SM E215B-E245B 7 EN

SECTION 2
E215B-E245B
UPPERSTRUCTURE
CONTENTS
Group 1 - Upperstructure
Group 2 - Control valve
Removal and installation of

upperstructure....................................... W2-1-1
Preparation ....................................... W2-1-1
Removal of upperstructure ............... W2-1-1
Removal and installation of control valveW2-3-1

Preparation ....................................... W2-3-1
Removal of control valve................... W2-3-1
Installation of control valve................ W2-3-2
Removal and installation of the cab ....... W2-1-2

Removal of the cab ........................... W2-1-2
Installation of the cab ........................ W2-1-3
Control valve ports ................................. W2-3-3
Removal and installation of

counterweight........................................ W2-1-4
Removal of counterweight ............... W2-1-4
Installation of counterweight ............ W2-1-5
Preparation for disassembly................... W2-3-12
Disconnecting hoses of swivel joint

lower side.............................................. W2-1-6
Assembly................................................ W2-3-25
Swivel joint lower side hoses ................. W2-1-7

Removal and installation of main frame. W2-1-8
Removal of main frame..................... W2-1-8
Installation of main frame.................. W2-1-9
Group 2 - Pump device
Assembly and disassembly of control

valve...................................................... W2-3-12
Disassembly........................................... W2-3-13
Inspection after disassembly.................. W2-3-25
Maintenance standards.......................... W2-3-32
Group 4 - Swing device

Removal and installation of swing deviceW2-4-1
Preparation ....................................... W2-4-1
Removal............................................ W2-4-2
Installation......................................... W2-4-3
Removal and installation of hydraulic

pump device.......................................... W2-2-1
Preparation ...................................... W2-2-1
Removal............................................ W2-2-1
Installation ........................................ W2-2-1
Disassembly and assembly of swing

motor ..................................................... W2-4-4
Preliminary operations ...................... W2-4-5
Disassembly...................................... W2-4-5
Assembly .......................................... W2-4-7
Disassembly and assembly of pump

device.................................................... W2-2-2
Disassembly and assembly of swing

reducer .................................................. W2-4-9
Preliminary operations ...................... W2-4-10
Disassembly...................................... W2-4-10
Assembly .......................................... W2-4-13
Disassembly hydraulic pump device ..... W2-2-3

Assembly .......................................... W2-2-7
Maintenance standard ........................... W2-2-11
Disassembly and assembly of regulator W2-2-12
Disassembly of regulator .................. W2-2-14
Assembly of regulator ....................... W2-2-18
Disassembly and assembly of pto gear
casing.................................................... W2-2-21
Disassembly ..................................... W2-2-22
Assembly .......................................... W2-2-23
Maintenance standard ...................... W2-2-23
Maintenance standards.......................... W2-4-18

Swing motor ...................................... W2-4-18
Swing reduction gear ........................ W2-4-19
Group 5 - Pilot valve

Removal and installation of right and
left pilot valve ........................................ W2-5-1
Preparation ....................................... W2-5-1
Removal............................................ W2-5-1
Installation......................................... W2-5-2
Removal and installation of travel pilot
valve...................................................... W2-5-3
Preparation ....................................... W2-5-3
Removal............................................ W2-5-3
Installation......................................... W2-5-4
Disassembly right and left pilot valve ..... W2-5-5
Disassembly right and left pilot valve W2-5-6
Assembly right and left pilot valve.......... W2-5-9
Assembly right and left pilot valve..... W2-5-10
Pilot valve (for travel) ............................. W2-5-13
Construction ........................................... W2-5-13
Disassembly and assembly.................... W2-5-14
Drain of hydraulic pilot control unit ......... W2-5-21
UPPERSTRUCTURE
E215B-E245B
REMOVAL AND INSTALLATION OF UPPERSTRUCTURE

WARNING
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear
and appropriate to hold the weight of load.
Preparation
Removal of upperstructure
1.
Park the machine on a firm, level surface.
1.
2.
To drain the hydraulic pressure from the

Hydraulic System, refer to procedure
Releasing the hydraulic pressure at page T21-47.
Remove the front equipment and the boom

cylinders, performing the operations described
in the procedure at pages W4-1-1 (Refer to:
Section 4 - Front Attachment).
2.
Remove the cab, performing the operations

described in the procedure at page W2-1-2
3.
Remove the counterweight, performing the

operations described at page W2-1-6.
4.
Disconnect the hoses of swivel joint lower side,

performing the operations described in the
procedure at page W2-1-6.
5.
Remove the main frame performing the

operations described in the procedure at page
W2-1-8.
3.
Cut-off the engine. Press the valve located on

the hydraulic oil cap to release any residual
pressure present in the tank itself. Remove
hydraulic oil tank cap. Connect a vacuum pump
to maintain negative pressure in the hydraulic
oil tank.
NOTE: be sure to run the vacuum pump

continuously while working.
W2-1-1
E215B-E245B
UPPERSTRUCTURE
REMOVAL AND INSTALLATION OF THE CAB

Removal of the cab
1.
Remove floor mat.
2.
Remove cover (1).

Lift cover (1) upwards and remove it. (Fixed
with 2 clips).
3.
Remove cover assy (2).

1) Loosen 4 sems bolts (3) M6x16 and lift
cover assy (2) up.
2) Disconnect each connector for both
speakers. Then remove cover assy (2).
4.
Remove the harness connector (See section

T2, group 3)
1) Disconnect connectors of cluster gauge
harness: (CN-5F), (CN-6F), (CN-61F), (CN62F) and earth wire (P-1) at rear right of cab.
2) Disconnect antenna cable coming from
backside of tuner at rear left of cab.
5.
Remove the plastic tube for the window washer

from the rear left of cab.
6.
Remove the right panel of cab.

1) Remove 2 caps (4), loosen 2 sems bolts (5)
M6x25 and 1 sems bolt (6) M6x16, and right
panels (7) and (8) are freed.
: TORX driver T30
2) Lift cover (9) upwards and remove it. (Fixed
with 3 clows and 2 clips).
3) Unfix 3 harness clips (10) of inside on right
panel (8). And free the harnesses
connected to key switch.
4) With harnesses are connected condition,
install key switch cover (9) to bracket (11) of
rear cab temporally. (See Fig. SM0261).
5) Disconnect harness connectors of work light
switch on right panel (7), air conditioner
panel and cigarette lighter, and remove right
panel (7) and (8).
6) Loosen sems bolts (12) M6x16 and (13)
M6x40, one each, and remove front panel
(14) with air conditioner duct.
: Plus driver
3
2
SM0259
Disassembly and assembly of cover (1)

and cover assy (2)
3
5
10
7
10
5
10
4
12
14
13
SM0261
Disassembly and assembly of right panels

(8), (9) and (14)
W2-1-2
UPPERSTRUCTURE
7.
E215B-E245B
Remove cab attaching bolt.
1) 5 capscrews (15) M12x65 and 1 capscrew

(16) M12x30
2) 2 nuts (17) M16
8.
Slinging cab.
1) Remove two plastic plugs at the front of the
ceiling of the cab. Then place a wire sling
with eye bolts (18) and a hook around the
cab, as shown in Fig. SM0263.
2) Then lift up slowly avoiding interference with
surroundings.
Eye bolts M10 (q.ty 2).
Wire with hook:
Length 1.5 m (4ft 11in), Dia. 8 mm (0.315in)
(3 pcs).
Weight of cab: Approx. 250 kg. (550 lbs)
11
SM0261
17
15
installation of the cab

Install it in reverse order of removing according to
the Tightening Torque Table.
Allen wrench
HEX
Tightening
torque
Nm (lbfft)
Nut M16 - (17)
24
191 (140)
Capscrew - (2), (9)
19
79.4 (60)
Sems bolt M6 (5), (6)
Torxdriver
T30
8.5 (6.3)
Sems bolt M6 (12), (13)
Plus driver
5.0 (3.7)
Tightening position
15
16
15
Smontaggio e rimontaggio
dei bulloni di fissaggio
15
cabina
15
SM0262
18
18
SM0263
W2-1-3
E215B-E245B
UPPERSTRUCTURE
REMOVAL AND INSTALLATION OF

COUNTERWEIGHT
Removal of counterweight
1.
Remove plugs (1) from the counterweight and

attach two M36 eye bolts to the counterweight.
NOTE: approximate mass of counterweight: 4600

kg
2.
3.
Attach wire rope (2) to eye-bolts (3) using

shackles.
Take out slack of wire rope by applying tension
slowly with a crane or hoist.
Wire with hook:
Length 1.5 m, dia. more than 16 mm (2 pcs.).
Remove 4 bolts (4) M30.

Lift counterweight using a crane or hoist.
: 46 mm
4.
SM0264
Remove shim (5), (6), (7) from the frame.
3
5
6
7
5.
SM0265
Lower the counterweight on proper stand.
SM0266
W2-1-4
UPPERSTRUCTURE
E215B-E245B
Installation of counterweight
NOTE: approx. weight of counterweight: 4600 kg
1.
2.
Attach lifting tools (2) to eye-bolts (3) of

counterweight.
Install shim (5), (6), (7) onto the frame as it was.
3
3.
Lift counterweight and install it onto the frame.
5
6
4.
Install bolts (4) and washers to counterweight

and tighten temporarily.
: 46 mm
4
5.
Remove wire rope.

Tighten the bolts (4) with a power wrench and
torque wrench.
SM0265
: 46 mm
: 1570+200
Nm
-100
6.
Remove eye-bolts (3) and install plugs (1) onto

the counterweight.
W2-1-5
SM0267
E215B-E245B
UPPERSTRUCTURE
DISCONNECTING HOSES OF SWIVEL JOINT

LOWER SIDE
Disconnect the hose on the lower side of swivel joint.
NOTE: close all openings with plugs to keep clean.
1.
Disconnect the two hose (1). (E Port: PF1/2)

: 27 mm
Tightening torque: 78.5 Nm
2.
Disconnect the hose (2) and (3).

(A and B Port: PF1)
: 36 mm
Tightening torque: 177 Nm
3.
Disconnect the hose (4) and (5).

(C and D Port: PF1)
: 36 mm
4.
Disconnect the two hose (6). (F Port: PF1/4)

: 19 mm
Tightening torque: 29.4 Nm
C
B
A
E
SM0268
W2-1-6
UPPERSTRUCTURE
E215B-E245B
SWIVEL JOINT LOWER SIDE HOSES
2
1
section A - A
SM0269
W2-1-7
E215B-E245B
UPPERSTRUCTURE
REMOVAL AND INSTALLATION OF MAIN

FRAME
Removal of main frame
NOTE: approximate mass of main frame 5000 kg.
1.
2.
Insert two upper swing body lifting jigs (2) and

two counterweight fastening cap screws (M30)
(1) into the counterweight mounting holes from
above.
3
4
Attach two chain blocks (4) to the boom foot

side.
3.
Attach wire ropes (3) like illustrated in the figure

beside.
Use chain blocks (4) for easy adjustment of
wire rope lengths and to level the frame.
IMPORTANT: make sure rear slings do not touch

engine.
Wire ropes:
D 16 mm x 2.5 m, 2 pcs
D 16 mm x 1.5 m, 2 pcs
Chain blocks:
for 2,000 kg, 2 pcs
Special tool for lifting
P/n 38xxxxxxx, 2 pcs
4.
ST. No. 38xxxxxxx
Put matching marks (M) on swing bearing and

main frame.
SM0270
5
SM0271
W2-1-8
UPPERSTRUCTURE
5.
E215B-E245B
Remove the 32 bolts (5) M20x100, the reamer

bolt (6) M20, from the swing bearing.
: 30 mm
6.
Lift main frame slightly from undercarriage.

Level main frame by adjusting the chain blocks
(4).
7.
Remove main frame.

6
SM0272
Installation of main frame

NOTE: approximate mass of main frame 5000 kg.
Installing is done in the riverse order of removing.
1.
Clean mating surfaces of upper frame and

swing bearing.
2.
Apply Loctite # 515 to the inside of the

capscrews on the contact surface (A) (fig.
SM0272).
3.
Slinging upper frame.

Match marks and install it with a reamer bolt (6)
and a washer temporarily.
SM0273
CAUTION
Confirm the reamer bolt position (X) referring to Fig
SM0274.
4.
OUTER (S) ZONE POSITION
Apply Loctite # 262 onto thread of bolts (5)

then, install bolts.
: 30 mm
5.
19,5
Apply Loctite # 262 onto thread of reamer bolts

(6) then, install reamer bolt.
: 30 mm
(*)
SM0274
(*) Apply Loctite # 515 to the shared area
W2-1-9
E215B-E245B
UPPERSTRUCTURE
NOTE:
W2-1-10
PUMP DEVICE
E215B-E245B
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP DEVICE

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.Prevent these
dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
3.
Preparation
1.
Park the machine on a firm, level surface..
2.


oil tank.

Removal
Installation
1.
Remove all protection panels and doors to give

access to the Hydraulic Pump Device.
1.
2.
Disconnect all electrical connectors.
NOTE: hydraulic pump device weight: 143 kg.
3.
Remove all hoses and collector from hydraulic

pump device.
2.
4.
Lift the hydraulic pump device by means of

hoist and ropes.
Install the hydraulic pump device to the engine

by means of related bolts.
: 19, 22, 30, 36 mm
: 17 mm
: 8, 10 mm
: 431 43.1 Nm
Fasten the hydraulic pump device by means of

hoist and lifting ropes.
3.
Install all hoses and collector to the hydraulic

pump device.
NOTE: hydraulic pump device weight: 143 kg.
: 19 mm
: 29,4 Nm
5.
: 22 mm
: 39,2 Nm
Remove the fixing bolts of hydraulic pump

device and draw it from engine.
: 30 mm
: 137,2 Nm
: 17 mm
: 36 mm
: 156,9 Nm
: 8 mm
: 64 Nm
: 10 mm
: 108 Nm
4.
Connect all electrical connectors.
5.
Install all protection panels and doors.
W2-2-1
E215B-E245B
PUMP DEVICE
DISASSEMBLY AND ASSEMBLY OF PUMP DEVICE

9
532
728
824
262
113
251
401
127
214
212
717
724
124
546
901
808
954
407 325
725
156
406
261
774
313
710
151 153
152
468
710
271
717
127
123
412
413
792
789 732
535
953
886
806
534
702
531
548
141
124
314
490
490
727
116
717
157
725
111
8
727
467
885 886
466
211
885
312
886
710
435
435
4
10
11
SM0275
NOTE: the number in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
4
5
6
7
8
9
10
11
111
113
116
123
124
127
141
151
152
153
156
157
211
212
214
251
261
262
271
312
313
314
325
401
406
Pilot pump
PTO gear casing
O-Ring (Q.ty 2)
Cover
Socket bolt (Q.ty 2)
Regulator
Short-circuit valve
Socket bolt
Shaft (F)
Shaft (R)
1st gear
Roller bearing (Q.ty 2)
Needle bearing (Q.ty 2)
Bearing spacer (Q.ty 4)
Cylinder block (Q.ty 2)
Piston (Q.ty 18)
Shoe (Q.ty 18)
Plate (Q.y 2)
Spherical bushing (Q.ty 2)
Cylinder spring (Q.ty 18)
Shoe plate (Q.ty 2)
Swash plate (Q.ty 2)
Tilting bushing (Q.ty 2)
Swash plate support (Q.ty 2)
Cover (front)
Cover (rear)
Pump casing (Q.ty 2)
Valve block
Valve plate (front)
Valve plate (rear)
Sensor Block
Socket bolt M20210 (Q.ty 8)
407
412
413
435
466
467
468
490
531
532
534
535
546
548
702
710
717
724
725
727
728
732
774
789
792
806
808
824
885
886
901
953
954
W2-2-2

Plug VP PF 1/4 (Q.ty 2)
Plug nptf 1/16 (Q.ty 27)
Tilt Pin m242 (Q.ty 2)
Servo piston M242 (Q.ty 2)
Stopper (Q.ty 2)
Stopper (Q.ty 2)
Spacer (Q.ty 2)
Feed back Pin (Q.ty 2)
O-Ring (Q.ty 2)
O-Ring (Q.ty 2)
O-Ring (Q.ty 2)
O-Ring (Q.ty 18)
O-Ring (Q.ty 6)
O-Ring (Q.ty 3)
O-Ring (Q.ty 4)
O-Ring (Q.ty 2)
Oil seal
Backup ring (Q.ty 2)
Backup ring (Q.ty 2)
Hex. nut M16 (Q.ty 2)
Hex. nut M20 (Q.ty 2)
Snap ring (Q.ty 2)
Valve plate pin (Q.ty 2)
Spring pin (Q.ty 4)
Eye bolt M10 (Q.ty 2)
Set screw M1630 (Q.ty 2)
Set screw M20 (Q.ty 2)
PUMP DEVICE
E215B-E245B
DISASSEMBLY HYDRAULIC PUMP DEVICE
Proceed with disassembly operations in a clean

place.
Spread rubber sheet or cloth on work bench to
protect parts from damaging.
Clean the parts removing dust and rust, etc. on

pump surface with wash oil.
Drain out the oil in the pump casing by removing

drain port plugs (466 and 468).
435
435
:19, 36 mm
311
312
466
1.
SM0276
Removing piloto pump.

Remove the socket bolts (435), then remove
pilot pump (4).
: 8 mm
2.
Removing PTO gear casing.

Remove the socket bolts (435), then remove
PTO gear casing (5).
435
: 8 mm
SM0278
3.
Removing regulator.
Remove the socket bolts (412) e (413), then
remove regulator (9).
: 6 mm
SM0277
W2-2-3
E215B-E245B
4.
PUMP DEVICE
Loosen socket bolts (401) that fasten swash

plate support (251), pump casing (271) and
valve block (312).
312
271
401
: 17 mm
SM0279
5.
Place the pump level on a work bench with its

mounting surface of the regulator facing down.
Then separate pump casing (271) and valve
block (312).
312
271
NOTE: When facing the mounting surface of the

regulator down, place a rubber board on a work
bench so as not to score the mounting surface.
When the pump casing has been separated from
the valve block, draw out the 1st gear (116) at the
same time.
SM0280
6.
Draw out cylinder (141) out of pump casing

(271) in parallel to shaft (111). At the same time
draw out piston (151), plate (153), spherical
bushing (156) and cylinder spring (157).
271
141(151)(157)
153
156
NOTE: use care so as not to score the sliding

surface of the cylinder, spherical bushing, shoe and
the swash plate.
SM0281
W2-2-4
PUMP DEVICE
7.
E215B-E245B
Remove socket bolt (406) and seal cover (261).
406
: 6 mm
261
NOTE: the seal cover may be drawn out with ease

if it is taken out by tightening bolts in the tapped
holes of the seal cover.
An oil seal is fitted to seal cover. Therefore, use care
so as not to score the oil seal.
SM0282
8.
Knock lightly on the mounting flange of swash

plate support (251) from the pump casing (271)
side and separate the swash plate support from
the pump casing.
271
251
SM0283
9.
Draw out shoe plate (211) and swash plate

(212) from pump casing (271).
271
212
(211)
SM0284
10. Tap lightly the shaft end (111 and 113) by

means of a plastic hammer and draw out the
shaft from the swash plate support.
251
111
(113)
SM0285
W2-2-5
E215B-E245B
PUMP DEVICE
11. Remove valve plate (313 and 314) from valve

block (312).
312
NOTE: the valve plate may come off during the

separation of pump casing from valve block.
314
(313)
SM0286
12. If necessary, remove stoppers (534 and 535),

servo piston (532) and tilting pin (531) from
pump casing (271), and remove needle bearing
(124) from valve block (312).
531
806
NOTE: When removing the tilting pin, use care so

as not to score the head of the tilting pin, using a jig.
It is hard to separate the tilting pin from the servo
piston in some cases as Loctite is coated on the
mating part between them. Use care so as not to
score the servo piston by applying unreasonable
force.
Do not draw out needle bearings except when their
service life has ended.
Do not loosen hex nuts (806 and 808) of valve block
(312) and swash plate support (251). A set flow rate
changes.
534
535
532
808
271
312
124
251
SM0287
W2-2-6
PUMP DEVICE
E215B-E245B
Assembly
1.
Assembly is a reverse order of disassembly,

but notice the following:
- Repair scored parts at disassembly. Get
replacements ready beforehand
- Wash parts sufficiently in cleaning oil and dry
them with jet air.
- Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
- In principle, replace sealing parts such as ORings and oil seals.
- Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
- Do not mix up front pump parts with rear
pump parts.
2.
Attach swash plate support (251) to pump

casing (271) by tapping the swash plate
support lightly with a plastic hammer.
271
NOTE: When the servo piston, the tilting pin, the

stoppers have been removed, install them to the
pump casing beforehand.
When tightening servo piston and tilting pin, use a
jig so as not to damage the head of the tilting pin and
feedback pin.
Coat the screwed part with Loctite 262.
251
SM0288
3.
Install swash plate placing the pump casing

with its mounting surface of the regulator facing
down. Insert the tilting bushing of the swash
plate into tilting pin (531), and fit swash plate
(212) to swash plate support (251) properly.
NOTE: Confirm by your both hands that swash plate

moves smoothly.
The shaft be installed easily if grease is applied to
the sliding parts of swash plate and swash plate
support.
Do not damage the sliding surfaces of shoe plate.
271 (531)
251
212
SM0289
W2-2-7
E215B-E245B
4.
PUMP DEVICE
Install shaft (111) fitted with bearing (123),

bearing spacer (127) and snap ring (824), to
swash plate support (251).
251
NOTE: Do not knock on the shaft with a hammer or

somethings.
Fix the bearing by lightly tapping the outer race of it
by means of a plastic hammer and set it exactly to
the end by using a steel rod and others.
123
127,824
111
SM0290
5.
nstall seal cover (261) to pump casing (271)

and fix it with socket bolts (406).
271
: 6 mm
: 29.4 Nm
261
NOTE: Coat the oil seal in seal cover with a thin film
of grease.
Handle the oil seal with sufficient care so it is not
scored.
406
SM0291
6.
Assemble the piston cylinder sub compound to

the cylinder block (141), piston (151), shoe
(152), plate (153), spherical bushing (156) and
cylinder spring (157).
Align the spherical bushing with the cylinder
spline and insert them into the pump casing.
141(151,152,157)
156
153
SM0292
W2-2-8
PUMP DEVICE
7.
E215B-E245B
Install valve plate (313 and 314) to valve block

(312) by aligning pin.
312
NOTE: do not mistake the suction and delivery

sides of the valve plate.
314
(313)
SM0293
8.
Install valve block (312) to pump casing (271)

and fasten them together with socket bolts
(401).
312
271
401
: 17 mm
: 430 Nm
NOTE: Work will be promoted if assembly is started
from the rear pump.
Exercise care so as not to mistake the direction of
the valve block (312). Install it so the regulator
comes up as seen from the front side and the
suction flange comes on the right.
Insert the 1st gear into the valve block beforehand
and connect it with the spline of the shaft.
9.
Install regulator (9) pinching feedback pin of

tilting pin in feedback lever of the regulator,
then install the regulator and fasten socket bolt
(412) e (413).
SM0294
: 6 mm
: 29,4 Nm
IMPORTANT: do not mistake the front regulator for
the rear regulator.
SM0295
W2-2-9
E215B-E245B
PUMP DEVICE
10. Install gear casing (5) and fasten it with socket

bolt (435).
: 8 mm
: 17 Nm
435
SM0278
11. Install pilot pump (4) and fasten it with socket

bolt (435).
: 8 mm
: 17 Nm
435
435
311
312
466
W2-2-10
SM0276
PUMP DEVICE
E215B-E245B
MAINTENANCE STANDARD:
Unit: mm (poll.)
Part name and inspection item
Standard
dimension (mm)
Recommended
value for
replacement (mm)
Clearance between piston and cylinder

bore (D-d)
0.039
0.067
Replace piston or cylinder.
0 ~ 0.1
0.3
Replace piston shoe assy.
4.9
4.7
Replace piston shoe assy.
41.1
40.3
Replace cylinder spring.
23.0
22.0
Replace a set of spherical bushing

or retainer plate.
Remedy
SM0520
Gap between piston and caulked part of

shoe (d)
SM0521
Thickness of shoe (t)
t
SM0522
Free height of cylinder spring (L)
L
SM0523
Combined height of retainer plate and

spherical bushing (H-h)
SM0524
Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section).
Swash plate (shoe plate face).
Cylinder (sliding section).
Roughness of each surface.
Surface
correction.
roughness
Standard
surface
(correction value)
W2-2-11
requiring
roughness
3-Z
Less than 0.4 Z (lapping)
E215B-E245B
PUMP DEVICE
DISASSEMBLY AND ASSEMBLY OF REGULATOR
626
625
624
753
627
623
621
898
733
732
631
622
874
613
875
612
652
875
814
654
643
836
653
646
644
651
897
655
728
645
611
438
630
629
802
756
763
628
924
412
413
656
757
438
Y
418
E
601
722
496
755
079
041
755
466
734
887
876
615
439
642
755
724
730 725
F
876
8-724
041
755
466
641
755
755
858
708
662
801
614
755
858
466
SM0296
NOTE: the number in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
W2-2-12
PUMP DEVICE
041
079
412
413
418
438
439
466
496
541
543
545
601
611
612
613
614
615
621
622
623
624
625
626
627
628
629
630
631
641
642
643
644
645
Check valve
Solenoid proportional reducing valve
Plug PF 1/4 (Q.ty 3)
Plug (Q.ty 18)
Seat (Q.ty 2)
Stopper (Q.ty 2)
Steel ball (Q.ty 2)
Casing
Feed back lever
Lever 1
Lever 2
Fulcrum plug
Adjust plug
Compensating rod
Piston case
Compensating rod
Spring seat
Outer spring
Inner spring
Adjust stem
Adjust screw
Cover
Lock nut M301.5
Sleeve
Pilot cover
Spool
Pilot piston
Spring seat
Stelo di regolazione
646
651
652
653
654
655
656
662
708
722
724
725
728
730
732
733
734
753
755
756
757
763
801
802
814
836
858
874
875
876
887
897
898
924
Tightening torque of bolt, plug and nut

Tightening torque
Nm (lbfft)
No.
Thread size
412, 413
M8
29 (21)
438, 438
M6
12 (8.9)
418
M5
6.9 (5)
466
PF 1/4
36 (26)
496
NPTF1/16
8.8 (6.5)
630
M30x1.5
160 (118)
801
M8
16 (12)
802
M10
19 (14)
W2-2-13
E215B-E245B
Pilot spring
Sleeve
Spool
Spring seat
Return spring
Set spring
Block cover
Spring
O-Ring
O-Ring (Q.ty 3)
O-Ring (Q.ty 8)
O-Ring
O-Ring
O-Ring
O-Ring
O-Ring
O-Ring
O-Ring
O-Ring (Q.ty 7)
O-Ring
O-Ring
O-Ring
Nut M8 (Q.ty 2)
Nut M10
Snap ring
Snap ring
Snap ring (Q.ty 2)
Pin 411.7 L
Pin 48 L (Q.ty 2)
Pin 5x8 L (Q.ty 2)
Pin
Pin 419 L
Pin 7.5x11 L
Socket bolt M820
E215B-E245B
PUMP DEVICE
Disassembly of regulator
1.

place.
2.
Clean the parts removing dust and rust, etc. on

regulator surface with wash oil.
3.
Remove regulator remove socket bolts (412)

and (413) and separate the regulator from the
pump body.
438
656
629
413
412
: 6 mm
4.
Remove socket bolt (438) and separate the port

plate (656).
: 5 mm
5.
438
Remove socket bolts (438) and remove cover

(629).
601
: 5 mm
SM0297
NOTE: the cover is equipped with adjust screws

(628 and 925), adjust stem (627), lock nut (630), hex
nut (801) and set screw (924). Do not loosen those
parts. If they are loosened, preadjusted set pressure
and flow values change.
624,625,626
627
801
629( 628 )
630 924
W2-2-14
SM0298
PUMP DEVICE
6.
E215B-E245B
After removing the cover (629) sub assy, take

out outer spring (625), inner spring (626) and
spring seat (624) from the compensating part.
Then take out adjust stem (645), pilot spring
(646) and spring seat (644) from the pilot part.
(A)
645
644,646
629
NOTE: Adjust stem (645) comes out easily if an M4

bolt is used (A).
SM0299
7.
Remove socket bolt (439) and pilot cover (641).

Once the pilot cover comes off, separate set
spring (655) from the pilot section.
: 5 mm
439
641
SM0501
8.
Remove snap ring (814), spring seat (653),

return spring (654) and sleeve (651).
814(653)
NOTE: Sleeve (651) is equipped with snap ring

(836).
When removing snap ring (814), return spring (654)
comes out, use care so as not to lose it.
654,
651(836)
SM0502
9.
Remove snap ring (858) and take out fulcrum

plug (614) and adjust plug (615).
858
615
614
SM0503
W2-2-15
E215B-E245B
PUMP DEVICE
NOTE: fulcrum plug (614) and adjust plug (615)

come off easily if a M6 bolt is used.
614
SM0504
10. Remove lever 2 (613) with tweezer.
NOTE: do not draw out pin (875).
613(875)
SM0505
11. Draw out pin (874) and remove feedback lever

(611).
874
NOTE: push out pin (874) from above with a slender
steel rod ( 4 x 100) so as not to interfere with lever
(612).
611
SM0506
611
SM0507
W2-2-16
PUMP DEVICE
E215B-E245B
12. Remove lever 1 (612).

612
NOTE: do not draw out pin (875).
875
611
874
897
613
875
13. Draw out pilot piston (643) and spool (652).
14. Draw out piston casing (622), compensating

piston (621) and compensating rod (623).
643
SM0504
NOTE: Piston casing (622) comes out from the

opposite side of the piston casing if compensating
rod (623) is pushed out.
466
662
15. Remove VP plug (466) from pilot cover (641)

and draw out spool (642) and spring (662).
642
466
641
W2-2-17
SM0509
E215B-E245B
PUMP DEVICE
Assembly
1.
Assembly is the reverse order of disassembly.

Do the work paying attention to the following:
- Repair those parts that were damages during
disassembly and prepare replacement parts
beforehand.
- Clean parts thoroughly in cleaning oil, blow
them with jet air and assemble parts in a
clean place.
- Always tighten screws and plugs to the
specified torque. Tolerance of torque should
be within 10%
- Do not fail to coat the moving parts with clean
hydraulic oil, before assembly.
- Replace seals such as O-Ring.
2.
3.
4.
612
875
611
874
897
613
Put the pin mounted in lever 1 (612) into the

groove of the compensating rod. Then
assemble the lever to the pin that is pressed in
the casing (601).
875
SM0510
Assemble compensating rod (623) into the

compensating hole of casing (601).
652
651
836
655
654
653
Assemble spool (652) and sleeve (651) into the

spool hole of the casing.
NOTE: Make sure that the spool and the sleeve

move smoothly in the casing.
Beware of the direction of the spool.
5.
623
814
SM0511
Assemble feedback lever (611). Then put pin

(874) into the pin hole of the feedback lever.
874
NOTE: The work is eased if the pin is put in the

feedback lever a little, beforehand.
Take care so as not to mistake the direction of the
feedback lever.
611
652
SM0512
W2-2-18
PUMP DEVICE
6.
Assemble pilot piston (643) into the negative

control hole of the casing.
NOTE: make sure that the pilot piston moves

smoothly.
7.
E215B-E245B
613(875)
Place pin (875) pressed in lever 2 (613) into the

groove of the pilot piston and assemble lever 2
(613).
SM0513
8.
Assemble fulcrum plug (614) so pin (875)

pressed in the fulcrum comes in the pin hole of
lever 2 (613). Then fit snap ring (858).
614(875,858)
9.
Insert adjust plug (615) and fit a snap ring

(858).
NOTE: Use care so as not to mistake the holes into

which the fulcrum and adjust plug are inserted.
Operate the feedback lever and make sure that the
gap is not large and that the lever moves smoothly.
SM0514
858
615
614
SM0515
W2-2-19
E215B-E245B
PUMP DEVICE
10. Assemble return spring (654) and spring seat

(653) into the spool hole and fit snap ring (814).
11. Assemble set spring (655) into the spool hole.

Place compensating piston (621) and piston
casing (622) into the compensating hole and
attach pilot cover (641) with socket bolts (438
and 439).
: 5 mm
622(621)
: 11.7 Nm
SM0516
12. Assemble spool (642) and spring (662) into

pilot cover (641) and tighten VP plugs (466).
466
: 19 mm
: 36 Nm
662
13. Put spring seat (644), pilot spring (646) and

adjust stem (645) into the pilot hole. Then
assemble spring seat (624), inner spring (626)
and outer spring (625) into the compensating
hole.
642
466
641
SM0509
NOTE: do not mistake the direction of the spring

seat.
14. Attach cover (629) fitted with adjust screws

(628 and 925), adjust stem (627), lock nut
(630), nut (801) and socket bolt (924). Then
fasten them with socket bolts (438).
644,645,646
626
625(624)
: 5 mm
: 12 Nm
15. Attach block cover (656) and tighten screws

(438).
SM0517
: 5 mm
: 12 Nm
16. Install the regulator on the pump and fasten

socket bolt (412 and 413).
624, 625, 626
:6 mm
627
: 29 Nm
801
629 ( 628 )
630 924
W2-2-20
SM0518
PUMP DEVICE
E215B-E245B
DISASSEMBLY AND ASSEMBLY OF PTO GEAR CASING
128
117
126
435
711
262
414
886
826
128
885
728
886
115
468
326
435
125
118
825
115
117
118
125
126
128
262
326
414
125
Idle shaft
2nd gear
3rd gear
Ball bearing (Q.ty 2)
Roller bearing
Bearing spacer (Q.ty 2)
Cover
Gear casing
SM0519
435
468
711
728
825
826
885
886
W2-2-21
Flange socket M1020 (Q.ty 4)

VP plug PF3/4
O-Ring
O-Ring
Snap ring
Snap ring
Spring pin
Pin (Q.ty 2)
E215B-E245B
PUMP DEVICE
Disassembly
1.

place.
414
2.
Remove dust, rust, etc, on pump surface with

wash oil (468).
262
: 27 mm
: 74 Nm
3.
468
Remove the socket bolts (414). Then remove

the cover (262).
SM0525
: 8 mm
: 33.3 Nm
4.
115
Remove snap ring (885) and idle shaft (115).

Then draw out 2nd gear (117), roller bearing
(126) and bearing spacer (128).
117
(126, 128)
NOTE: roller bearing can not be separated from 2nd

gear (117).
SM0526
5.
Remove snap ring (825) and draw out 3rd gear

(118) and ball bearing (125).
NOTE: ball bearing (125) can not be separated from

3rd gear (118).
125
118
SM0527
W2-2-22
PUMP DEVICE
E215B-E245B
Assembly
Assembly is a reverse order of disassembly, but
notice the following:
- Repair scored parts at disassembly.
replacements ready beforehand.
Get
- Wash parts sufficiently in cleaning oil and dry

them with jet air.
- Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
- In principle, replace sealing parts such as O-Rings
and oil seals.
- Tighten socket bolts and plugs to specified
torques in this Manual.
Maintenance standard
In case a pitching (1 pit is more than 1mm, while the
area ratio is more than 5%) is seen on the gear tooth
surface of 2nd gear (117) and 3rd gear (118),
replace the gears. Replace the gears also in case
they show excessive damage.
Air pulling out point
1.
After the relief valve installation, start the

engine.
2.
Loosen the air pulling out plug (1), until O-ring

(2) comes off, to allow the air flows out.
3.
Air pulling out operation is completed when, for

two seconds, only hydraulic oil flows out from
plug (1).
4.
Tighten the plug (1) to specified torque.
: 17
: 23 Nm (17 lbf.ft)
SM1251
W2-2-23
E215B-E245B
PUMP DEVICE
NOTE:
W2-2-24
CONTROL VALVE
E215B-E245B
REMOVAL AND INSTALLATION OF CONTROL VALVE

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
3.
Preparation
1.
2.

Releasing the hydraulic pressure at page. T21-47.

oil tank.

Removal of control valve

1.
Remove the panel protecting the control valve,

removing the securing screws.
: 19 mm
2.
Disconnect all hoses, pipes and connectors

from the control valve (1).
NOTE: attach caps to hoses and pipes. Attach

labels or tags to hoses and pipes, to aid in
assembly.
3.
Remove the control valve securing screws (2).

: 19 mm
NOTE: control valve assembly mass: 232 kg.
4.
Remove the control valve.
W2-3-1
SM0528
E215B-E245B
CONTROL VALVE
Installation of control valve

1.
Install control valve (1) to frame and tighten the

bolts (2).
: 19 mm
: 235 Nm
2.
Connect all hoses, pipes and connectors to the

control valve.
2
2
2
SM0528
Connector / Bolt
Tread size
Ports
PF 1/4
Pss, PLc2, PBp1, PBp2, PL, PB1, PTb,

PCa, PCb, PCc, XAb
PF 3/8
PAa1, PBa1, Pab, PBb, Pac, PBc, PAL,

PBL, Par,PBr, Pas, PBs, PAa2, PBa2,
Pao, Pbo, DR
PF 3/4
MU
M10
M12
3.
Name
Hose nut
Tightening
Tightening Remarks
Opposing
Opposing
torque
torque
flats
flats
Nm (lbfft)
Nm (lbfft)
19
36 (27)
19
29 (21)
22
74 (55)
22
49 (36)
36
162
(119)
36
118 (87)
Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc
14
42,4 (31)
Ab, Bb, Ao, Bo
14
57 (42)
17
62,2 (45)
17
96 (70)
ORS
Joint
Sems
bolt
P1, P2
T1, T2
Install the panel protecting the control valve

using the relevant securing screws.
: 19 mm
: 108 Nm
W2-3-2
CONTROL VALVE
E215B-E245B
CONTROL VALVE PORTS (1/2)
Functions
Ports
Ports on upper sides
LEFT
Ports
RIGHT PBp1 P1 bypass cut
P2 bypass cut PBp2

Option
Arm (R) relief valve
PBa2 Arm 2 in
PAo
Mu
Bucket (R)relief valve
XAb
Boom lowering valve
PBb
Boom down
Arm 1 out PBa1

Swing (LH)
PBs
Boom conflux
PB1
Travel left forward
PAL
Tank return
Functions
PAr
-
T2
Make-up line
Boom (H) relief valve

Travel right forward
Main relief valve
PCb
P1 unload
P1
P1 pump
P2
P2 pump
Ports on rear sides (on machine)
LEFT
RIGHT
Ports on right sides (on machine)
UPPER SIDE
LOWER SIDE
Bucket dump
BC
Bucket dump
PBc
Bucket (H) stroke limit
PCc
AC
Bucket digging
Boom up
Ab
Bb
Boom down
Drain
Dr
BR
Travel right reverse
Travel right forward
AR
ATT power boost
PL
SM0529
W2-3-3
E215B-E245B
CONTROL VALVE
CONTROL VALVE PORTS (2/2)
Function
Ports
Option
Bo
Ports on left side (on machine)
LOWER
SIDE
Ports
UPPER
SIDE
Function
Ao
Option
Ba
Arm 1 out
PLc2 Arm in lock release
Arm 1 in
Aa
Swing left
Bs
Pss
Swing low pressure sensor
Travel left reverse
BL
As
Swing right
AL
Travel left forward
T1
Tank return
Ports on lower side (on machine)
LEFT SIDE
RIGHT SIDE
Travel left reverse
PBL
PTb Travel straight
P2 unload
PCa
PBr
Travel right reverse
Swing right
PAs
PAb
Boom up
Boom (R) relief valve
Bucket (H) relief valve
Arm (H) relief valve
Arm in PAa1
Option
PBo
PAc
Bucket digging
PAa2 Arm 2 in
SM0530
W2-3-4
CONTROL VALVE
E215B-E245B
Control valve (1/6)
273x10
T2
P1 unload
(Travel priotity)
Travel right
273x10
Travel left
USE FOR YN30V00101F1
PAL
PCb
PAr
PB1
Boom conflux
(P2 unload)
D
PBs
Boom
Swing
PBb
PCc
Pss
PBa1
Bucket
Arm 1
F
PAo
PA
PBa2
Arm 2
Option
MU
G
K
(P3)
PBp1
PBp2
K
A
PAo
PBa2
PBp1
PBp2
274x4
275x4
(P4)
(P3)
213
212
PAa2
273x10
W2-3-5
PBo
273x10
SM0531
E215B-E245B
CONTROL VALVE
Control valve (2/6)
J
164
154
101
P2
T2
T1
JJ
PBL
YT1
PAL
PAs
YS1
PBs
PCa
P2-20
YBG1
PB1
Pss
PAa1
YA1
PBa1
PBo
YP1
PAo
SECTION A-A
(P4)
163
162 163 169
155 162
154
164
P1
102
973
973
PCb
P1-20
PTb
973
973
YT1
PAr
YB1
PBr
PBb
973
PAb
973
973
PBc PCc
YK1
PAc
974
973
PBa2
YAG
1
PAa2
974
(P3)
SM0532
162
162
169
155
W2-3-6
163
162
SECTION B-B
CONTROL VALVE
E215B-E245B
Control valve (3/6)

202
333
331
336
329
327
P1 unload
Travel left
PCb
201
333
331
PAL
336
601
331
261
309
324
MR
323
PL
159
AL
512
511
521
522
CP2
552
562
562
551
164
162
CMR2
CMR1
331
261
306
163
162
BL
552
522
512
307
261
331
327
329
336
331
333
202
201
333
331
336
324
323
163
264
205
PBL
SECTION C-C
PTb
Travel priority
Travel right
Boom conflux
PAr
202
333
331
PB1
339
306
326
325
331
261
161
511
521
331
261
163
511
521
551
164
163
161
CCb
Ar
CP1
551
164
305
551
164
Br
310
164
(T3)
264
PBr
205
SECTION D-D
SM0533
PCa
P2 unload
W2-3-7
154
261
331
327
329
336
331
333
202
E215B-E245B
CONTROL VALVE
Control valve (4/6)

Swing
203
333
331
603
211
279 x 3
331
215
Boom
AbR
XAb
204
PBs
336
333
Pss
331
322
321
336
322
266
321
261
331
261
303
160
514
524
556
164
511
521
551
164
161
As
CRb
162
163
511
523
Ab
LCs
LCb
Bb
556
164
162
Bs
161
301
264
602
266
264
206
PAb
205
160
BbR
PAs
SECTION E-E
551
164
209
216
333
331
336
322
321
602
Bucket
PCc
Arm 1
PBa1
PBc
BaR
BcR
331
261
304
CRar
Bc
511
521
551
164
Ba
LCc
LCa
201
333
331
336
322
321
603
171
331
261
211
160
514
524
556
164
511
521
551
164
Ac
162
Aa
302
161
264
264
603
205
PAc
AcR
PAa1
SECTION F-F
W2-3-8
AaR
205
605
SM0534
CONTROL VALVE
E215B-E245B
Control valve (5/6)
Arm 2
201
333
331
340
328
321
PBa2
Option
201
PAo
333
331
336
324
331
261
AoR
308
323
604
331
MU
162
162
162
511
521
551
164
515
521
261
311
Ao
511
521
LCAT2
LCo
551
164
LCAP2
551
164
Bo
162
161
604
BoR
264
PAa2
205
264
PBo
205
SECTION G-G
T2
161
P1
511
T1
521
CT1
163
163
551
162
511
164
P2
521
CT2
551
164
SECTION H-H
W2-3-9
SM0535
E215B-E245B
CONTROL VALVE
Control valve (6/6)
207
266
160
278 x 5
264
264
528
527
T2
517
T1
518
SECTION J-J
PBp1
PBp2
606
606
163
SM0536
SECTION K-K
W2-3-10
CONTROL VALVE
Tightening torque
Nm (lbfft)
No.
Parts Name
Q.ty
Tightening torque
Nm (lbfft)
E215B-E245B
No.
Parts Name
Q.ty
101 Casing A
321 Spring
102 Casing B
322 Spring
323 Spring
220~250 (162~184) 154 Plug PF3/4
110~130 (81~96)
155 Plug PF1/2
324 Spring
20~24 (15~18)
159 Plug PT1/4
325 Spring
7.8~9.8
160 Plug PT1/16
326 Spring
161 O-ring
327 Spring
162 O-ring
15
328 Spring
163 O-ring
11
329 Spring
164 O-ring
19
331 Spring seat
24
333 Spacer bolt
12
169 O-ring
9,8~14 (7.2~13)
171 Socket bolt
336 Stopper
10
201 Cover
339 Stopper
202 Cover
340 Stopper
203 Cover
511 Poppet
11
204 Cover
205 Cover
512 Poppet
514 Poppet
515 Poppet
209 Cover
517 Boost check valve
211 Lock valve selector sub
518 Poppet
212 Plate
521 Spring
11
206 Cover
Back pressure
207
valve cover
9.8~14 (7.2~13)
16~18
Loctite #262
check
213 Plate
522 Spring
215 Boom dowering valve
523 Spring
216 Piston
524 Spring
261 O-ring
12
527 Spring
264 O-ring
10
266 O-ring
528 Spring
25~34 (18~25)
273 Socket bolt
40
98~120 (72~89)
274 Socket bolt
98~120 (72~89
275 Socket bolt
25~34 (18~25)
278 Socket bolt
9.8~14 (7.2~13)
279 Socket bolt
301 Boom spool sub
302 Arm 1 spool

303 Swing spool
230~260 (170~192) 551 Plug

130~150 (96~111)
13
552 Plug
230~260 (170~192) 556 Plug
562 O-ring
69~78 (51~58)
601 Main relief valve
69~78 (51~58)
602 Over load relief valve
69~78 (51~58)
304 Bucket spool
69~78 (51~58)
604
305 Boom conflux spool
69~78 (51~58)
306 Travel spool
98~120 (72~89)
606 By-pass cut valve
307 Travel priority spool
140~180 (103~133) 973 Socket bolt
308 Arm 2 spool sub
140~180 (103~133) 974 Socket bolt
309 P1 unload spool
310 P2 unload spool
311 Option spool
W2-3-11
Plug assy for relief valve

hole
E215B-E245B
CONTROL VALVE
ASSEMBLY AND DISASSEMBLY OF

CONTROL VALVE
PREPARATION FOR DISASSEMBLY
General precautions
As all the hydraulic components are precisely

machined, it is essential to carry out disassembly
and reassembly in an especially clean location.
When handling the control valve, take special

care to prevent the entry of foreign matter, such
as dust or sand.
Cap each port of the control valve before

removing the valve from the machine. Before
disassembly, confirm that each cap is in place
and then clean the exterior of the assembly.
Use a workbench. Lay a clean sheet of paper or
rubber mat over the workbench.
When carrying or moving the control valve, hold

the body, and never put pressure on a lever, an
exposed spool, or the end cover. Handle the
valve with care.
Tests(for relief characteristics, leaks, overload

valve setting, flow resistance, etc.) that are
desired after disassembly and reassembly
require hydraulic testing apparatus.
For this reason, do not disassemble hydraulic

units that you are capable of disassembling but
cannot test or adjust.
Prepare beforehand washing fluid, hydraulic oil,
grease, etc.
Tools
Prepare the following tools before disassembling
the control valve.
No.
a
Tools
Vise
Q.ty
Remarks
Box and wrench
1 of each
size
Allen wrench
1 of each
size
Spanner
Loctite # 262
Spatula
Pincers
Adjustable wrench
24 mm, 27 mm, 32 mm
5 mm, 6 mm, 10 mm, 12 mm, 14 mm, 22 mm
32 mm
W2-3-12
CONTROL VALVE
E215B-E245B
DISASSEMBLY
Place the control valve on a work bench so as to
locate back pressure check valve upwards.
IMPORTANT: disassemble the valve in a clean
place, and be careful not to damage flange surfaces
or plate mounting surfaces.
1.
Disassembling P1 unload spool

1.1 Loosen the socket bolts (273) and remove
the spring cover (202) and the O-ring (261)
for P1 unload spool.
SM0537
1.2 Draw out, from casing B (102), as a assy of

P1 unload spool (309), spring seat (331),
springs (327), (329), stopper (336) and bolt
(333).
IMPORTANT: when drawing out the spool assy,
use care so as not to score casing B (102).
SM0538
SM0504
1.3 Fix the P1 unload spool assy with vise via a

protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring
seat (331), springs (327), (329) and stopper
(336) from P1 unload spool (309).
SM0539
SM0540
W2-3-13
E215B-E245B
2.
CONTROL VALVE
Disassembling the travel spool (left travel

and right travel)
the spring cover (201) and the O-ring (261)
for travel.
SM0541
2.2 Draw out the assy of travel spool (306),

spring seat (331), springs (323), (324),
stopper (336) and bolt (333) from casing A
(101) or casing B (102).
take care so as not to score the casing A (101) or the
casing B (102).
SM0542
2.3 Fix the travel spool assy with vise via a

protective plate (aluminum plate, etc.).
Remove bolt (333) and separate spring seat
(331), springs (323), (324) and stopper
(336) from travel spool (306).
SM0543
SM0544
W2-3-14
CONTROL VALVE
3.
E215B-E245B
Disassembling the boom conflux spool

3.1 Loosen socket bolts (273) and remove
spring cover (201) for boom conflux and Oring (261).
3.2 Draw out the assy of boom conflux spool
(305), spring seat (331), springs (325),
(326), stopper (339) and bolt (333) from
casing A (101).

use care so as not to score casing A (101).
SM0545
3.3 Fix the boom conflux spool with vise via a

(339) from boom conflux spool (305).
SM0546
4.
Disassembling the boom spool

spring cover (203) for boom spool and Oring (261), (266).
4.2 Draw out the assy of boom spool (301),
stopper (336) and bolt (333) from casing B
(102).

take care so as not to score casing B (102).
SM0547
W2-3-15
E215B-E245B
CONTROL VALVE
4.3 Fix the boom spool assy with vise via a

(336) from boom spool (301). Do not
disassemble boom spool (301) further
unless there is special reason.
SM0548
5.
Disassembling the swing spool

the spring cover sub (204) and the O-ring
(261), (266) for swing. Do not disassemble
spring cover sub (204) further unless there
is special reason.
5.2 Draw out the assy of swing spool (303),
stopper (336) and bolt (333) from casing A
(101).

SM0549
5.3 Fix the swing spool assy with vise via a

(336) from swing spool (303).
SM0550
W2-3-16
CONTROL VALVE
6.
E215B-E245B
Disassembling bucket spool

bucket spring cover (209) and O-ring (261).
SM0801
6.2 Draw out the assy of bucket spool (304),

stopper (336) and bolt (333) from casing B
(102).
use care so as not to score casing B (102).
SM0802
6.3 Fix the bucket spool assy with vise via a

(336) from bucket spool (304).
6.4 When needed to disassemble the spring
cover of bucket spool, loosen plug (551)
with casing B (102) installed. After removed
cover (209) from casing B (102), remove
plug (551) and then take out piston (216).
SM0803
W2-3-17
E215B-E245B
7.
CONTROL VALVE
Disassembling arm 1 spool

7.1 Loosen socket bolts (273), and remove
spring cover (201) and O-ring (261) of arm 1
spool.
7.2 Draw out the assembly which is consist of
arm 1 spool (302), spring seat (331), spring
(321, 322), stopper (336) and bolt (333)
from casing A (101).

SM0804
7.3 Fix the arm 1 spool assy with vise via a

protective plate (aluminum plate etc.) and
remove bolt (333). Then remove spring seat
(331), spring (321, 322) and stopper (336)
from arm 1 spool (302).
SM0805
8.
Disassembling arm 2 spool

spring cover (201) and O-ring (261) of arm 2
spool.
arm 2 spool (308), spring seat (331), spring
(321, 328), stopper (340) and bolt (333)
from casing B (102).
IMPORTANT:when drawing out the spool assy, use

care so as not to score casing B (102).
SM0806
8.3 Fix the arm 2 spool assy with vise via a

from arm 2 spool (308). Do not disassemble
arm 2 spool (308) further unless there is
special reason.
SM0807
W2-3-18
CONTROL VALVE
9.
E215B-E245B
Disassembling option spool

spring cover (201) and O-ring (261) of
option spool.
option spool (311), spring seat (331), spring
(323, 324), stopper (336) and bolt (333)
from casing A (101).

SM0808
9.3 Fix the option spool assy with vise via a

from option spool (311).
SM0809
10. Disassembling travel straight spool

the spring cover (202) and the O-ring
(261) for travel straight.
10.2 Draw out the assy of travel straight spool
(307), spring seat (331), springs (327),
(329), stopper (336) and bolt (333) from
casing B (102).
take care so as not to score the casing B (102).
10.3 Fix the travel straight spool assy with vise
via a protective plate (aluminum plate,
etc.). Remove bolt (333) and separate
spring seat (331), springs (327, 329) and
stopper (336) from travel straight spool
(307).
W2-3-19
SM0810
E215B-E245B
CONTROL VALVE
11. Disassembling P2 unload spool

spring cover (202) of P2 unload spool and
O-ring (261).
P2 unload spool (310), spring seat (331),
spring (327, 329), stopper (336) and bolt
(333) from casing A (101).
SM0811
11.3 Fix the P2 unload spool assy with vise via

a protective plate (aluminum plate etc.)
and remove bolt (333). Then remove
spring seat (331), spring (327, 329) and
stopper (336) from P2 unload spool (310).
SM0812
12. Removing spool covers

12.1 Travel, boom, bucket, arm 1, arm 2 and
option
Loosen socket bolts (273) and remove
spool cover (205) and O-ring (264).
12.2 Swing
Loosen socket bolts (273) and remove
spool cover (206) and O-ring (264), (266).
Do not disassemble spool cover (206)
further unless there is special reason.
SM0813
W2-3-20
CONTROL VALVE
E215B-E245B
13. Removing relief valve and plug assy for

relief valve hole
13.1 Remove the main relief valve (601) and

overload relief valve (602), (603) and
(605) from the casing.
NOTE: distinguish overload relief valve between

(602), (603) and (605) with a tag to prevent them
from being confused during reassembly, as they are
the same in appearance and shape but differ in
pressure setting.
Regarding the disassembly of the relief valves
themselves, do not disassemble it.
SM0814
SM0815
13.2 Remove plugs assy (604) for relief valve

from the casing.
SM0816
W2-3-21
E215B-E245B
CONTROL VALVE
14. Removing by-pass cut valve

14.1 Remove by-pass cut valve (606) from the
casing.
NOTE: remove the by-pass cut valve, giving
particular attention to the poppet and spring which
may be remained on the inside of casing.
SM0817
15. Removing lock valve selector valve sub

and boom lowering valve
15.1 Loosen socket bolt (211-171) and remove
lock valve selector valve sub (211) from
the casing.
Further disassembly of the lock valve
selector sub is not allowed.
15.2 Loosen socket bolt (279) and remove
boom lowering valve (215) from the
casing.
SM0818
W2-3-22
CONTROL VALVE
E215B-E245B
16. Removing back pressure check valve

16.1 Loosen socket bolt (278) and remove
back pressure check valve (207) from the
casing.
SM0819
16.2 Remove springs (527), (528), boost check

valve poppet sub (517) and by-pass check
valve poppet (518) from the casing. The
further disassembly of boost check valve
poppet sub (517) is not allowed.
Replace control valve so that the spool cover face
directs downward.
IMPORTANT: when replacing, take care so as not
to score the spool cover.
SM0820
17. Removing plate

17.1 Loosen socket bolts (274), (275) and
remove plates (212), (213).
17.2 After removing plates, remove all O-rings
(162), (163) remained on the casing side.
SM0821
W2-3-23
E215B-E245B
CONTROL VALVE
18. Removing check valve

18.1 Remove plugs of load check valve,
conflux check valve, etc. and then remove
poppet (511) and spring (521).
18.2 Load check valve on the swing section
Remove plug (556) and then remove
IMPORTANT: the plug and spring in use differ from
the above (18.1). Do not mix the parts when
assembling parts again.
18.3 Load check valve on arm 2 section
SM0822
IMPORTANT: the poppet in use differs from the

above (18.1). Do not mix the parts when assembling
parts again.
18.4 Lock valve.
IMPORTANT: the plug, poppet and spring in use
differ from the above (18.3). Do not mix the parts
when assembling parts again.
18.5 Main relief valve
IMPORTANT: the plug, poppet and spring in use
differ from the above (18.4). Do not mix the parts
when assembling parts again
The plugs in which the procedure for disassembly is
not included in the above procedure are usually
used to block auxiliary holes and holes caused by
casting. Do not disassemble further if unnecessary.
19. Disassembling casing

19.1 Further disassembly of the casing is not
allowed.
W2-3-24
SM0823
CONTROL VALVE
E215B-E245B
INSPECTION AFTER DISASSEMBLY

Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a clean
sheet of paper or cloth for inspection.
Control valve
1.
Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.
2.
Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust.
3.
If the check valve seat of the casing or the block has dents or damage on its surface, smooth it by lapping.
IMPORTANT: Take care not leave lapping compound behind in the casing or block.
4.
Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from scratches,
dents, and the like. Remove any small defects with an oil stone or lapping compound.
5.
Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages
are free from foreign matter.
6.
Replace any broken or deformed spring with new one.
7.
Replace all O-ring with new ones.
Relief valve
1.
Make sure that the poppet and the seat surface at the tip of the seat are without fault and that the contact
surface is even all over.
2.
Manually confirm that the main poppet slides smoothly onto and off the seat.
3.
Confirm that the outer circumference of the main poppet and the inner circumference of its seat are free
from defects such as scratches.
4.
Confirm that each spring is free from breakage, deformation, and excessive wear.
5.
Confirm that the orifices of the main poppet and its seat are not clogged.
6.
Replace all O-rings with new ones. (Between casing and seal)
REASSEMBLY
Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly
procedures.
For the tightenig torque of socket bolts and plugs refer to page W2-3-11.
Precautions on reassembling O-ring
1.
Confirm that O-rings are free from defects caused by poor handling.
2.
Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3.
Do not stretch O-rings to the extent that they become permanently set.
4.
When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves
after installation, and can cause oil leaks.
5.
Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance
Standards.".
W2-3-25
E215B-E245B
CONTROL VALVE
Installing check valve

1.
Load check valve, conflux check valve, and so on

Attach poppet (511) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the
specified torque. (9 places)
2.
Load check valve of swing section

specified torque. (1 place)
3.
Load check valve of arm 2 section

specified torque. (1 place)
4.
Lock valve section

5.
Main relief valve section

IMPORTANT: take care to prevent misassembling of parts and assembling position error because the parts in
1. to 5. are similar in shape.
Assembling plate
1.
Place O-rings (162), (163) in casing.
2.
Attach plates (212), (213) and tighten socket bolts (274), (275) to the specified torque.
Replace control valve so that this plate face directs downward.

Assembling back pressure check valve
1.
Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527) and (528).
2.
Attach O-rings (264), (266) in back pressure check valve cover, attach it to casing A (101) and tighten
socket bolt (278) to the specified torque.
Assembling boom lowering valve

1.
Attach boom lowering valve (215) to O-ring and tighten the socket bolts (279) to the specified torque.
Assembling lock valve selector sub

1.
Attach lock valve selector sub (211) to the casing and tighten socket bolt (171) to the specified torque.
Assembling by-pass cut valve

1.
Attach by-pass cut valve (606) to casing and tighten it to the specified torque.
IMPORTANT: take care to prevent drop of poppet and spring when attaching by-pass cut valve.
W2-3-26
CONTROL VALVE
E215B-E245B
Assembling relief valve and relief valve hole plug assembly

1.
Tighten main relief valve (601), port relief valves (602), (603), (605) and relief valve hole plug assembly
(604) in respective place to the specified torque.
IMPORTANT: Assemble it giving attention to the label attached when disassembling to prevent mistake
because the port relief valves (602), (603), (605) are similar in shape.
Assembling P2 unload spool
1.
Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum plate,
etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified
torque.
NOTE:
2.
apply Loctite #262 when tightening bolt (333).

take care not to deform P2 unload spool (310) because of careless over clamping.
Place P2 unload spool assembly in casing A (101).
IMPORTANT: Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
3.
Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and
tighten socket bolt (273) to the specified torque.
Assembling travel priority spool

1.
Hold the mid section of travel priority spool (307) with vise provided with protection plate (aluminum plate,
torque.
NOTE:
2.

Take care not to deform travel priority spool (307) because of careless over clamping.
Place travel priority spool assembly in casing B (102).
IMPORTANT: place travel priority spool assembly in casing B (102) carefully. Do not squeeze it into place.
3.
Attach spring cover (202) with O-ring (261) attached to the spring side of travel priority spool assembly,
and tighten socket bolt (273) to the specified torque.
W2-3-27
E215B-E245B
CONTROL VALVE
Assembling spool in option

1.
Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum plate, etc.),
fit spring seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) to the specified torque.
NOTE:
2.

take care not to deform option spool (311) because of careless over clamping
Place spool assembly in option in casing A (101).
IMPORTANT: place option spool assembly in casing A (101) carefully. Do not squeeze it into place.
3.
Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and
Assembling arm 2 spool

1.
Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.),
NOTE:
2.

take care not to deform arm 2 spool (308) because of careless over clamping.
Place arm 2 spool assembly in option in casing B (102).
IMPORTANT: place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.
3.
Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten
Assembling arm 1 spool

1.
Hold the mid section of arm 1 spool (302) with vise provided with protection plate (aluminum plate, etc.)
and fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified
torque.
NOTE:

take care not to deform arm 1 spool (302) because of careless over clamping.
Place arm 1 spool assembly in casing A (101).
IMPORTANT: place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.
2.
Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and
W2-3-28
CONTROL VALVE
E215B-E245B
Assembling bucket spool

1.
Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum plate, etc.),
NOTE:
2.

take care not to deform bucket spool (304) because of careless over clamping.
Place bucket spool assembly in casing B (102).
IMPORTANTE: Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.
3.
Attach spring cover (209) with O-ring (261) attached to the spring side of bucket spool assembly and
4.
Attach piston (216) to spring cover (209), place O-ring (164) in plug (551) and tighten to the specified
torque.
Assembling swing spool

1.
Hold the mid section of swing spool (303) with vise provided with protection plate (aluminum plate, etc.),
NOTE:
2.

take care not to deform swing spool (303) because of careless over clamping.
Place swing spool assembly in casing A (101).
IMPORTANT: place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.
3.
Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly
W2-3-29
E215B-E245B
CONTROL VALVE
Assembling boom spool

1.
Hold the mid section of boom spool (301) with vise provided with protection plate (aluminum plate, etc.),
NOTE:
take care not to deform boom spool (301) because of careless over clamping.
2.
Place boom spool assembly in casing B (102).
IMPORTANT: place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.
3.
Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool assembly
Assembling boom conflux spool

1.
Hold the mid section of boom conflux spool (305) with vise provided with protection plate (aluminum plate,
torque.
NOTE:
take care not to deform boom conflux spool (305) because of careless over clamping.
2.
Place boom conflux spool assembly in casing A (101).
IMPORTANT: place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.
3.
Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool assembly
Assembling travel spool (travel right and left)

1.
Hold the mid section of travel spool (306) with vise provided with protection plate (aluminum plate, etc.),
NOTE:
apply Loctite #262 when tightening bolt (333)
take care not to deform travel spool (306) because of careless over clamping.
2.
Place travel spool assembly in casing A (101) or casing B (102).
IMPORTANT: place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into
place.
3.
Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly and tighten
W2-3-30
CONTROL VALVE
E215B-E245B
Assembling P1 unload spool

1.
Hold the mid section of P1 unload spool (309) with vise provided with protection plate (aluminum plate,
torque.
NOTE:
take care not to deform P1 unload spool (309) because of careless over clamping.
2.
Place P1 unload spool assembly in casing B (102).
IMPORTANT: place P1 unload spool assembly in casing B (102) carefully. Do not squeeze it into place.
3.
Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool assembly and
Assembling spool cover, and so on

1.
Travel, boom, bucket, arm 1, arm 2, option

- Place O-ring (264) in spool cover (205) and tighten socket bolt (273) to the specified torque.
2.
Swing
- Place O-rings (264), (266) in spool cover (206) and tighten socket bolt (273) to the specified torque.
W2-3-31
E215B-E245B
CONTROL VALVE
MAINTENANCE STANDARDS
Inspection of components
Part name
Casing
Spool
Inspection item
1. Look for
corrosion.
scratches,
Criterion and remedy
rusting
1. If any of the following parts are damaged,

replace the casing.
Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
Area of sealing part that is in contact with
and
O-ring.
Sealing and seating part of main or
overload relief valve.
Area of seating part or sliding part of
poppet.
Sealing part of plug.
Defects of other parts that seem to prevent
normal function.
1. Look for scratches, galling, rusting and

corrosion.
1. If a detectable defect with your fingernail is

found on the sliding part of the outer
circumference, replace the spool.
2. Insert the spool in the casing bore, and 2. If the spool damages the O-ring or does not
move it while turning it
move smoothly, repair or replace the spool.
Poppet
1. Look for damage on the poppet and If spring is damaged, replace it.
the spring.
1. If the seat of poppet or spring are damaged,
correct or replace it.
2. Insert the poppet in the casing, and 2. If the poppet moves lightly without catching, it
move it.
is normal.
Spring and related parts
1. Look for rust, corrosion, deformation,

and breakage of the spring, spring 1. If damaged heavily, replace.
seat, stopper, spacer bolt and cover.
Main relief valve,

Port relief valve,
By-pass cut valve
1. Look for rust and damage on outer

1. Replace.
surface.
2. Inspect the contact face of the valve
2. If damaged, replace.
seat.
3. Inspect the O-ring, backup ring, and 3. As a general rule, replace all parts with new
seal
ones. (Between casing and seal)
W2-3-32
SWING DEVICE
E215B-E245B
REMOVAL AND INSTALLATION OF SWING DEVICE

WARNING
Preparation
1.
2.

3.

oil tank.

W2-4-1
E215B-E245B
SWING DEVICE
Removal
1.
Remove hose (1) from the Tee in the makeup

port M.
: 36 mm
6
2.
Remove the hoses (2 and 3) from the Tee in the

drain port Dr.
: 27 mm
3.
Remove the hoses (4 and 5) from the elbows of

the A, B port.
2
3
: 36 mm
SM0701
4.
Remove the hose (6) from the elbow of the PG

port.
: 19 mm
5.
6.
Put in plugs into the opened ports on the swing

motor unit.
Remove the swing motor unit by loosing the

screws (7) (q.ty 13).
: 30 mm
7.
Remove the plastic cap (8) M12 at the top of the

swing motor and install the lifting eye bolt.
: 36 mm
8.
Sling and remove the swing unit.
NOTE: swing unit weight: 192 kg
W2-4-2
SM0702
SWING DEVICE
E215B-E245B
Installation
1.
Clean mating surfaces of swing motor unit and

upper frame.
2.
Apply Loctite FAG3 on entire mounting surface

of swing motor unit.
3.
Place the swing unit on the upper frame.
NOTE: swing unit weight: 192 kg

4.
5.
Remove the lifting eye bolts and inserts on the

holes, the plastic caps (8) M12, previsiously
removed.
Fix the swing unit to the frame by tightening the
screws (7) (q.ty 13).
: 30 mm
6
4
: 539 54 Nm
6.
SM0702
Install the hoses (4 and 5) on the elbows of port

A and B.
: 30 mm
1
2
3
: 108 Nm
SM0701
7.
Install the hose (6) on the elbow of port PG.

: 19 mm
: 29.4 2.9 Nm
8.
Install the hoses (2 and 3) on the tee in the drain

port Dr.
: 27 mm
: 93.1 9.3 Nm
9.
Install the hose (1) on the make up port M.

: 36 mm
: 176.5 17.6 Nm
W2-4-3
E215B-E245B
SWING DEVICE
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

33
27
44
20
21
31
2
15 3 17 13-14
19
43
38
16
A
43
29
42
12 30
32
37
35
36
4
41
25
26
24
6
40
8
9
A-A
45
18
11
28
34
10
SM0703
12345678910 11 12 13 14 15 -
Relief valve (q.ty 2)

O-Ring (q.ty 2)
Swing shockless valve
Shockless valve casing
Drive shaft
Cylinder
Spring
Piston (q.ty 9)
Shoe
Set plate
Shoe plate
Valve plate
Plug (q.ty 2)
O-Ring (q.ty 2)
O-Ring (q.ty 2)
16 17 18 19 20 21 24 25 26 27 28 29 30 31 32 -
O-Ring (q.ty 2)
Socket bolt (q.t: 4)
Swing motor casing
Valve casing
Plunger (q.ty 2)
Spring (q.ty 2)
Swing shockless valve (q.t: 2)
O-Ring (q.ty 2)
Backup ring (q.ty 2)
Socket bolt (q.ty 4)
Roller bearing
Plug (PF 3/8)
Pin (q.ty 2)
Plug (q.ty 2)
O-Ring
W2-4-4
33 34 35 36 37 38 39 40 41 42 43 44 45 -
O-Ring (q.ty 2)
Oil seal
Brake piston
O-Ring
O-Ring
Brake spring (q.ty 16)
Friction plate (q.tty 3)
Separation plate (q.ty 4)
Plug (PF 1/4)
Roller bearing
Plug (PF 3/4) (q.ty 3)
Plug (PT 1/2)
Plug (PT 3/4)
SWING DEVICE
E215B-E245B
Preliminary operations
1.
Hydraulic components are precision products

and have small clearance. Therefore,
assemble and disassemble in a less dusty
clean place. Use clean tools and cleaning oil
and handle components with full care.
3.
Study the structural drawing before the work

begins and prepare necessary parts according
to your purpose and the scope of work. Seals
and O-Rings once removed can not be used
again.
2.
If a component is removed from the main body,

clean the area around the ports thoroughly and
plug them up so no dust and water do not enter.
When fitting them back to the body, do not
remove the plugs till piping is completed.
4.
The piston and the cylinder block are shop fitted

when new. If you intend to reuse them, put a
matching mark on the piston and the cylinder
block.
Disassembly
1.
2.
Remove the drain plug and drain hydraulic oil

from casing (18).
Fix the motor on a work bench so the drive shaft

(5) end comes down. On that occasion, put a
matching mark on the mating parts of casing
(18) and valve casing (19).
17
12
1
19
38
NOTE: choose a clean place, and lay with a rubber

sheet or a cloth on a work bench. Handle the valve
casing with care so parts do not have dents.
3.
18
Loosen relief valve (1) and separate it from

valve casing (19).
: 41 mm
4.
Loosen anti-reaction valve sub assy (3) and

remove from valve casing (17).
5
: 6 mm
5.
Separate plugs (31) from valve casing (19) and

draw out springs (21) and plungers (20).
: 17 mm
6.
SM0704
27
Loosen socket bolts (27) and separate valve

casing (19) from casing (18).
NOTE: if the socket bolt (27) are loosened, the valve

casing (19) floats off casing (18) by the force of
brake springs (38).
7.
Separate valve plate (12) from valve casing

(19).
: 17 mm
20
21
31
SM0705
W2-4-5
E215B-E245B
8.
9.
SWING DEVICE
Draw out brake spring (38) from brake piston

(35).
Draw out the brake piston (35) with the special
tool (xxxxxxxxx).
38
35
10. Lay the motor on its side again and draw out
cylinder block (6) from drive shaft (5), draw out
piston (8), set spring (7), plate (10) and shoe
plate (11).
11. Draw out friction plate (39) and separator plate
(40) from casing.
12. Draw out drive shaft (5) using a plastic mallet.
SM0706
Perform the following operations as required:

a. Drawing the inner race of roller bearing (28)
from drive shaft (5), using a press.
b. Drawing out the outer race of roller bearing
(28) from casing (18), by lightly tapping the
steel rod from the oil seal (34) housing side.
11
c. Separate the outer race of roller bearing (42)

from valve casing (19), using a slide hammer
bearing puller.
IMPORTANT: do not reuse the bearing.
5
10
39
40
6
SM0707
5
34
28
18
SM0708
W2-4-6
SWING DEVICE
E215B-E245B
Assembly
1.
Place casing (18) on a proper bench facing

upward.
The following operations are necessary only when

the roller bearings (28) and (42) are removed:
a. Shrinkage fit the inner race of roller bearing
(28) into drive shaft (5).
b. Shrinkage fit the inner race of roller bearing
(42) to drive shaft (5).
c. Fit oil seal (34) to casing (18).
d. Assemble the outer race of roller bearing (28)
into casing (18), by lightly tapping the steel
rod.
2.
Attach drive shaft (5) to casing (18).
3.
Insert shoe plate (11).
4.
Set the set plate (10) and spring (7), then set
piston sub (8, 9) assy.
34 28 18
SM0709
5.
Assemble piston sub assy (8, 9) fixed in

retainer plate (10) into cylinder (6), match it to
the spline of drive shaft (5) and insert it in place.
6.
Place casing (18) with oil seal facing downward

and assemble separator plate (40) and friction
plate (39) into casing (18).
11
10
5
SM0710
39
40
SM0711
W2-4-7
E215B-E245B
SWING DEVICE
7.
Fit O-rings (36), (37) to casing (18).
8.
Assemble brake piston (35) into casing (18).
9.
Assemble brake spring (38) into brake piston

(35). Make sure that a spring is placed securely
in the spot faced part of the brake piston.
36
37
NOTE: this operation is necessary only where roller

bearing (42) is removed.
10. Insert the outer race of roller bearing (42) into
valve casing (19), while lightly tapping the steel
rod using a hammer.
18
SM0712
11. Assemble valve plate (12) into valve casing

(19) and fit O-ring (32) in it.
3
12. Install valve casing (19) to casing (18) and

fasten them with socket bolts (27).
17
42 12
1
19
: 17 mm
38
: 431 Nm
35
32
13. Fit plunger (20) and spring (21) to valve casing

(19). Then tighten plug (31) fitted with O-ring
(33) against valve casing (19).
18
: 14 mm
: 334 Nm
14. Fit relief valve (1) to valve casing (19).
: 41 mm
5
:177 Nm
SM0713
15. Fit anti-reaction sub assy (3) to valve casing

(19).
27
: 6 mm
: 29 Nm
20
21
31
SM0705
W2-4-8
SWING DEVICE
E215B-E245B
DISASSEMBLY AND ASSEMBLY OF SWING REDUCER
19
28
16
6
20
3
10
15
12
18
17
5
9
23
22
31
32
25
26
13
24
27
21
11
30
SM0714
12345678910 -
Pinion shaft
#1 sun gear
#1 pinion (q.ty: 3)
#2 sun gear
#2 pinion (q.ty: 4)
Ring gear
#1 spider assy
#2 spider assy
Shaft (q.ty: 4)
Spherical bearing
11 12 13 15 16 17 18 19 20 21 -
Spherical bearing
Oil seal
Housing
Thrust washer (q.ty: 6)
Needle bearing (q.ty: 3)
Needle bearing (q.ty: 4)
Thrust washer (q.ty: 8)
Snap ring
Snap ring
Sleeve
W2-4-9
22 23 24 25 26 27 28 30 31 32 -
Spring pin (q.ty: 4)

Socket bolt (q.ty: 11)
Cap (q.ty: 2)
Tube
Elbow
Plug
Snap ring (q.ty: 3)
Oil seal
Grease fitting
Relief fitting
E215B-E245B
SWING DEVICE
Preliminary operations:
1.
Before disassembly, clean thoroughly the

swing reduction unit outer, checking for no
damage or scratches.
2.
Drain out the gear oil from reduction unit.
3.
Remove the draining pipe.
4.
In order to case the re-assembly, before

disassembly put a matching mark (X) on the
parts to be connected on the reduction casing.
23
x
x
27
SM0715
Disassembly
1.
Place the reduction unit assy on a stable work

bench as shown in figure, remove plug (27),
drain out oil put a matching mark on the
matching surface of the figure on the right side.
2.
Loosen all socket bolt (18) (M14). Attach eye

bolts (M10) in the lifting bolt holes in the top
surface of the swing motor and lift the assy by
crane.
If it is hard to remove the swing motor assy from
the reduction unit, float it by inserting a flatblade screwdriver in the groove of the flange.
SM0716
: 12 mm
3.
Remove #1 sun gear (2).
4.
The spider assy (7) [consisting of thrust

washers (15), #1 pinions (3), needle bearings
(16) and snap rings (28)] can be removed from
the spline easily if it is lifted up in that condition.
5.
6.
6
13
Attach eye bolts (M10) to the top surface of ring

gear (6) and lift the ring gear lightly by a wire
sling.
Put a flat-blade screwdriver into the matching
surface of ring gear (6) and housing (13) and
remove ring gear (6) by lightly tapping the outer
circumference of the ring gear with a plastic
mallet.
Draw out #2 sun gear (4) and remove the #2
spider assy (8).
SM0717
SM0718
W2-4-10
SWING DEVICE
E215B-E245B
NOTE: particularly if no failure is found, the further

disassembly is not allowed.
Check on parts for possible failure according to the
inspection procedure shown in maintenance
standards.
It is recommended that the pinion shaft and housing
assy are replaced together as one set. But if it is
unavoidably necessary to replace a part of them,
follow the procedure shown below.
7.
Remove retaining ring (20) from pinion shaft

(1).
8.
Pull pinion shaft (1), sleeve (21), oil seal (30)

and spherical bearing (lower) (11) out by
means of press while supporting housing (13)
with special tool (xxxxxxxxx).
SM0719
NOTE: spherical bearing (upper) (10) and oil seal

(12) are left in the housing.
9.
20
Pull oil seal (30), sleeve (21) and spherical

bearing (lower) (11) out by means of special
tools (xxxxxxxxx) and (xxxxxxxxx) while
supporting pinion shaft assy as shown in the
figure.
Press force: 30 t
NOTE: do not reuse the removed oil seal and

bearing.
xxxxxxxxx
SM0720
xxxxxxxxx
21
30
11
xxxxxxxxx
SM0721
W2-4-11
E215B-E245B
SWING DEVICE
10. Set housing (13) as shown in the figure, insert

special tool (xxxxxxxxx) between bearing (10)
and oil seal (12) and remove bearing (10) by
striking from the upper side.
13
11. Remove oil seal (12) from housing (13).

NOTE: do not reuse the removed oil seal and
bearing.
12. Disassembe #1 spider assy performing the
following operations.
12
10
a. Remove retaining rings (28) with a plier.

b. Remove thrust washers (15), pinions (3)
and needle bearings (16).
xxxxxxxxx
SM0722
NOTE: the shaft attached to spider assy (17) is

caulked. When replacing parts, replace the spider
assy as a set. Pinions (3) can not be replaced singly.
Replace them in a set of three.
15
16 28
13. Disassembling #2 spider assy performing the

a. Draw out spring pin (22).
b. Draw out shafts (9) from spider (8) and
remove thrust washers (18), pinions (5) and
needle bearings (24).
NOTE: pinions (5) can not be replaced singly.
Replace them in a set of four.
17
15
SM0723
9
18
5
24
18
22
SM0724
W2-4-12
SWING DEVICE
E215B-E245B
Assembly
1.
Sufficiently clean every part with wash oil and

dry it with compressed air.
2.
Check on every part for failure.

xxxxxxxxx
3.
Attach oil seal (30) to sleeve (21) by means of

special tool (xxxxxxxxx).
4.
Insert sleeve (21) and oils seal (30) assy in

pinion shaft (1).
5.
Apply gear oil to the perimeter of axis of pinion

shaft (1) lightly to prevent seizure.
6.
Seal sufficient grease in spherical bearing

(lower) (11) and force it in pinion shaft (1) by
means of special tool (xxxxxxxxx).
Press force: 4~5 t
30
21
SM0725
NOTE: since the bearing is formed with a partition at

the center section, seal grease in it from both sides.
1
21
30
SM0726
xxxxxxxxx
11
SM0727
W2-4-13
E215B-E245B
SWING DEVICE
7.
Apply sufficient grease to the pinion shaft assy.

Grease: lithium extreme-pressure grease
(SHELL Albania EP2 or equivalent)
8.
Place housing (13) on level bench and attach

eye bolt to screw (M10) at the axis end of pinion
shaft assy, and perpendicularly hang up pinion
shaft assy and place it in the housing.
NOTE: horizontally orient the outer race of spherical

bearing and insert it in by striking lightly. If the outer
race is tilted, it is hard to insert even if striking.
Then do not force to insert it in, but take it away once
and horizontally orient the outer race twice and
insert it in again.
9.
Set housing assy so that the pinion directs

downward and fit oil seal (12) in housing (13) by
SM0728
NOTE: apply Loctite #515 to the perimeter of oil

seal. Fill one third (1/3) of the space of the
grooveshaped section provided on the oil seal (12)
lip with grease. Insert it horizontally giving attention
to the lip of oil seal so as not be damaged.
13
SM0729
xxxxxxxxx
12
13
SM0730
W2-4-14
SWING DEVICE
10. Press fit spherical bearing (upper) (10) in pinion
shaft (1) and housing (13) at the same time by
E215B-E245B
xxxxxxxxx
10
11. Attach retaining ring (20).

12. Assemble #1 Spider assy performing the
a. Coat the bore surface of pinion (3) with
grease. Put pinion (3) on thrust washer (15)
and assemble needle bearings (16) into the
bore surface.
b. Fit thrust washers (15), pinions (3) and fit
snap rings (28) by means of pliers.
13
SM0731
20
SM0732
16 28
15
15
SM0733
W2-4-15
E215B-E245B
SWING DEVICE
13. Assemble #2 Spider assy performing the

a. Coat the bore surface of pinion (5) with

grease. Put pinion (5) on thrust washer (18)
and fit needle bearing (17) to the bore
surface.
b. Fit thrust washer (18) and pinion (5), insert
shaft (9) into spider (8) and drive spring pin
(22).
6 - 7 mm
14. Insert #2 spider assy (8) in spline axis of pinion

shaft.
6 - 7 mm
18
5
15. Install #2 sun gear (4) directing the spline

upward.
17
A
22
SM0734
SM0735
SM0736
W2-4-16
SWING DEVICE
E215B-E245B
16. Apply a thin film of sealant Loctite #515 to the

matching surface of housing (13) and ring gear
(6) and assemble them, aligning the gear teeth
and according to the matching marks given.
6
13
17. Mesh the #1 spider assy (7) with ring gear (6)
and set them in place.
18. Mesh #1 sun gear (2) with #1 pinions (3) and

set them in place.
19. Fit drain tube (25) and plug (27).
SM0737
: 12 mm
: 70 Nm
20. Fill in 3 L of gear oil (API GL-5).

21. Attach eye bolts (M10) in the tapped holes of
the swing motor and put a wire sling in them.
Coat the matching surface of ring gear (6) with
sealant Loctite #515.
Insert the spline joint of the swing motor and
match the matching marks. Coat socket bolts
(23) with sealant Three-Bond 1360K and fasten
them.
: 12 mm
SM0738
: 181 Nm
23
x
x
25
27
SM0739
W2-4-17
E215B-E245B
SWING DEVICE
MAINTENANCE STANDARDS
Swing motor
Unit: mm (poll.)
Item
Standard
dimension (mm)
Recommended
value for
replacement (mm)
0.027
0.052
0.3
Replace piston and shoe assy.
5.5
5.3
Replace piston and shoe assy.
2.0
1.8
Replace.
Remedy
Clearance between piston and cylinder

bore (D-d)
Replace piston or cylinder.
Gap between piston and caulked part of

shoe (d)
Thickness of shoe (t)
Thickness of friction plate (t)
Standard for correcting sliding surfaces

If the surface roughness of the sliding surface of parts exceeds the following standard, correct it or replace the
parts.
Standard for correcting sliding surfaces
Name of parts
Shoe
Standard surface
roughness
Surface roughness
requiring correction
0.8Z (Ra=0.2) (lapping)
3Z (Ra=0.8)
Shoe plate
3Z (Ra=0.8)
Cylinder
12.5Z (Ra=3.2)
Valve plate
6.3Z (Ra=1.6)
NOTE: lap each sliding surface to a standard roughness level or finer. If the spherical sliding surface of the
spring (7) and cylinder (6) are roughened, replace parts in pairs.
W2-4-18
SWING DEVICE
E215B-E245B
Swing reduction gear
A D
C
D
E
C
B
SM0740
Code
Item
Repairable level (mm)
Wear in #1 planetary shaft
0
39 -0.011
Wear in #2 planetary shaft
0
29 -0.009
Service Limit (mm)
No flaking
B
Remedy
Replace
spider assy
entire
Replace four shafts

as a set
Condition of There should be no pitting exceeding 1.6 mm dia, Replace (Planetary

tooth face
abnormal wear or seizure
pinion should be
replaced in a set of
Condition of
There should be no cracks
four.)
tooth flank
Gears
Thickness of thrust washer
0
1,6-0.2
1.3
Replace
Thickness of thrust washer
0
2.0-0.2
1.6
Replace
Wear in shaft (diameter of

part coming in contact with
oil seal)
94.9
Replace
0
95-0.087
W2-4-19
E215B-E245B
SWING DEVICE
NOTE:
W2-4-20
PILOT VALVE
E215B-E245B
REMOVAL AND INSTALLATION OF RIGHT AND LEFT PILOT VALVE

WARNING
Preparation
1.
2.

3.

pressure present in the tank itself.
Removal
1.
Free and lift rubber cap (5) complete with plate

(4) unlocking its hooks using a screwdriver.
2.
Remove side panels (2) and (3) removing

securing screws.

3.
Remove the handgrip (1) removing lock-nut (6)

disconnecting the relevant electric connection.

: 22 mm
IMPORTANT: attach an identification tag on each
hose to aid in reassembly.

4.
Disconnect hoses from port connector PF 3/8

(7) and PF 1/4 (8) of pilot valve body (9).
60
: 19, 22 mm

NOTE: attach a cap on each of disconnectd hose

ends.
5.
Remove pilot valve (9) removing securing

screws (10) M6x25 complete with washers.
: 5 mm
60
W2-5-1
E215B-E245B
PILOT VALVE
Installation
1.
Install pilot valve (9) on the frame tightening

securing screws (20) M6x25 complete with
washers.

: 5 mm
: 11.8 Nm (8.7 lbfft)

2.

Connect hoses to pilot valve body (9).
: 19 mm (Port: P)
3

60
: 29.4 Nm (22 lbfft)

: 22 mm (Port: 1 to 8, T)
LEFT SIDE
: 49 Nm (36 lbfft)
3.
Tighten the handgrip on the pilot valve (9),

tighten lock-nut (6) and reconnect the electric
connector.
: 22 mm
4.
Install side panels (2) and (3) tightening

securing screws.
5.
Arrange rubber cap (5) complete with plate (4)

locking the hooks on side panel (2).
RIGHT SIDE
BUCKET
1
(H)
RED
BUCKET
(R)
BLUE
5 SWING (L)
GRAY
6 SWING (R)
RED
7 ARM (H)
BLUE
3 BOOM (H)
GREEN
8 ARM (R)
GREEN
4 BOOM (R)
GRAY

60
W2-5-2
PILOT VALVE
E215B-E245B
REMOVAL AND INSTALLATION OF TRAVEL PILOT VALVE

WARNING
Preparation
1.
2.

3.

pressure present in the tank itself.
.
Removal
1.
Remove the cover under the cab
2.
Remove the floor mats in the cab.
3.
Remove the pedal removing securing screws

(1) (Q.ty 4) then remove the levers, removing
securing screws (2) (Q.ty 4).
: 13, 17 mm
4.
Disconnect pressure sensors (7) from body (8).

: 24 mm

IMPORTANT: attach an identification tag on each

hose to aid in reassembly.

5.
Disconnect pipes (from 3 through 6) of body

(8).
: 19, 22 mm
NOTE: attach a cap on each of disconnected hose

ends.
6.
Remove body (8) removing securing screws (9)

complete with washers.
: 17 mm
W2-5-3

60
E215B-E245B
PILOT VALVE
Installation
1.
Install body (8) on the frame tightening securing

screws (9) complete with washers.
: 17 mm
: 37 Nm (27.4 lbfft)
2.
Connect pipes (from 3 through 6) to body (8).

: 19 mm
: 16.7 Nm (12.3 lbfft)
: 22 mm
: 30 Nm (22.0 lbfft)
3.
Connect pressure sensors (7) to body (8).

: 24 mm
: 16.7 Nm (12.3 lbfft)

4.
Install the levers tightening securing screws (2)

and the pedals tightening securing screws (1).
: 17 mm
: 46.1 Nm (34.1 lbfft)
: 13 mm
: 23.5 Nm (17.4 lbfft)
5.
Install the cover under the cab

: 19 mm
: 108 Nm (80.0 lbfft)
W2-5-4
60
PILOT VALVE
E215B-E245B
DISASSEMBLY RIGHT AND LEFT PILOT VALVE
60
123456-
Adjusting nut M14

Boots
Circular plate
Joint M14
Plate
Seal (Q.ty 4)
789121415-
Plug (Q.ty 4)
O-Ring (Q.ty 4)
Push rod (Q.ty 4)
Spring seat 1 (Q.ty 2)
Spring (Q.ty 4)
W2-5-5
171819202122-
Spring (Q.ty 2)
Spring (Q.ty 2)
Washer 2 (shim) (Q.ty 4)
Spool (Q.ty 2)
Spool (Q.ty 2)
Casing
E215B-E245B
PILOT VALVE
Disassembly right and left pilot valve

Be sure to thoroughly read "Precautions for
Disassembly and Assembly" on page W1-1-1
before starting the disassembly work.
NOTE: replace O-Ring
operations, as a rule.
every
disassembly
1.
Plug each port of pilot valve, and clean it.

P Port : PF 1/4
14 Port and T: PF 3/8
2.
Fix pilot valve with vise, via a protective plate

(Alminum plate etc.), and remove boot (2).
3.
Remove adjusting nut (1) applying spanners to

circular plate (3).
60
: 22, 32 mm
4.
Remove circular plate (3).
: 32 mm

5.
Turn joint (4) in counterclockwise with jig (E)

(380001055) to remove it.
: 24 mm
60
WARNING
When the force of return springs (15) is high, never
loosen joint (4). If loosened, it might result in
jumping out of plate (5) plug (7) and push rod (9).
Remove joint (4) pressing plate (5) downward with
two fingers.
(

60
W2-5-6
PILOT VALVE
6.
E215B-E245B
Remove plate (5).

NOTE: When the force of return spring (15) is

high, press plate to let it come up slowly.
When the force of return spring (15) is low, plug (7)
is left in casing (22) due to sliding resistance of ORing (8).
60

60
7.
Pull plug (7) out with a driver.

WARNING
To prevent personal injury, plug (7) must be

removed slowly and evenly until the return spring
(15) force is completely released
8.
Remove push rod (9), plug (7), pressure

reducing valve assy (spool) and the return
springs (15) from casing (22).
NOTE: record combination of port holes on casing

and the pulled out parts. The stroke differs
according to direction.
60

60
W2-5-7
E215B-E245B
9.
PILOT VALVE
Press springs seats (12 and 14) so that the

movement is 7 mm (max), then remove spools
(20 and 21) through the larger hole of the seat.

IMPORTANT: Never push down spring seat (12) in

7 mm or more. (For port 1 and 3).
Never push down spring seat (14) in 9.4 mm or
more. (For port 2 and 4).

60
10. Remove spool (20 and 21), spring seats (12

and 14), springs (17 and 18) and washer (19).

60
11. Pull out push rod (9) from plug (7).

12. Remove O-Ring (8) from plug (7).
60
13. Remove inside seal (6) from plug (7) with small
driver
Cleaning parts
1.
Clean parts with wash oil roughly and the parts

of pilot valve completely.
2.
Dry parts by swabbing clean waste cloth.
3.
Apply rust preventives on parts.

W2-5-8
60
PILOT VALVE
E215B-E245B
ASSEMBLY RIGHT AND LEFT PILOT VALVE

60
12345678-
Adjusting nut M14

Boots
Circular plate
Joint M14
Plate
Seal (Q.ty 4)
Plug (Q.ty 4)
O-Ring (Q.ty 4)
910111213141517-
Push rod (Q.ty 4)

Spring (Q.ty 4)
Spring (Q.ty 2)
Spring (Q.ty 2)
W2-5-9
18192021222324-
Spring (Q.ty 2)
Washer 2 (shim) (Q.ty 4)
Spool (Q.ty 2)
Spool (Q.ty 2)
Casing
2E4 Port
1E3 Port
E215B-E245B
PILOT VALVE
Assembly right and left pilot valve

1.
Fit washer 2 (19), springs (17) and (18), spring

seats (12) and (14) to spools (20) and 21).

60
2.
Push spring seat 1 (12) so that the movement

is 7 mm or less, and install spool (20) through
the large hole of spring seat 1.
For spring seat 1 (14), push spring seat (14) in
9.4 mm or less and install spool (21).

IMPORTANT: never push down spring seat (12) in

7 mm or more. (For port 1 and 3).
Never push down spring seat (14) in 9,4 mm or
more. (For port 2 and 4).

60
3.
Place springs (15) into ports 1 of casing (22),

and then install pressure reducing valve assy in
it.
Place spring (16) into ports 2,4 and then install
pressure reducing valve assy in it.

NOTE: install the removed respective assy into

respective holes.

60
W2-5-10
PILOT VALVE
4.
E215B-E245B
Fit O-Ring (8) and seal (6) into plug (7).

Apply hydraulic oil on surface of push rod (9).

60
60
5.
Insert push rod (9) in plug (7).
6.
60
Fit plug (7) assy to casing (22).

NOTA: When the force of spring (15) is low, it stops

at the position where it is pushed in by the sliding
resistance of O-Ring (8).
When the force of spring (15) is high, attach plate (5)
and press 4 push rods by hand at the same time,
and tighten joint (4) temporarily.
Install spools (20) ande (21) straight and evenly into
the hole of casing (22).
Take care so that plugs (7) and plate (5) do not jump
out of casing (22)
60

60
W2-5-11
E215B-E245B
7.
PILOT VALVE
nstall joint (4) on casing (22) with special tool

(E) (380001055) securely.
: 22 mm
: 47.12.9 Nm (34.82.1 lbfft)

(
60
8.
Install circular plate (3) to joint (4).
IMPORTANT: screw it in until it comes in contact

with 4 push rods (9) equally.
The exceeding of screw in may cause malfunction of
machine.
9.
Screw adjusting nut (1), applying Loctite #277

to the thread of joint, until it touches circular
plate (3), and tighten it applying spanner to stop
circular plate returning.
60
: 22 mm
: 68.64.9 Nm (503.6 lbfft)
: 32 mm
*
10. Apply heat-resisting grease (G) to joint (4)

rotating section and the top of push rod (9).

60
11. Cover it with boots (2).

12. Spray rust preventives through each port and
attach plug respectively.
60
W2-5-12
PILOT VALVE
E215B-E245B
PILOT VALVE (FOR TRAVEL)

CONSTRUCTION
R
R
K
R
\

\
[
[

I
G
/RFWLWH
J
7
J

7

U
X
W 7

L 7
N 7
K

X
W 7

M
X

T
7

/RFWLWH
U

7 aa
60
No.
Parts
NOTE: T=tightening torque Nm (lbfft)

Q.ty
No.
Parts
Rubber boots
Foot pedal (Switch plate)
2
(2)
Q.ty
12-x Seal 14203
12-y Wiper ring
6-d
Switch plate
13
Damper spring
6-f
Regulation screw M828
14
Check valve kit
(2)
6-g
Set screw M5x8
14-q Plug M8
6-l
Damping screw
14-r Ball M6, 35
Retaining plate kit
7-h
Plate
7-i
7-j
7-k
(1)
15
Orifice
15-u Plug M6
Capscrew M1020
15-t Orifice M6, 0.6
Shaft
17
(4)
4
4
Shuttle valve kit
(2)
17-w Shuttle valve & orifice
Set screw M410
Flange kit
17-r Ball M6, 35
10
Control spool
17-z Orifice M5, 0.8
11
Return spring
21
Plug
12
Damper flange kit
(4)
22
Valve body
12-o Damper plunger 14
W2-5-13
2
2
E215B-E245B
PILOT VALVE
DISASSEMBLY AND ASSEMBLY

1.
Boot replacement

NOTE: the pilot control unit does not need to be
removed from the machine to perform this
operation.
1) Remove both faulty boots.

(using a flat screw driver if necessary)
2) Replace both boots with a new one.
* Reassembly:
First fit the lower part of the rubber boot (5)
on the retaining plate (7-h) between the 2
switch plate (6)
Then put the lower part in the external
groove of the retaining plate.
Finish by fitting the upper part of the
rubber boot on the switch plate.
K
60
2.
Switch plate removal

1) Remove:
The pilot control unit from the machine
Both rubber boots
2) Remove the screw (7-k) locking the axis
using a 2 mm socket wrench. (See Fig.
SM0757 A)
* Reassembly:
Apply a droplet of Loctite #262 on the
locking screw thread.
Torque: 1.2 Nm (0.89 lbfft)
3) Fit a M3 screw on the switch plate axis (7-j)
in order to remove it (Using pliers if
necessary). (See Fig. SM0757 B)
* Reassembly:
Position the axis so that the hole (f) is
aligned with the locking screw (7-k) as
shown on the picture (See Fig. SM0757 C)
4) Mark out the position of the switch plate
before removing it.
5) Repeat the operation for the second switch
plate.
6) Reassemble parts in reverse order.
W2-5-14
N
&
M
'
60
PILOT VALVE
3.
E215B-E245B
Switch plate adjustment
I
NOTE: if the switch plate (6) is replaced, it is
necessary to adjust the regulation screws (6-f).
1) Unscrew the 2 locking screws (6-g) using a
2.5 mm socket wrench
* Reassembly :
locking screw thread.
Torque: 3 Nm 2.2 (lbfft)
2) Set the switch plate (6) horizontally
3) Screw on simultaneously both regulation
screws (6-g) using a flat screw driver
(5.5x150) until feeling some resistance.
NOTE: do not misadjust the two damping screws
(6-l).
J

60
4) Tighten the locking screws (6-g) to hold the

regulation screws (6-f) in position.
5) Repeat the operation for the second switch
plate making sure both switch plates are
parallel.
O
I
4.
Retaining plate removal (7-h)

1) Remove
Both rubber boots
Both switch plates (6)
2) Unscrew simultaneously both screws (7-i)
holding the retaining plate using a 8 mm
socket wrench.
* Reassembly :
screw thread.
Torque: 30 Nm (22 lbfft)

60

L
K
60
W2-5-15
E215B-E245B
PILOT VALVE
3) Lift the retaining plate (7-h) to remove it.

* Reassembly:
Use the retaining plate (7-h) to insert the 4
guides into the body simultaneously and
perpendicularly (22).
5) Drain the pilot control unit.
5.

K
Damping plunger seals replacement
60
1) Remove:
The pilot control unit from the machine.
Both rubber boots.
Both switch plates.
The retaining plate.
2) Remove the wiper ring (12-y) Remove the
wiper ring (12-o).
* Reassembly:
Replace with a new wiper ring (12-y).
R
\
%
60
CAUTION
Always place the damping plunger (12-o) prior to
the wiper ring (12-y), and make sure the wiper ring
(12-y) is correctly positioned.
K
\
3) Remove the damping plunger (12-o).

4) Using a needle, remove the seal (12-x)
placed inside the body (22)
* Reassembly:
Replace with a new seal and grease it.
[
R

60
[
W2-5-16

60
PILOT VALVE
A: Squeeze the seal (12-x) between your
fingers to obtain a 8-shape.
B, C: Insert the seal (12-x) ithin the groove
with your fingers (lip in bottom position).
D: Push the seal (12-x) against the side
using the round head of a small socket
wrench.
[
$
IMPORTANT: during the reassembly, make sure
the seal (12-x) is correctly positionned, and pay
attention not to damage nor twist it.
5) Repeat the operation for the other 3
assemblies.
6) Extract the damping springs (13) from the
body (22) (using flat nose pliers).
7) Inspect the damping springs (13). If defects
are detected, replace the 4 springs.
6.
E215B-E245B
[
[
&
'
60
Guide/plunger and regulation unit replacement.

1) Remove
The pilot control unit from the machine.
Both rubber boots
Both switch plates
The retaining plate
2) Guide/plunger replacement:
Insert the end of a thin screwdriver
between the guide and the body (22),
carefully lift the guide to remove it from the
body.
NOTE: hold the guides with the other hand during

the extraction operation to limit the effect of the
return spring.
3) Remove the guide / plunger assembly.
4) Repeat the operation for the other 3 subassemblies.
5) Visually check that the guides / plungers are
in good condition. If defects are present,
replace the 4 sub-assemblies.

60
W2-5-17
E215B-E245B
PILOT VALVE
6) Guide/plunger
and
relulation
unit
replacement.
Extract the regulation units from the body
(22) (using flat nose pliers).
Inspect the regulation units. If defects are
detected on the parts, replace the 4 units.
7) Return spring replacement (11):
Extract the return springs (11) from the
body (22) (using flat nose pliers).

60
Inspect the return springs (11). If defects

are detected, replace the 4 springs.


60
7.
Throttle kit replacement

1) Remove
Both rubber boots
Both switch plates
The retaining plate
The damping plungers and springs
2) Unscrew the screw (15-u) using a 3 mm
socket wrench
* Reassembly:
screw thread
Screw on until it sets just above the body
(22).
W2-5-18
X

60
PILOT VALVE
E215B-E245B
3) Unscrew the throttle (15-t) using a 3 mm

socket wrench.
* Reassembly:
4) Repeat the operation for the other 3
assemblies.
5) Replace with new screws (15-u) and new
throttles (15-t).

X
W
60
8.
Shuttle valve kit removal (17)

1) Remove the pilot control unit from the
machine

disassembled to perform this operation.
2) Unscrew the shuttle valve (17-w) using a 4
mm socket wrench
* Reassembly:
Thoroughly clean the body to remove any
trace of loctite.
shuttle valve thread (17-w).
60
IMPORTANT: wait for 8 hours before using the

machine to let the Loctite #242 dry completely.
Z
60
W2-5-19
E215B-E245B
PILOT VALVE
3) Put the body up-side-down to remove the

shuttle valve (17-w) and the ball (17-r).
4) Unscrew the throttle (17-z) using a 2.5 mm
socket wrench.
* Reassembly:
Hand tighten
5) Repeat the operation for the other
subassemblies.
6) Inspect the shuttle valves (17-w), balls (17-r)
and throttles (17-z).
If defects are detected, replace all the
assemblies.
60
W
]
Z
60
9.
Check valve kit removal (14)

1) Remove the pilot control unit from the
machine
T

disassembled to perform this operation.
2) Unscrew the check valve plug (14-q) using
a 4 mm socket wrench.
* Reassembly:
Drain the pilot control unit
Torque: 5 Nm (3.7 lbfft)
3) Put the body (22) up-side-down to remove
the ball (14-r).
4) Repeat the operation for the second check
valve kit.
5) Inspect the check valve plugs (14-q), Orings and balls (14-r). If defects are
detected, replace all the assemblies.
60

T
U
W2-5-20
60
PILOT VALVE
E215B-E245B
DRAIN OF HYDRAULIC PILOT CONTROL UNIT

1.
When removing the retaining plate, the throttle

kit or the shuttle valve kit, it is necessary to
drain the pilot unit.
2.
Reassemble the pilot unit control completely.
3.
Install the pilot unit control in the machine.
4.
Slightly unscrew the check valve plug (14-q)

using a 4 mm socket wrench
5.
Switch on the machine.
6.
Operate gently the pedal until the bubbles

disappear.
7.
Tighten the check valve plug (14-q).

Torque: 5 Nm (3.7 lbfft)
8.
Repeat the operation for the other check valve

plug.
T
W2-5-21
60
E215B-E245B
PILOT VALVE
NOTE:
W2-5-22

SM E215B-E245B 7 EN

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SECTION 2

Group 2 - Control valve

Removal and installation of

Removal and installation of control valveW2-3-1

Removal and installation of the cab ....... W2-1-2

Control valve ports ................................. W2-3-3

Removal and installation of

Preparation for disassembly................... W2-3-12

Disconnecting hoses of swivel joint

Swivel joint lower side hoses ................. W2-1-7

Group 2 - Pump device

Assembly and disassembly of control

Group 4 - Swing device

Removal and installation of hydraulic

Disassembly and assembly of swing

Disassembly and assembly of pump

Disassembly and assembly of swing

Disassembly hydraulic pump device ..... W2-2-3

Maintenance standards.......................... W2-4-18

Group 5 - Pilot valve

REMOVAL AND INSTALLATION OF UPPERSTRUCTURE

Park the machine on a firm, level surface.

To drain the hydraulic pressure from the

Remove the front equipment and the boom

Remove the cab, performing the operations

Remove the counterweight, performing the

Disconnect the hoses of swivel joint lower side,

Remove the main frame performing the

Cut-off the engine. Press the valve located on

NOTE: be sure to run the vacuum pump

REMOVAL AND INSTALLATION OF THE CAB

Remove floor mat.

Remove cover (1).

Remove cover assy (2).

Remove the harness connector (See section

Remove the plastic tube for the window washer

Remove the right panel of cab.

Disassembly and assembly of cover (1)

Disassembly and assembly of right panels

Remove cab attaching bolt.

1) 5 capscrews (15) M12x65 and 1 capscrew

installation of the cab

Nut M16 - (17)

Capscrew - (2), (9)

Sems bolt M6 (5), (6)

Sems bolt M6 (12), (13)

REMOVAL AND INSTALLATION OF

Remove plugs (1) from the counterweight and

NOTE: approximate mass of counterweight: 4600

Attach wire rope (2) to eye-bolts (3) using

Remove 4 bolts (4) M30.

Remove shim (5), (6), (7) from the frame.

Lower the counterweight on proper stand.

Attach lifting tools (2) to eye-bolts (3) of

Install shim (5), (6), (7) onto the frame as it was.

Lift counterweight and install it onto the frame.

Install bolts (4) and washers to counterweight

Remove wire rope.

Remove eye-bolts (3) and install plugs (1) onto

DISCONNECTING HOSES OF SWIVEL JOINT

Disconnect the two hose (1). (E Port: PF1/2)

Disconnect the hose (2) and (3).

Disconnect the hose (4) and (5).