenance Instruction

Always check height, width and weight limitations

Carefully read the explanation to each and all safety

Assess exact paths of gas ducts, water mains,

Machine-mounted safety plates are colour coded

Such paths should be opportunely defined by

It is fundamental that all machine operators know

Never exceed machine lifting capacity.

Do not allow unauthorised personnel to operate or

Always keep the operators compartment, step

Prior to starting the engine, check, adjust and lock the

Do not jump on or off the machine. Always keep both

Obey all hand signals, safety indications and signs.

Never operate the machine or its attachments from

Ensure that nobody is within the excavator operating

Be careful of possible slippery conditions of the steps

Ensure that engine speed is appropriate to the job to

Due to the presence of flammable fluids, never

Adjust all rear-view mirrors for maximum visibility of

If any hydraulic control or system exhibits erratic

properly protected against possible backlash in

Air in these circuits may cause incorrect movements

In darkness, check area of operation carefully before

Do not operate the machine until this condition is

Keep the operators compartment free of foreign

Operators must know the performance of the

Do not carry riders on the machine. Study and

If noise level is high and exceeds 90 dB (A) over 8

Make sure that bystanders are clear of the machine

Do not operate the machine if you are extremely tired

When backing, always look to where the machine is

Where removable counterweights are provided, do

Be alert of the position of bystanders. Should

When operating the machine, keep in mind height

Always give way to loaded machines.

Also, get to know load limits of the ground and

Maintain a clear vision of the surroundings of the

Beware of fog, smoke or dust that obscure visibility.

When pulling loads or towing through a cable or

Whenever possible, avoid crossing over obstacles

Always wear heavy gloves when handling chains or

When obstructions must be crossed, do so with

Chains and cables should be securely anchored

Ease up to the break-over point, pass the balance

Keep anyone clear of anchor points and cables or

To overcome deep trenches or sinking ground, place

Do not pull or tow unless the operators

the attachment if necessary, only after assessing that

The load must always be properly arranged in the

The gradient you may attempt to overcome is limited

Do not lift and move the bucket overhead where

Avoid operating the attachment too close to an

The excavator is no lifting and transportation means,

Avoid faggots, bushes, logs and rocks. Never drive

- The machine must be equipped compulsorily with

Be alert to avoid changes in adherence conditions

- Nobody should be allowed to remain under the

The word bulldozing generally refers to work in

Never exceed specified loading capacity. Incorrect

Position the machine dependent upon the loading

All loading capacities are referred to the machine

Never use the bucket or attachment as a man lift