OPERATIONAL PERFORMANCE TEST

M0103

OPERATIONAL PERFORMANCE TEST

E215B-E245B

SECTION AND GROUP CONTENTS

Section 4

OPERATIONAL PERFORMANCE TEST

Group 1
Group 2
Group 3
Group 4

Introduction
Standard Performances
Test Procedures
Mechatro Controller

SECTION 4

OPERATIONAL PERFORMANCE
TEST

CONTENTS
Group 1 - Introduction
How to Use the Maintenance Standard
and Cautions to Be Exercised ........... T4-1-1
Preparation for Performance Tests......... T4-1-2

Group 2 - Standard Performances

Performance Inspection Standard
Table.................................................. T4-2-1

Group 3 - Test Procedures

Measurement of engine speed ............... T4-3-1
Measurement of hydraulic pressure........ T4-3-2
Measuring travel performances .............. T4-3-7
Measuring swing performances .............. T4-3-11
Measuring attachment operating
performances ..................................... T4-3-15
Measuring performances of swing
bearing............................................... T4-3-17

Group 4 - Mechatro Controller

Engine control input/output ..................... T4-4-1
Engine control ......................................... T4-4-2
Engine control equipment ....................... T4-4-3
Adjustment of mechatro controller output
(A-B-C adjustment) ............................ T4-4-4

E215B-E245B

INTRODUCTION

E215B-E245B

HOW TO USE THE MAINTENANCE

STANDARD AND CAUTIONS TO BE
EXERCISED
Application

Cautions to be Exercised at Judgment

WHEN THE MACHINE IS NEW

EVALUATION OF MEASURED DATA

Confirm that the performances are in accordance

with standard specifications as compared to the
performance standards.
AT SPECIFIC SELF INSPECTION (RULE BY
COUNTRY)

Disagreement of measuring conditions, variations of

data peculiar to a new machine, and measuring
errors are to be evaluated. Determine generally at
what levels measured values are located, instead of
determining whether or not values fall within or run
out of the reference values.

Use the data for the criterion, for the purpose of

correction, adjustment and replacement.

DETERMINING CORRECTION, ADJUSTMENT

OR REPLACEMENT

WHEN PERFORMANCES ARE DETERIORATED

Machine performances deteriorate with time as

parts wear and some deteriorated performances
may be restored to new levels. Therefore, determine
correction, adjustment or replacement, depending
upon the operating hours, kind of work and
circumstances in which the machine is placed, and
condition the machine performances to its most
desirable levels.

Determine whether it is caused by a fault or end of

service life after long hours of operation, to be used
for safety and economical considerations.
WHEN MAIN COMPONENTS ARE REPLACED
For example, use data to restore performances of
pumps and others.

Other Cautions to be Exercised

Terminology

PARTS LIABLE TO DEGRADE

STANDARD VALUES
Values to be used to condition or assemble a new
machine. Where special notes are not given, these
values represent standard specifications (machine
with standard attachments and standard shoes).
REFERENCE VALUES FOR REMEDY
Values at which readjustment is required. In order to
ensure performance and safety it is strictly
prohibited to use the machine over the specified
values.
SERVICE LIMIT
This is the limit value at which reconditioning is
impossible without replacement of parts. If the value
is expected to exceed the service limit before next
inspection and correction are performed, replace
the parts immediately. The operation over the
specified values causes increase of damage and
requires the down time of machine, and also causes
safety problems.

Rubber products, such as, hydraulic hoses, ORings, and oil seals deteriorate with time; replace
them at regular intervals or at overhauls.
PARTS REQUIRING REGULAR REPLACEMENT
Out of critical hoses that are necessary to secure
safety, we designate Very Important Parts (V.I.P)
and recommend that they should be replaced
regularly.
INSPECTION AND REPLACEMENT OF OILS AND
GREASES
In performing maintenance, it is necessary for the
user to familiarize himself with how to handle the
machine safely, cautions to be exercised and
inspection/lubrication procedures. Refer to the
operators manuals as well.

T4-1-1

E215B-E245B

INTRODUCTION

PREPARATION FOR PERFORMANCE

TESTS
Observe the following rules in order to carry out
performance tests accurately and safely.
The machine
1.

Repair any defects and damage found, such as

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

Test area
1.

Select a hard and flat surface.

2.

Secure enough space to allow the machine to

run straight more than 20 m, and to make a full
swing with the front attachment extended.

3.

SM1231

If required, rope off the test area and provide

signboards to keep unauthorized personnel
away.

Precautions
1.

Before starting to test, agree upon the signals

to be employed for communication among
coworkers. Once the test is started, be sure to
communicate with each other using these
signals, and to follow them without fail.

2.

Operate the machine carefully and always give

first priority to safety.

3.

While testing, always take care to avoid

accidents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.

4.

Avoid polluting the machine and the ground

with leaking oil. Use oil pans to catch escaping
oil. Pay special attention to this when removing
hydraulic pipings.

Make precise measurement

1.

Accurately calibrate test instruments

advance to obtain correct data.

in

2.

Carry out tests under the exact test conditions

prescribed for each test item.

3.

Repeat the same test and confirm that the test

data obtained can be produced repeatedly. Use
mean values of measurements if necessary.

T4-1-2

SM1232

STANDARD PERFORMANCES

E215B-E245B

PERFORMANCE INSPECTION STANDARD TABLE

NOTE: unless otherwise specified, measure it on "H" mode.

Measuring Position

Inspection Item

Standard
Value

Unit

Adjusting
Point

Hydraulic oil in tank

NAS 9
or less

Class

Sampling

Tank surface

50 5

Radiator surface

75 15

Atmospheric
temp
50 C ~ -10 C

Position

Cleanliness of hydraulic oil

Water temperature

H mode Hi idle
Measure the engine speed at
multi display on the gauge
cluster, or measure with diesel
speed meter

Auto-Idle
B mode Hi idle

ATT Travel

Power
boost

Bucket

Arm

Swing

Travel

RH

LH

P1

a1

P2

a2

P1

a1

P2

a2

a1

R
H
R
H
R
LH
RH
Forward
Reverse
Forward
Reverse

Main pump

Main relief
valve pressure

Full throttle (Hi Idle)

1050 50
2000 50

1800 50

Boom

Over load relief valve pressure

2000 50

S mode Hi idle
a5

PF 1/4

a1

Adjustment
not
required Perform all
measurement with the
air-conditioner OFF

PR1

HI idle

34.3 +0.7

MR1

Boom up

37.8 +1.0

MR1

-0

-0,5

-0.5

39.7 +0
-5.9

OR3

Boom up

37.8 +0

OR4

Boom down

39.7

OR1

Bucket digging

OR2

Bucket dump

OR7

Arm in

OR8

Arm out

OR5

Swing LH

OR6

Swing RH

37.8

-4.0
+0
-5.9
+0
-4.0
+0
-4.0

39.8 +0

-5.9

a2

+6.0
29.0 +0

a1

34.3 +0,7

a2

34.3 +0,7

T4-2-1

min-1

5.0 +0,5

37.8
a2

Low throttle

2000 50

G pump

1000 50

A mode Hi idle

Pilot primary pressure circuit

High pressure circuit

Port

H mode Lo idle
Engine speed

Std. Measuring condition

Hydraulic oil temperature

Size

Measuring
Condition

-0,5

-0,5

MPa

Simultaneous
Operation of travel RH
and LH

E215B-E245B

STANDARD PERFORMANCES

Inspection Item

Standard value

Sprocket revolution
(RH, LH)
E215B

1st speed

32~28

2nd speed

50~45

Sprocket revolution
(RH, LH)
E245B

1st speed

28~24

nd

45~40

speed

Operating speeds

Arm
Operating time
of cylinder

Positioner
Swing speed
Travel speed
E215B
Travel speed
E245B

Performance

Bucket

In

3.0~3.6

Out

2.3~2.9

Digging

2.2~2.8

Dumping

1.7~2.3

In

2.9~3.5

Out

4.1~4.7

RH - LH

4.2~5.4

st

1 speed

Iron shoe

25.2~28.2

2nd speed

Iron shoe

16.9~18.9

1st speed

Iron shoe

29.5~32.5

Iron shoe

18.5~21.5

nd

speed

Amount of travel
deviation

2nd speed

Parking brake drift

15 Gradient

Performance of Swing
brake

Neutral position after

180 full speed swing

Swing parking brake

drift

ATT amount of drift

Measuring
condition

Unit
min-1

min-1

(At no load)

s / 3 rev

0~240

mm / 20 m

mm / 5 min

55~75

degree

15 Gradient

mm

Tip of the bucket tooth

80

Boom cylinder

Arm cylinder

Amount of horizontal play at the bucket tooth

30~50

mm / 5 min

mm

NOTE: over load relief valves OR1~OR8 described in advance

correspond to the following operations.
1.

Bucket digging

5.

Swing left

2.

Bucket dump

6.

Swing right

3.

Boom up

7.

Arm in

4.

Boom down

8.

Arm out

T4-2-2

(At no load)

(8)
(5)

(4)
(6) (1)

(7)

(2)
(3)

TEST PROCEDURES

E215B-E245B

MEASUREMENT OF ENGINE SPEED

Warming up of engine
Start engine to raise the coolant temperature of
engine to 60 to 90C (140 to 194F) at surface of
radiator upper tank.
The E/G coolant tem-perature gauge is used to
measure.
The range in white color shows the temperature of
approx. 65 to 105C (149 to 221F), so confirm that
the pointer indicates the temperature within the
white range.
SM0600

Engine speed measured value through service

diagnosis
1.

Turn "ON" the starter switch with the buzzer

stop switch pressed.

2.

A program No. and an actual engine revolution

are displayed as the No.2 Item.

3.

The screen advances like No.2, No.3....each

time the "Wiper switch" on the gauge cluster is
pushed.

4.

The screen returns like No.45, No.44....each

time the "Washer switch" is pushed.

5.

The display does not disappear unless the

starter switch is turned to"OFF".

GAUGE CLUSTER

BUZZER STOP
SWITCH
WASHER
SWITCH

WIPER
SWITCH
SCREEN CHANGE SWITCH

NO.2 ENG
G-3 SPEED SET
MEAS
G-5 ENG PRS.
WATER TEMP
MODE
H-1 ACCEL VOLT.
POS.
G-1 MOTOR STEP
POS.
COIL A
COIL B
G-2 LIMIT SW.

SM0851

1000
1000
LIVE
20 C OFF
H
0.3 V
0%
30
0%
1.5 A
1.5 A
OFF
SM0852

T4-3-1

E215B-E245B

TEST PROCEDURES

MEASUREMENT OF HYDRAULIC
PRESSURE
Preparing to measure hydraulic pressure
HYDRAULIC EQUIPMENT
6.9 MPa (1000psi) pressure gauge: 1unit
49 MPa (7100psi) pressure gauge: 2 units
Pressure measuring equipment and instrument for
analysis: 1 set

a5
B3
Dr3

A3

MEASURING CLEANLINESS OF HYDRAULIC OIL

A2
(A1)

PSV2

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

Place to install pressure gauge

MAIN CIRCUIT
After releasing the pressure in hydraulic oil tank and
system, replace plugs PF1/4 of main pump gauge
ports (a1) (a2) with plugs for pressure
measurement, and attach pressure gauge 49 MPa
(7100 psi).
PILOT CIRCUIT
Replace pilot gauge plug (a5) with plug PF1/4 for
pressure measurement, and attach pressure gauge
6.9 MPa (1000 psi).

T4-3-2

(PSV1)

a1

a2

SM0853

TEST PROCEDURES

E215B-E245B

Pressure adjustment position

MAIN CONTROL VALVE
Relief valve position on main control valve.

ARM (R)
OR8

PLUG FOR
OPTIONAL RELIEF

FRONT
MACHINE

USE FOR YN30V00101

F1

MAIN RELIEF
(ATT & TRAVEL)

BOOM (H)
OR3

BUCKET (R)
OR2

View from the top of the machine

BOOM (R)
OR4

SM0854

BUCKET (H)
OR1

MACHINE
FRONT

ARM (H)
OR7
View from the bottom of the machine

T4-3-3

PLUG FOR
OPTIONAL RELIEF
SM0855

E215B-E245B

TEST PROCEDURES

PILOT RELIEF VALVE

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

B3

A3

PR1

SWING OVER LOAD RELIEF

The swing motor is equipped with plugs PA, PB for
pressure measurement, but the measurement is
carried out using gauge ports (a1) and (a2).

a5

Dr3

SM0856

SWING RIGHT
OVERLOAD RELIEF
OR6

SWING LEFT
OVERLOAD RELIEF
OR5

(A)

(B)

PB

PA

SM0857

a5
B3
Dr3

A3

A2
(A1)

PSV2
(PSV1)

a1

T4-3-4

a2

SM0853

TEST PROCEDURES

E215B-E245B

Procedure for adjusting relief valve

PILOT RELIEF VALVE
Adjust it with adjust screw (311).
: 24 mm
: 29.4 Nm (22 lbfft)
: 6 mm
No. of turns of adjust
screw

Pressure change MPa

(psi)

1 turn

Approx. 2.1 (305)

311
LOCK NUT HEX24
SM0858

2-STAGE MAIN RELIEF VALVE

(Commom for travel and ATT sections)
Start from the boosting side, first. Loosen nut (1),
adjust the pressure with adjusting screw (2) and
tighten nut (1) after completion of the adjustment on
the boosting side.
Then, loosen nut (3), adjust the pressure on the
standard side with adjusting screw (4) and tighten
nut (3) after completion of the adjustment.

4 3

: 32 mm
: 27.4~31.4 Nm (20~23 lbfft)

SM0859

: 22 mm
: 27.4~31.4 Nm (20~23 lbfft)
: 19 mm Adjust screw
: 6 mm

No. of turns of adjust

screw

Pressure change MPa

(psi)

Boosting side 1 turn

Approx. 17.6 (2560)

STD side 1 turn

Approx. 17.6 (2560)

OVER LOAD RELIEF VALVE

(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust screw
(2).
: 22 mm
: 27.4~31.4 Nm (20~23 lbfft)
: 6 mm
No. of turns of adjust
screw

Pressure change MPa

(psi)

1 turn

Approx. 17.7 (2560)

1
SM0860

T4-3-5

E215B-E245B

TEST PROCEDURES

OVER LOAD RELIEF VALVE (SWING)

When the adjustment of pressure is required,
loosen lock nut (1) and adjust the pressure with cap
(2).

: 30, 38 mm
: 118 Nm (87 lbfft)
: 12 mm

No. of turns of adjust

screw

Pressure change MPa

(psi)

1 turn

Approx. 10 (1450)

SM0861

OVER LOAD RELIEF VALVE (TRAVEL)

This valve was adjusted by valve maker. When
adjustment is required, loosen nut (1) and adjust the
pressure with adjusting screw (2).

: 17 mm
: 6 mm
2
SM0862

T4-3-6

TEST PROCEDURES

E215B-E245B

MEASURING TRAVEL PERFORMANCES

Travel speed
PURPOSES
Measure the travel sprocket revolution and confirm
the performances between the hydraulic pump and
the travel motor of the travel drive system.
CONDITIONS
Hydraulic oil temperature ;45~55C (113~131F)
Crawler on the right and left sides are tensioned
evenly.
PREPARATION
Attach the reflection panel with a magnet to the
travel motor cover.
Swing the swing frame through 90 as shown in
Figure and make the crawler on one side take off the
ground, using the attachment.
MEASUREMENT
Engine revolution:
2-speed travel switch:

SM0863

REFLECTION
PANEL

Hi idle
1st speed and 2nd
speed
Right and left

Measuring points:
Method, example 1:
Measure revolution with a stroboscope
Method, example 2:
Measure the revolutions per minute visually.

SM0864

E215B
Unit: min-1

Sprocket revolution
Measurement
item
H mode 1st
speed
RH&
LH
H mode
2nd speed

Standard
value

Reference
value for
remedy

Service
limit

32~28

25.2~22.8

20.4 or
less

50~45

39~35.3

32.5 or
less

E245B
Unit: min-1

Sprocket revolution
Measurement
item
H mode 1st
speed
RH&
LH
H mode
2nd speed

Standard
value

Reference
value for
remedy

Service
limit

28~24

22~19

17 or less

45~40

34~31

29 or less

T4-3-7

E215B-E245B

TEST PROCEDURES

Deviation of travel
PURPOSE
Measure the amount of deviation at 20m (66ft) travel
and confirm the horizontal balance between the
hydraulic pump and the travel motor of the travel
drive system.
CONDITION
Hydraulic oil temperature:

45~55 C
(113~131F)
RH and LH crawler are tensioned evenly.
Firm, level ground
Engine revolution:
Hi idle.

Approx. 30~40 cm

PREPARATION

SM0865

1.

Straight course more than 30m (108ft).

2.

Travel position in which the bottom of the

bucket is lifted by about 30cm (1ft).

MEASUREMENT
1.

2.

Measure the max. deviation distance of the

circular arc in the 20m (66ft) length, excluding
the preliminary run of 3~5m (10~16ft).
Operate the travel lever at the same time.

Travel deviation

A
20m

Unit: mm (in)/20m (66ft)

Measuring
position

Standard
value

Reference value
for remedy

Service
limit

240 (9.45)
or less

480 (18.9)

720 (28.4)

SM0866

T4-3-8

TEST PROCEDURES

E215B-E245B

Performances of parking brake

PURPOSE
Confirm that the parking brake holds a stopped
condition of the machine in a no-load travel position
and on a 15 degree slope.
CONDITION

BOOM FOOT PIN

A slope with (Approx. 15 deg) gradient and a

stopped condition in a no-load travel position.
ARM TOP PIN

PREPARATION
Place an angle meter on the shoe plate and confirm
that it makes an angle more than 15 degree.
Hang a perpendicular in parallel with the guide
frame rib on the track frame and put a mark
(matching mark) on the shoe plate.

15 degree slope

SM0867

MEASUREMENT
Five minutes after the engine stops, measure the
movement distance of the matching mark.
Parking brake

Units: mm (in)/5 min

Measuring
position

Standard
value

Reference value
for remedy

Service
limit

1 (0.04)

2 (0.08)
GUIDE FRAME

ANGLE METER

SM0868

T4-3-9

E215B-E245B

TEST PROCEDURES

Drain rate of travel motor

PURPOSE
To measure the drain rate of the travel motor and to
confirm the performances of the travel motor.
CONDITIONS
Hydraulic oil temperature:
Engine revolution:

45~55C
(113~131F)
Hi idle

PREPARATION
1.

Place a stopper under the RH and LH travel

sprockets.

2.

Stop the engine and release pressure from the

hydraulic circuit.

3.

Connect a hose with the drain port of the travel

motor and take drain in a container.

MEASUREMENT AT TRAVEL LOCK

90 o 10
(3.54") (0.394")

FORWARD
o 22 PIPE
(0.866")
RIB "A"

40
(1.57")
150
(5.91")

STOPPER
"B"

ROTARY DIRECTION

o 80
(3.15")
SM0869

WARNING
Unless you observe the rotary force direction at
travel lock, rib "A" may be broken by stopper "B" in
some cases.
1.

Start the engine and relieve pressure at the full

stroke of the travel lever.

2.

Measure the drain rate for 30 seconds of

relieving.

Drain rate of travel motor

E215B
Unit: (gal)
L/30 s

Drain rate of travel motor

Measuring
position

Standard
value

Reference value
for remedy

Service limit

Drain rate

9 (2.4)

16 (4.2)

23 (6.1)

E245B
Unit: (gal)
L/30 s

Drain rate of travel motor

Measuring
position

Standard
value

Reference value
for remedy

Service limit

Drain rate

7 (1.6)

14 (3.5

21 (4.6)

T4-3-10

SM0870

TEST PROCEDURES

E215B-E245B

MEASURING SWING PERFORMANCES

Swing speed
PURPOSE
Measure the swing time and confirm the
performances between the hydraulic pump and the
swing motor of the swing drive system.
CONDITIONS
Hydraulic oil temperature:
Firm, level ground
Engine revolution:

45~55C
(113~131F)
Hi idle

PREPARATION
Put the bucket empty and extend the boom, arm and
bucket cylinder fully.
And the machine becomes a position of minimum
reach.
MEASUREMENT AT TRAVEL LOCK
Swing the machine by bringing the swing lever to its
full stroke. Measure the time required to make two
turns after one turn of preliminary run and calculate
the time required for one turn.

Swing speed

Unit : sec/rev

Measuring
position

Standard
value

Reference value
for remedy

Service limit

Swing speed
at min. reach

4.2~5.4

5.4~6.9

7.2~

T4-3-11

SM0871

E215B-E245B

TEST PROCEDURES

Performance of swing brake

PURPOSE
Confirm the braking torque performances by the
swing relief valve.
BOOM FOOT
PIN

ARM TOP
PIN

CONDITIONS
Hydraulic oil temperature:
Firm, level ground
Engine revolution:

45~55C
(113~131F)
Hi idle
SM0872

PREPARATION
1.

Put the bucket empty, retract the arm cylinder

fully and extend the bucket cylinders fully. And
move the boom so that the arm top pin is
positioned at same height with boom foot pin.

2.

Put a matching mark on the outer

circumference of the swing bearing of the upper
frame side and of the track frame side. Place
two poles (flags) on the front and back of the
extended line of the matching mark.

MEASUREMENT AT TRAVEL LOCK

1.

2.

When operating in regular swing speed, by

shifting lever to neutral position at pole position
the swing operation stops.
Calculate the swing drift angle by the following
equation, after the upper swing body stops,
using the amount of deflection (m) of the
matching marks on the swing race and the
length (m) of the circumference of the swing
race:

Swing
angle ()

drift

Amount of deflection of
matching marks [m (ft-in)]

Circumferenzial lenght of
swing race [m (ft-in)]

Swing brake performance

x 360

MEASURING THE LENGTH OF THE ARC OVER

THE OUTER CIRCUMFERENCE OF OUTER RACE
MATCHING MARKS ON
OUTER RACE

MATCHING MARKS
ON INNER RACE
SM0873

Unit : degree

Measuring
position

Standard
value

Reference value
for remedy

Service limit

Swing 180

75

85

90

T4-3-12

TEST PROCEDURES

E215B-E245B

Performance of swing parking brake

PURPOSE
To confirm the mechanical performances of the
swing parking brake that is fitted to the inside of the
swing motor.
CONDITIONS
On a slope of 15 degree incline.
Stop the machine at right angles with the slope. Put
the bucket empty, retract the arm cylinder fully and
extend the bucket cylinder fully. And move the boom
so that the arm top pin is positioned at same height
with boom foot pin.
PREPARATION

SM0874

Put the angle meter on the shoe plate and make

sure that the angle is more than 15 degree.
Put a matching mark on the outer race side and on
the inner race side.

MEASUREING THE LENGTH OF THE ARC OVER

THE OUTER CIRCUMFERENCE OF OUTER RACE
MATCHING MARKS ON
OUTER RACE

MEASUREMENT AT TRAVEL LOCK

When five minutes has passed after the engine
stops, measure the length of the movement of the
matching marks.

Performance of swing
parking brake

Unit : mm(in)/5min

Measuring
position

Standard
value

Reference value
for remedy

Service limit

1 (0.04)

2 (0.08)

T4-3-13

MATCHING MARKS
ON INNER RACE
SM0875

E215B-E245B

TEST PROCEDURES

Drain rate of swing motor

PURPOSE
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.
CONDITIONS
Hydraulic oil temperature:

45~55C
(113~131F)

Firm, level ground

Engine revolution:

Hi idle

PREPARATION
1.

Stop the engine.

2.

Release pressure from inside the hydraulic

circuit.

3.

Disconnect the swing motor drain hose from its

end returning to the hydraulic oil tank and take
oil in a container.

4.

Put a plug to the tank side.

MEASUREMENT AT SWING LOCK

1.

Start the engine and put the side faces of

bucket against the inside of the right or left shoe
plates.

2.

Relieve the swing motor at full stroke of the

swing motion.

3.

Collect the amount of drained oil in a container

for 30 seconds.

Drain rate of swing motor

Unit : L(gal)/30sec

Measuring
position

Standard
value

Reference value
for remedy

Service limit

Drain rate

2.1 (0.55)

5.2 (1.4)

6.2 (1.6)

T4-3-14

SM0876

TEST PROCEDURES

E215B-E245B

MEASURING ATTACHMENT OPERATING

PERFORMANCES
Operating time of cylinders
PURPOSE
Measure the operating time of the boom, arm,
positioning and bucket and confirm the
performances between the hydraulic pump and the
cylinder of the attachment drive system.
CONDITIONS
Hydraulic oil temperature:

45~55C
(113~131F)
Engine revolution:
Hi idle
Operating time excluding the cushion stroke.
PREPARATION
Firm level ground with the bucket empty.
MEASUREMENT
Measurement 1 ; Boom up and down

30cm (1ft)

With the boom operating lever at full stroke,

measure the required operating time of the bucket
between the ground surface and its highest position.
WARNING
When lowering the boom, allow the bucket onto a
soft ground or cushioning such as rubber tires ;
never put the bucket against concrete or other solid
material.
5

Measurement 2 ; Arm in and out, positioning, bucket

digging and dump
In a position in which the tooth of the bucket rises to
a level of about 30cm (1ft) above ground, measure
the full stroke operating time required with the arm
and bucket operating levers at full stroke.
Cylinder Operating time

Unit : sec

Measuring
position

Standard
value

Reference value
for remedy

Service limit

2.2~2.8

2.8~3.6

3.8~

1.7~2.3

2.2~2.9

3.0~

2.5~3.1

3.2~4.0

4.2~

2.2~2.8

2.8~3.6

3.8~

3.5~4.1

4.4~5.9

5.5~

2.6~3.2

3.3~4.1

4.3~

3.0~3.6

3.8~4.6

5.0~

2.3~2.9

2.9~3.7

3.9~

2.9~3.5

3.7~4.4

4.6~

10

4.1~4.7

5.2~6.0

6.3~

30cm (1ft)

10
SM0877

T4-3-15

E215B-E245B

TEST PROCEDURES

Oil tightness of cylinders

PURPOSE
Confirm that the cylinder oil tight by checking the
moving length of the cylinder rods.

B
BOOM FOOT PIN

CONDITIONS
Hydraulic oil temperature:

45~55C
(113~131F)

Firm, level ground

After cylinders are replaced, bleed off air from the
cylinders, before checking for oil tightness.
Retract the arm cylinder rod 50mm (2in) from stroke
end so that the piston does not match a same range
of the cushioning mechanism.
PREPARATION
Put the bucket empty. Extend the arm cylinder rod
50mm (2in) from the most retracted position. And
extend the bucket cylinders fully. Then hold the
boom so that the arm top pin is positioned at same
height with boom foot pin.
MEASUREMENT
Measure the items five minutes after the engine is
turned off.
Oil tightness of cylinder

Unit: mm(in)/5min

Measuring
position

Standard
value

Reference value
for remedy

Service limit

7 (0.28)

11 (0.43)

14 (0.55)

6 (0.24)

9 (0.35)

11 (0.43)

80 (3.1)

120 (4.7)

160 (6.3)

T4-3-16

D
ARM TOP PIN

SM0878

TEST PROCEDURES

E215B-E245B

MEASURING PERFORMANCES OF SWING

BEARING
PURPOSE
Measure the gap between the lower frame and the
bottom face of the swing bearing and estimate the
degree of wear of the swing bearing.
CONDITIONS
Firm, level ground
The swing bearing mounting bolts are not loosened.
The swing bearing is lubricated well, not making
abnormal sound during turning.
PREPARATION
1.

Install a dial indicator to the magnetic base and

fix it to the lower frame.

2.

Direct the upper swing body and the lower

frame toward the travel direction, bring the
probe of the dial indicator in contact with the
bottom surface of the outer race on the swing
body side and set the reading at zero.

LOCATION OF BEARING
MOUNTING BOLTS

SWING BEARING
A

DIAL INDICATOR
LOWER FLAME

MEASUREMENT
Measuring position 1 and 2
Measure the displacement of the outer race in the
axial direction in position 1 [The arm at 90~110
and the crawler front is lifted by attachment about
30cm (1ft)] and in position 2, using a dial indicator.
Axial play of swing bearing

SM0879

Unit: mm (in)

Measuring
position

Standard
value

Reference value
for remedy

Service limit

0.8~1.8
(0.03~0.07)

2.3~3.3
(0.09~0.13)

3.6 (0.14)

90 ~100

30cm

SM0879

Position 1

BOOM FOOT
PIN

ARM TOP
PIN

SM0872

Position 2

T4-3-17

E215B-E245B

TEST PROCEDURES

Measuring position 3
Retract the arm cylinder fully and extend the bucket
cylinder fully. And move the boom so that the arm
top pin is positioned at same height with boom foot
pin. Then swing the bucket right and left by man
power.
But in this case, the gap of the attachment is
included.
Right and left movement of
the tip of bucket

BOOM FOOT
PIN

ARM TOP
PIN

Unit: mm (in)

Measuring
position

Standard
value

Reference value
for remedy

Service limit

Benna

30~50
(1.18~1.97)

80 (3.15)

120 (4.72)

T4-3-18

SM0872

Position 3

MECHATRO CONTROLLER

E215B-E245B

ENGINE CONTROL INPUT/OUTPUT

M-2:
GOVERNOR MOTOR
C-2:
GAUGE CLUSTER

E-1:
FUSE&RELAY
BOX

ENGINE SPEED
SENSOR

STARTER
SWITCH

C-1:
MECHATRO CONTROLLER

ACCEL
POTENTIO METER

ENGINE

PUMP
PROPORTIONAL
VALVE

SM0881

T4-4-1

E215B-E245B

MECHATRO CONTROLLER

ENGINE CONTROL
Engine control assy

3
1
11

3
3
5
Section A-A

10

HIGH

LOW
LOW

HIGH
2
4
2
Section B-B

Detail aa
9

Section C-C

1 - Governor motor
2 - Lever assy
3 - Sems-Bolt M8x25 (Q.ty 4) 23.5 Nm (17.3 lbf x ft)
4 - Bracket
5 - Capscrew (Q.ty 3) 19.6 Nm (14.5 lbf x ft) Apply Loctite #242
6 - Rod
7 - Nut M10 10.7 Nm (7.89 lbf x ft)
8 - Nut M10 10.7 Nm (7.89 lbf x ft)
9 - Nut M8 (Q.ty 2) 23.5 Nm (17.3 lbf x ft)
10 - Sems-Bolt M6x16 (Q.ty 2) 4.4 Nm (3.25 lbf x ft)
11 - Sems-Bolt M6x20 9.6 Nm (7.08 lbf x ft)

T4-4-2

SM0882

MECHATRO CONTROLLER

E215B-E245B

ENGINE CONTROL EQUIPMENT

Governor motor and C1 controller
1.

By operating accel dial, the input voltage

change issensed by CN1028 pin of C1
controller.

2.

The C1 controller computes the input voltage,

andoutputs command to governor motor (M2),
and incline governor lever of engine to the
swing angle corresponding to accel dial set
value.

3.

The limit switch in the governor motor is the

starting point of the governor motor.

OIL SEAL
OUTPUT
SHAFT

REDUCTION GEAR SECTION

MOTOR SECTION

CAM
LIMIT
SWITCH

SM0883

Speed sensor
Installing place: engine flywheel housing.
Sensor attaching procedure: push it into place and
fix with partially self-sealing cylindrical screw
M6x12, tightening torque 82 Nm.

CN-136F

SM0884

Work mode select switch

If the work mode select switch is pressed, a signal
istransmitted to the C1 controller and changes the
work modes in the order of HBAS and back
to H again.

WORK MODE
SELECT SWITCH

SM0885

T4-4-3

E215B-E245B

MECHATRO CONTROLLER

ADJUSTMENT OF MECHATRO
CONTROLLER OUTPUT (A-B-C
ADJUSTMENT)
Purpose of the adjustment
There are 3 kinds of adjustment of mechatro
controller as shown below; every adjustment is an
essential function to ensure performance of
machine.
1.

Adjustment of engine ("A" adjustment)

This adjustment is performed to set the relation
between the stepping command output from
mechatro controller to governor motor and the
engine speed.

2.

Adjustment of pump ("B" adjustment)

This adjustment is performed to correct the
output variation by coordinating the output
hydraulic pressure with engine rated output.

3.

Adjustment of unloading valve ("C" adjustment)

This adjustment is performed to correct the
open variation of unloading valve to improve
the operability further.

In cases where the adjustment of mechatro

controller is required
When the following parts are replaced or repaired,
carry out the adjustment without fail:
1.

Mechatro controller

2.

Engine

3.

Hydraulic pump or hydraulic pump proportional

valve

4.

Unloading proportional
unloading valve.

valve,

spool

of

Preparation
1.

Raise the oil temperature to about 50C

(122F) to warm up the engine.

2.

Turn the air-con OFF.

3.

Turn the starter key switch OFF to stop the

engine.
When the mechatro controller was replaced,
the following error code is displayed because
the adjustment data is not entered.
A215, A225, A015, A025, A035

As the error codes other than those shown above

may suggest failures of machine, repair the machine
into the ordinary operating condition according to
Error Code List.

T4-4-4

MECHATRO CONTROLLER

E215B-E245B

Adjusting procedure

MULTI DISPLAY

WORK MODE SELECT SWITCH

BUZZER STOP SWITCH

WASHER SWITCH
WIPER SWITCH

SELECT SWITCH

SM0886

ADJUSTMENT OF ENGINE ("A" ADJUSTMENT)

PROCEDURE
1.

Turn starter key switch ON keeping the work

mode selector switch on the gauge cluster
pressed, and hold it for 5~10 seconds, and then
release it. (If the engine is started, the following
indication is not displayed. Therefore do not
start the engine.)

2.

Keep buzzer stop switch on gauge cluster

pressed for 5 seconds and release it and the
screen for selecting adjustment is displayed.
When adjustment data is not entered in
mechatro controller, "READY" is indicated. If
the adjustment operation is once performed,
"FIN" is indicated.And the lever lock solenoid is
automatically released, disabling all operations.

3.

Press selector switch on gauge cluster to

display "START ENG"."Engine SPEED", P1,
P2 "PUMP PRESSURE" and "STEP" (stepping
command) are indicated.

T4-4-5

SM0887

E215B-E245B
4.

5.

MECHATRO CONTROLLER

After starting engine, press selector switch on

gauge cluster, and "MEMORY ENG" is
displayed, the engine speed is automatically
increased, and the adjustment of engine is
performed.
(When trying to limit engine speed, press
selector switch on gauge cluster at the speed
as it is, and the adjustment of engine is
terminated. The torque adjustment and
unloading adjustment required later are not
performed, and default value is written.).
When normal HIGH idling speed is detected,
the adjustment is completed. And "FINISH
ENG" is displayed.
(Press the buzzer stop switch on gauge cluster
while this display is appeared, and the
adjustment of engine is completed. The torque
adjustment and unloading adjustment required
later are not performed, and default value is
written.)

FINISH ENG
ENGINE SPEED
2000rpm
PUMP PRESSURE
C-1 2.0M C-2
STEP
400

2.0M

SM0888

ADJUSTMENT OF PUMP
("B" ADJUSTMENT)
PROCEDURE
1.

The adjustment automatically shifts from

engine to pump, the speed shifts from LOW
idling to HIGH idling. And "MEMORY PUMP" is
displayed.
And the unloading proportional valve and pump
proportional valve actuate, accordingly the
loading of pump is increased.The "ENGINE
SPEED", P1, P2 "PUMP PRESSURE" and P1,
P2 pump "PROPO-VALVE" current (command
value) are indicated.

2.

After detection of the engine rated speed, the

adjustment of pump is automatically
completed. And "FINISH PUMP" is displayed.
(Press the buzzer stop switch on gauge cluster
while this display is appeared and the
adjustment is completed. The unloading
adjustment required later is not performed, and
default value is written.).

T4-4-6

FINISH PUMP
ENGINE SPEED
2000rpm
PUMP PRESSURE
C-1 35.0M C-2
PROPO-VALVE
E-1 300mA E-2

35.0M
300mA

SM0889

MECHATRO CONTROLLER

E215B-E245B

ADJUSTMENT OF UNLOADING VALVE (C

ADJUSTMENT)
PROCEDURE
1.

2.

The adjustment shifts from pump to unloading,

and the unloading valve actuates, accordingly
the pump pressure is detected.
And "MEMORY UNLOAD" is displayed.The
"ENGINE
SPEED",
P1,
P2
"PUMP
PRESSURE" and P1, P2 "PROPO-VALVE"
voltage (command value) are indicated".

MEMORY UNLOAD
ENGINE SPEED
2000rpm
PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
D-1 300mA D-2 300mA

When the unloading valve operates to the

specified value, the adjustment of unloading
proportional valve is automatically terminated.
And "FINISH UNLOAD" is displayed.
The speed is shifted to the speed
corresponding
to
acceleration
potentiometer.The adjusting current value is
indicated on the display of current of P1, P2
unloading proportional valves. The adjusting
range is usually 520~635mA.

Stop the engine. (The adjusted data is automatically

stored.).
SM0890

CORRECTIVE ACTION TAKEN WHEN THE

ADJUSTMENT CAN BE NOT PERFORMED
1.

In cases where the adjustment of engine can

not be performed; And ERROR ENG" is
displayed.
Judging condition: The read engine speed is
50rpm lower than the last value.
It is conceived that the error is caused by the
speed read error, pump load applied to the
engine and unusual stepping command applied
to the governor motor in the course of
adjustment.
a. Checking speed sensor:
check that it is free from wrong reading of
speed due to engine vibratio.
b. Checking load applied to pump:
check that it is free from abnormal increase
of pump pressure during adjustment of
engine through adjustment screen.

T4-4-7

E215B-E245B
2.

MECHATRO CONTROLLER

In cases where the adjustment of pump can not

be performed; And "ERROR PUMP" is
displayed.
Judging condition 1:
P1 and P2 average pump pressure at the time
when the adjustment is completed is 25MPa or
less.

SM0891

Judging condition 2:
the adjustment does not complete although the
pump proportional valve current reaches to the
specified value.
The P1 and P2 pump pressures usually
increase to 33~38MPa. When the pressure
does not increase:
a. Identify the reason why the pressure does
not increase,
Check that the relief valve operates
normally.
Check that the hydraulic circuit is free from
leak of pressure.
Check that the pressure sensor functions
normally. And so on.
b. Identify the reason why the actual flow rate
does not increase,
Check that the pump proportional valve
operates normally.
Check that the pump regulator operates
normally. And so on.
3.

In cases where unloading valve can not be

performed; And "ERROR UNLOAD" is
displayed.
Judging condition 1:
the pump pressure does not increase up to the
pressure in the range of the specified
adjustment. Or the increased pressure is held
as it is.
Judging condition 2:
pressure sensor of either P1 pump or P2 pump
is failed.
Normally the pump pressures of P1 and p2
pumps gradually increase to 10~25MPa.
(It may be affected by operating oil
temperature.)
When the pump pressure does not increase:
a. Identify the reason why the pressure does
not increase,
Check that the relief valve operates
normally.
Check that the hydraulic circuit is free from
leak of pressure.
Check that the pressure sensor functions
normally. And so on.

T4-4-8

SM0892

MECHATRO CONTROLLER

E215B-E245B

OTHER PRECAUTIONS
1.

In the event of a failure, there is case where the

adjustment may not be performed normally.
First serve the machine, and perform the
adjustment work.

2.

In the condition where large load is constantly

applied to engine, the adjustment could not be
performed normally.

WHEN THE ADJUSTMENT OF UNLOADING

VALVE
ONLY
IS
PERFORMED
(C
ADJUSTMENT)
In the event where only unloading valve and
unloading proportional valve are replaced, perform
the adjustment of unloading valve only.
PROCEDURE
1.

Turn starter switch ON keeping the work mode

selector switch on the gauge cluster pressed,
and hold it for 5~10 seconds, and then release
it.
(If the engine is started, the following indication
is not displayed. Therefore do not start the
engine.)

2.

Keep buzzer stop switch on gauge cluster

pressed for 5 seconds and release it and the
screen for selection of adjustment type is
displayed. And "ADJUST" is displayed.
When adjustment data is not entered in
mechatro controller, "READY" is indicated. If
the adjustment operation is once performed,
"FIN" is indicated.And the lever lock solenoid is
automatically released, disabling all operations.

3.

Change the adjusting items with washer switch

( ) and wiper switch ( ), and select "ADJUST
UNLOAD".
Like the output adjustment, when adjustment
data is not entered in mechatro controller,
"READY" is indicated. If the adjustment
operation is once performed, "FIN" is indicated.

4.

Press selector switch on gauge cluster to

display "START ENG".
"ENGINE
SPEED",
P1,
P2
"PUMP
PRESSURE" and "STEP" (stepping command)
are indicated.

T4-4-9

MULTI DISPLAY
(EXAMPLE)

SM0893

E215B-E245B
5.

6.

MECHATRO CONTROLLER

After starting engine, press selector switch on

gauge cluster and "MEMORY UNLOAD" is
indicated, the engine speed is automatically
increased and the adjustment of unloading
valve is performed.
"ENGINE
SPEED",
P1,
P2
"PUMP
PRESSURE" and "PROPO-VALVE" are
indicated.
When the unloading proportional valve
operates to the specified value, the adjustment
of unloading proportional valve automatically
completes. "FINISH UNLOAD" is indicated.
The speed is shifted to the speed
corresponding to acceleration potentiometer.
The value of adjusting current is indicated on
the display of current of P1 and P2 unloading
proportional valves. The adjusting range is
usually 520~635mA.

Stop the engine. (The adjusted data is automatically

stored.)
Operations in the event of a failure of
equipment of mechatro controller
PUMP EMERGENCY MODE
In the event where a failure of P1 or P2 pump
proportional valve represented in items of self
diagnosis is indicated on multi display provided on
the gauge cluster, the full power control of pump and
positive control through mechatro controller are
unavailable. Then the P1 and P2 pumps are
automatically switched to emergency mode, making
the operation with the power shift control of pump
and the constant power control by means of selfpressure possible. But be careful that, at emergency
mode, the accuracy of inching becomes poor, the
frequency of engine down is increased, and the
engine stalls in LOW speed condition.
CAUTION
The emergency mode should be used in only case
of emergency. We recommend that the defective
section is repaired by troubleshooting as early as
possible.

T4-4-10

MEMORY UNLOAD
ENGINE SPEED
2000rpm
PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
D-1 300mA D-2 300mA

SM0894