New holland e215b руководство

P1, P2 pressures are high.

When removing, free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface Spring is free from breakage.

12 Over valve

load

relief Check targeted Free from dust entered in over load relief Replace spool visually valve Seat is free from abnormality.

T5-2-27

E215B-E245B

TROUBLESHOOTING (BY TROUBLE)

21. Option selector valve malfunction: not switched to breaker circuit. (Indication of failure is displayed. For reference, see «Table47-1 Action of optional selector solenoid valve») No.

Sections

Contents/normal value Visual check

Corrective action, others

1

N&B selector spool

When removing, free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface Spring is free from breakage

2

N&B solenoid

selector Screw emergency

3

N&B solenoid

selector Carry out service • No.11 F-4 Option selector is B mode diagnosis COMP ON, MEAS ON Spool position BRK Selector switch BRK

4

N&B selector Carry out service • No.16 B-11 Check pressure sensor pressure sensor diagnosis Data List Check harness 3.0 MPa at B mode and 0.0 MPa at A mode

for Check that the error indication is Replace solenoid valve disappeared by turning emergency screw Check solenoid valve Check harness

22. Option selector valve malfunction: not switched to nibbler circuit. (Indication of failure is displayed. For reference, see «Table47-1 Action of optional selector solenoid valve») No.

Sections

1

N&B selector spool

2

N&B solenoid

Contents/normal value Visual check

Corrective action, others

When removing, free from abnormal Replace resistance against sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface Spring is free from breakage.

selector Carry out service • No.11 F-4 Option selector is A mode diagnosis COMP OFF, MEAS OFF Spool position NIB Selector switch NIB

T5-2-28

Check solenoid valve Check harness

TROUBLESHOOTING (BY TROUBLE)

E215B-E245B

Table 1 — Action of optional selector solenoid valve Safety Engine lock lever No. SW’s condition input

1

Running

ON

Safety lock lever relay’s output

OFF

Work mode

Optional selector valve COMP. MEAS.

A

OFF

Spool position

Selector valve detecting pressure sensor

Warning display

Failure diagnosis display

Nibbler

Normal

—

—

2

Running

ON

OFF

A

ON

Breaker

«SELECTOR Normal FAILURE»

3

Running

ON

OFF

A

OFF

Breaker

Normal

4

Running

ON

OFF

A

ON

Nibbler

Normal

—

[F042] displayed

5

Running

ON

OFF

B

ON

Breaker

Normal

—

—

6

Running

ON

OFF

B

OFF

Nibbler

Normal

«SELECTOR FAILURE»

VALVE [F043] displayed simultaneously

7

Running

ON

OFF

B

ON

N&B

Normal

«SELECTOR FAILURE»

VALVE

8

Running

ON

OFF

B

OFF

Breaker

Normal

—

[F043] displayed

9

Running

ON

OFF

—

—

—

Failure

«SELECTOR FAILURE»

VALVE [B113] displayed

10 Stopping

«SELECTOR FAILURE»

VALVE [F042] displayed simultaneously VALVE

—

—

—

—

—

—

—

—

—

—

11

—

OFF

—

—

—

—

—

—

—

12

—

—

ON

—

—

—

—

—

—

T5-2-29

E215B-E245B

TROUBLESHOOTING (BY TROUBLE)

2. ELECTRIC SYSTEMS 2.1 WIRING CHECKING PROCEDURE Check for continuity between connector terminals, presence or absences of short-circuit with other wires, and presence or absences of short-circuit with machine body grounding. 1.

CONNECTOR

Checking for disconnection between connectors. (When both ends measurement is easy because of short distance between connectors) Measure the resistance using tester. Pull out opposite connector first. When the resistance is zero (0), it is in normal condition.

WIRE TESTER

(When both ends measurement is difficult because of long distance between connectors) Measure the resistance using tester. Pull out opposite connector first. Where the resistance is zero (0), if the terminal on one side is connected to frame body grounding with jumper wire, it is in normal condition. The resistance is 1 M or more when the terminal on one side is not connected to frame body grounding with jumper wire, it is in normal condition.

2.

SM0104

JUMPER WIRE

TESTER FRAME BODY GROUNDING SM0105

Checking for presence or absence of shortcircuit with machine body Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1 M or more, it is in normal condition.

TESTER

FRAME BODY GROUNDING SM0106

3.

Checking for presence or absence of shortcircuit between wirings. Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1 M or more, it is in normal condition.

TESTER SM0107

T5-2-30

TROUBLESHOOTING (BY TROUBLE) 4.

Checking connector terminal for contact Insert male terminal into female terminal unit, and then check that the inserting force is equivalent to other female terminals. If looseness is there, replace the female terminal with new one. Clean the dirt terminal.

E215B-E245B

INSERT

MALE TERMINAL

FEMALE TERMINAL SM0108

ATTENTION Do not insert the male terminal the thickness differs. It may cause loose connection. 5.

Caution which should be paid in measuring voltage When measuring the power supply to electric equipment at connector position with the grounding terminal contained inside of connector, measure the voltage between grounding inside of connector and power terminal. When measuring the voltage between frame body grounding and power source, the disconnection of wiring to grounding inside of connector cannot be identified. Since the voltage may vary between with connector connected and with connector not connected. Measure the voltage with each connector connected whenever possible.

6.

Checking the general view of connector CRIMPED PART

a. Check the terminal crimped condition. Pull one electric cable with the about 3kg force, and make sure that the cable does not come out of the terminal. When came out, replace the terminal and crimp it again. b. Check connector for imperfect insertion Check that all top ends form a line on the same position as seen from the connector engaged side. When moved along, push it in further through wire inserting hole. c. Check connector for intruding of water. Pull out the connector and check that the inside is free from intruding of water. When water intruding is found, check rubber plug for damage and also that the sealing is fitted properly.

T5-2-31

RUBBER PLUG RECEPTACLE. CONTACT PLUG SEALING (is housed in plug) DOUBLE LOCK PLATE FOR PLUG DOUBLE LOCK PLATE FOR CAP CAP TAB.CONTACT RUBBER PLUG

SM0109

E215B-E245B 7.

TROUBLESHOOTING (BY TROUBLE)

When abnormality occurs at intervals When the abnormality situation can not be reoccurred during checking operation, try the following operations. a. Check that variable of display exists or not on the service diagnosis screen while shaking the harness or giving shock by operating the machine. b. Check that variables of resistance and voltage exist or not using tester while shaking the harness. c. Turn starter switch on and apply electricity continuously, and check it again after the temperature of wiring and equipment was raised.

8.

Checking on body grounding Check attaching bolts of grounding terminal for loosening. And also check that there is no loose connection due to corrosion. There are multiple groundings like centralized grounding box shown in the figure and battery grounding, engine grounding, horn grounding fixed together with horn, body grounding placed on attaching section of boom working light. Block of grounding is located under floor plate of cab.

T5-2-32

SM0110

TROUBLESHOOTING (BY TROUBLE) 2.2 TROUBLE 1.

Engine does not stop.

2.

«CPU DATA COMMUNICATION ERROR» is displayed on multi display.

3.

Auto accel does not actuate. (The engine speed does not automatically slow down.)

4.

Auto accel does not actuate. (The engine speed does not automatically speed up.)

5.

Wiper does not function.

T5-2-33

E215B-E245B

E215B-E245B 1.

TROUBLESHOOTING (BY TROUBLE)

Engine does not stop.

No .

Sections

Contents/normal value

Corrective action, others

1

Starter key switch Check signal of starter key switch ON by carrying out service diagnosis.

Check continuity between No.4 K-3 Key switch OFF at starter key switch OFF terminals of starter switch using tester position ON at starter key switch ON position

2

Engine forcible When ON is stop relay displayed with the starter switch OFF, then pull out R-25 engine forcible stop relay and carry out the service diagnosis.

No.4 K-3 Key switch Check on engine forcible OFF at starter key switch OFF stop relay position ON at starter key switch ON position

3

Wiring

2.

Voltage between 0 V when starter switch is OFF line No.62 among starter switch, engine forcible stop relay, enginestop solenoid and the body grounding

Check harness Check diode D-9 between starter switch and auto idling stop relay 1

«CPU DATA COMMUNICATION ERROR» is displayed on multi display.

No .

Sections

Contents/normal value

Corrective action, others

1

Fuse

No.1 fuse (5 A)

Not blown fuse

Check harness Replace fuse

2

Mechatro controller

Accel control

Engine speed varies according to Check mechatro controller and replace as necessary accel potentiometer operation. (Use remote control because the auto accel function is working.)

3

Wiring

See “WIRING Transmission circuit line No.770 PROCEDURE» from mechatro controller to gauge cluster

4

Gauge cluster

Gauge cluster

CHECKING Repair wiring

Replace gauge cluster

T5-2-34

TROUBLESHOOTING (BY TROUBLE) 3. No .

Auto accel does not actuate. (The engine speed does not automatically slow down.) Sections

Contents/normal value

1

Engine coolant Check engine temperature coolant temperature by carrying out service diagnosis.

2

Gauge cluster

3

Low sensor

4. No .

1

E215B-E245B

Corrective action, others

Replace engine coolant No.2 G-5 WATER TEMP Auto accel does not work in the sensor temperature -15 °C or less. Warm up and raise the coolant temperature to – 15 °C or more

Indication of auto Mark «Display/not display» for auto Replace gauge cluster accel accel switches by auto accel switch operation on gauge cluster.

pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor No.6 is in the range of 0~0.1 MPa at control lever neutral position.

Auto accel does not actuate. (The engine speed does not automatically speed up.) Sections

Low sensor

Contents/normal value

Corrective action, others

pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor No.6 is raised with control lever operated.

T5-2-35

E215B-E245B 5.

TROUBLESHOOTING (BY TROUBLE)

Wiper does not function.

Wiping range of forward and reverse movements

Wiper motor Rise up limit switch’s ON range Reverse limit switch’s ON range

Rise up (storing) position Upper reversing position Lower reversing position

SM0111

No.

Sections

Contents/normal value

Corrective action, others

1

Fuse

Check fuse No.20

Replace fuse

2

SW-19: Wiper interlock switch

Service diagnosis No.19 D125 Check wiper interlock switch Wiper switch display (D125) is OFF with front window closed. and repair it if necessary Check according to «WIRING CHECKING PROCEDURE» and repair it if necessary

3

Rise up limit switch Service diagnosis No.25 Wiper system built-in wiper motor Reverse limit switch Switch action in operation

Check according to «WIRING CHECKING PROCEDURE»

Normal condition

4

Rise up limit switch

ON

OFF

OFF

Reverse limit switch

ON

ON

OFF

R-31: Service diagnosis No.25 Wiper system Arc prevention relay When started by forward rotation: STOP START R-29: Arc prevention relay OFF ON ON ON ON Forward rotation Forward rotation relay OFF ON ON ON ON Reverse rotation relay OFF OFF OFF OFF OFF relay Check that the relay is worked as shown in the table. R-30: * When the limit switch does not change in OFF after 4 seconds Reverse rotation from the wiper startup, turn OFF all relay’s outputs. relay

T5-2-36

(STOP)

(STOP)

(REVERSE)

(FORWARD)

OFF

ON

ON

ON

OFF

OFF

OFF

OFF

OFF

OFF

ON

OFF

ON

ON

ON

OFF

OFF

Check that the relay is excited. Check relay & fuse box and replace it if necessary.

ON

TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

E215B-E245B

1. TROUBLE DIAGNOSIS MODE The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal output. 1.

Function There are two types of trouble diagnosis mode. 1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and engine system. 2) Trouble diagnosis mode 2: Used to diagnose pilot system. In any mode, with the attachment not operated, both selector valve and proportional valve are automatically actuated, the sensor detects the machine condition and the mechatro controller identifies the normal condition or failed condition of the system.

2.

How to use and flow chart The operation is performed through gauge cluster. No.1 Select service adjustment select screen. (Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing buzzer stop switch on the service diagnosis screen No.1.) No.2 Select Trouble diagnosis mode (Move the cursor to the desired position with screen change switch «

«, and press the select switch.)

No.3 Select either «DIAG MODE 1» or «DIAG MODE 2» (Move the cursor to the desired position with screen change switch «

«, and press the select switch.)

No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.

T5-3-1

E215B-E245B

No.1

TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

No.2

LANGUAGE/LOGO

No.3

8 FAULT DIAG MODE

ADJUSTING MODE 1 PRESET BY FACTORY

SELECT SWITCH

DIAG MODE 1 DIAG MODE 2

BUZZER STOP SWITCH

FEED

SCREEN CHANGE SWITCH

CASE OF DIAG MODE 1 SENSOR CHECK

CHECK

START ENG

ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA

C-2 00.0M

LOWER BOOM

DIAG MODE 1

RELEASE LOCK LEVER

TO GROUND

About 15 minutes

E-2 005mA D-2 300mA

Turn engine on manually.

BACK TO No.3

RESULT OF DIAGNOSIS

When not failed,

DIAG MODE 1

END

In diagnosis operation

START

ENGINE STOP

RESULT OF DETAIL

DIAG MODE 1

1 P1 UNLOAD

OK

O K DATA END

Engine stops automatically.

FEED

DIAG MODE 1 RESULT 1 P1 UN-LOAD PSV NG P1 UN-LOAD SPOOL NG

DATA END

BACK TO No.3

FEED

The data at the time of judgment can be confirmed with the select switch.

ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA

C-2 00.0M E-2 005mA D-2 300mA

The other judgments can be confirmed with the feed button.

RESULT OF DIAGNOSIS

When failed,

For tthediagnosing Forthe diagnosingitems, items,see seeTable Table 48-1. 1. When Whenrequired requiredto tostop stopin indiagnosis diagnosis operation, operation,press pressthe thebuzzer buzzerstop stopswitch switch and andthe theoperation operationisisforcedly forcedlystopped. stopped.

1 P1 UNLOAD

NG DATA END

FEED

ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA

C-2 00.0M E-2 005mA D-2 300mA

The suspected trouble sections are displayed in order of possibility. The suspected three sections in maximum are displayed. When desired to see other suspected trouble sections, press feed » » button. For diagnosis results and corrective actions to be taken, see Table 2.

SM0114

Notes: 1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. 2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve for possible abnormality. Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis. The preliminary investigation of electric system makes the time saving and high precision diagnosis possible. 3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an example. When multiple troubles are occurred at the same time, there is a case no accordance of diagnosis obtained. In this case, contact our dealer/distributor. 4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring to the trouble history.

T5-3-2

TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

E215B-E245B

No.4 CASE OF DIAG MODE 2 SENSOR CHECK

CHECK

START ENG

ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA

C-2 00.0M

DIAG MODE 2

LOWER BOOM

START

TO GROUND

E-2 005mA D-2 300mA

Turn engine on manually.

AT CONTROL LEVER IS NEUTRAL

Example: Case of boom up WHEN FINISHING OF DIAGNOSIS IS REQUIRED.

BOOM UP

BOOM UP

OK PRESSURE 0.0

MPa

PRESSURE 1.5

MPa

PRESSURE 3.0

BACK TO No.3 MPa

In the normal condition, OK is displayed when the control lever is moved to stroke end.

SM0115

SEARCHABLE OPERATION Boom up Boom down Bucket digging Bucket dump Arm in Arm out Swing Travel right Travel left P1 side option P2 side option

Notes: 1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers. 2. In the case of «DIAG MODE2», pump pressure is unloaded with unload valve in order not to actuate attachment. When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and «UNLOAD PSV NG» is displayed. Check the troubled section according to indication. 3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring to the trouble history.

T5-3-3

E215B-E245B

TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

Table 1 — Failure diagnosis Mode-1/Diagnosis item No.

Display

Contents of diagnosis

1

1 P1 UNLOAD

Is normal pressure generated in the condition that the flow rate at P1 side is minimum and the unloading valve is in the emergency position?

2

2 P1 UNLOAD

Is normal pressure generated in the condition that the minimum flow rate is relieved at P1 side?

3

3 P1 UNLOAD

Is normal pressure generated in the condition that the unload valve is fully opened, and P1 side flow rate is minimum?

4

1 P2 UNLOAD

Is normal pressure generated in the condition that the unload valve is in emergency position, and P2 side flow rate is minimum?

5

2 P2 UNLOAD

Is normal pressure generated in the condition that the minimum flow rate is relieved at P2 side?

6

3 P2 UNLOAD

Is normal pressure generated in the condition that the unload valve is fully opened, and P2 side flow rate is minimum?

7

1 P1 PUMP

Is normal pressure generated in the condition that the flow rate at P1 side is emergency and the unloading valve is in the emergency position?

8

2 P1 PUMP

Is normal pressure generated in the condition that the unload valve is emergency, and P1 side flow rate is minimum?

9

3 P1 PUMP

Is normal pressure generated in the condition that the unload valve is in emergency position, and P1 side flow rate is maximum?

10 1 P2 PUMP

Is normal pressure generated in the condition that the flow rate at P2 side is emergency and the unloading valve is in the emergency position?

11 2 P2 PUMP

Is normal pressure generated in the condition that the unload valve is emergency, and P2 side flow rate is minimum?

12 3 P2 PUMP

Is normal pressure generated in the condition that the unload valve is in emergency position, and P2 side flow rate is maximum?

13 1 TRAVEL-S

Is normal pressure generated in the condition that P1 side flow rate is minimum, unload valve is emergency position and travel straight is stroked fully?

14 2 TRAVEL-S

Is normal pressure generated in the condition that P2 side flow rate is minimum, unload valve is emergency position and travel straight is stroked fully?

15 1 P1 ENGINE

Is rated engine speed obtained in the condition that P1 side flow rate increases little by little when P1 side flow rate is relieved?

16 2 P2 ENGINE

Is rated engine speed obtained in the condition that P2 side flow rate increases little by little when P2 side flow rate is relieved?

Table 2 — Failure diagnosis Mode-1/Diagnosis and Remedy Diagnosis (Display) SENSOR CHECK NG

Possible cause

Remedy

Check each pressure sensor by Disconnection of pressure sensor, Short service diagnosis and replace it if circuit, Abnormal output necessary

Secondary pressure is excessive high against the command Check P1 unload proportional valve P1 UN-LOAD PSV NG Secondary pressure is excessive low and replace it if necessary against the command P1 UN-LOAD SPOOL NG

Stuck at full-stroke side

Check P1 unload spool and replace it if necessary

Stuck at neutral side T5-3-4

TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

E215B-E245B

Table 2 — Failure diagnosis Mode-1/Diagnosis and Remedy Diagnosis (Display)

Possible cause

Remedy

Secondary pressure is excessive high against the command Check P2 unload proportional valve P2 UN-LOAD PSV NG Secondary pressure is excessive low and replace it if necessary against the command P2 UN-LOAD SPOOL NG P1 B-P CUT NG P2 B-P CUT NG

Stuck at full-stroke side

Check P2 unload spool and replace it if necessary

Stuck at neutral side Stuck at closing side

Check P1 by-pass cut valve and replace it if necessary

Stuck at neutral side Stuck at closing side

Check P2 by-pass cut valve and replace it if necessary

Stuck at neutral side

P1 PUMP PSV NG

Secondary pressure is excessive high against the command Check P1 pump proportional valve Secondary pressure is excessive low and replace it if necessary against the command

P1 PUMP NG

Delivery rate is excessive large against the Check P1 pump regulator and command replace it if necessary. Delivery rate is excessive small against the Check P1 pump and replace it if necessary. command

P2 PUMP PSV NG

Secondary pressure is excessive high against the command Check P2 pump proportional valve Secondary pressure is excessive low and replace it if necessary against the command

P2 PUMP NG

Delivery rate is excessive large against the Check P2 pump regulator and command replace it if necessary. Delivery rate is excessive small against the Check P2 pump and replace it if necessary. command

S-TRAVEL PSV NG

Secondary pressure is excessive high against the command Check travel straight proportional Secondary pressure is excessive low valve and replace it if necessary against the command

S-TRAVEL SPOOL NG

Stuck at full-stroke side

Check travel straight spool and replace it if necessary

Stuck at neutral side

PUMP 1 PRESS. SENPressure is recognized lower than it is SOR NG

Check P1 high pressure sensor and replace it if necessary

PUMP 2 PRESS. SENPressure is recognized lower than it is SOR NG

Check P2 high pressure sensor and replace it if necessary

MAIN RELIEF NG ENGINE NG E/G R SENSOR NG

Set pressure decreases

Check main relief valve and replace it if necessary

Set pressure increases Output is lowered

Check engine and replace it if necessary

Characteristics is misaligned

Check engine speed sensor and replace it if necessary

T5-3-5

E215B-E245B

TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

[MEMO:]

T5-3-6

REPAIR INSTRUCTIONS

M0103

REPAIR INSTRUCTIONS

E215B-E245B

SECTION AND GROUP CONTENTS Section 1

GENERAL INFORMATION

Group 1 Group 2

Precautions for Disassembly and Assembly Tightening Torque

Section 2

UPPERSTRUCTURE

Group 1 Group 2 Group 3 Group 4 Group 5

Upperstructure Pump device Control valve Swing device Pilot valve

Section 3

UNDERCARRIAGE

Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7

Swing bearing Travel device Swivel joint Track adjuster Front idler Upper and lower roller Tracks

Section 4

FRONT ATTACHMENT

Group 1

Front attachment

SECTION 1

E215B-E245B

GENERAL INFORMATION

CONTENTS Group 1 — Precautions for Disassembly and Assembly Precautions for Disassembly and Assembly …………………………………… W1-1-1

Group 2 — Tightening Torque Torque Chart …………………………………… W1-2-1 Piping Joint……………………………………… W1-2-4

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

E215B-E245B

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY PREPARATIONS FOR DISASSEMBLY — Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work. — Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. — Check and record the items listed below to prevent problems from occurring in the future. 1. The machine model, machine serial number, and hour meter reading. 2. Reason for disassembly (symptoms, failed parts, and causes). 3. Clogging of filters and oil, water or air leaks, if any. 4. Capacities and condition of lubricants. 5. Loose or damaged parts. — Prepare the necessary tools to be used and the area for disassembling work. — Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves. — Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency measure and ambulance to prepare for accidents and fire. — Attach «Don’t operate» tag to control lever, and begin a meeting before starting the work. DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT — Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return side to tank, and take out the filter. — Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground. — Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.

— If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified through service training. — Make match mark on parts for reassembling. — Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and assembly are permitted or not. — For parts which are required to use jig and tools, don’t fail to use the specified jig and tools. — For parts which can not be removed in the specified procedure, never force removal. First check for the cause. — Inspecting parts. Measure the wear of parts and clearance, and record the measured values. — If an abnormality is detected, repair or replace the parts. — The removed parts should be put in order and tagged so as to install on proper places without confusion. — For common parts, pay attention to the quantity and places. REASSEMBLING HYDRAULIC EQUIPMENT — During the parts cleaning, ventilate the room. — Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them. — Replace the removed O-ring, back-up rings and oil seal with new ones, and apply gear oil on them before assembling. — Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid sealant on them. — Before assembling, remove rust preventives on new parts. — Use special tools to fit bearings, bushing and oil seal. — Assemble parts matching to the marks. — After completion, check that there is no omission of parts.

— Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before putting them on working. DISASSEMBLING HYDRAULIC EQUIPMENT — Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from responsibility on the manufacture’s side, disassembly, assembly and modification without permission are strictly prohibited. W1-1-1

E215B-E245B

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

INSTALLING HYDRAULIC EQUIPMENT — Confirm hydraulic oil and lubrication oil. — Bleeding Air from Hydraulic System Air release is required in the following cases: 1. Change of hydraulic oil 2. Replacement of parts on suction pipe side 3. Removing and attaching hydraulic pump 4. Removing and attaching swing motor 5. Removing and attaching travel motor 6. Removing and attaching hydraulic cylinder IMPORTANT: if hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged. — For air bleed of hydraulic pump and swing motor, loosen drain plug on the upper part, start engine, and run in low idling, then bleed air until hydraulic oil is comes out. After completion of comes, tighten plug securely. — For air bleed of travel motor and hydraulic cylinder, starts engine and operate it for 10 minutes or more at no-load and low speed. IMPORTANT: for cylinder, don’t move it to the stroke end at beginning. — Air in pilot circuit can be bleed out by only operating digging, swing and travelling motions thoroughly. — Check hydraulic oil level. Move attachments to hydraulic oil check position, as indicated in the figure. — Open the hydraulic pump compartment door, then check the oil level on visual indicator (1) located on the hydraulic oil reservoir. If the indicator is within level marks, the oil quantity is acceptable.

W1-1-2

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

E215B-E245B

Floating Seal Precautions 1.

In general, replace the floating seal with a new one. If the floating is to be reused, follow these procedures:

A

1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. 2) Check the seal ring face (A) for scuffing, scoring, corrosion, deformation or uneven wear. 3) Check O-Ring (B) for tears, breaks, deformation or hardening. 2.

B

If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble.

SM0172

1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air. 2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it. 3) Check that the O-Ring is not twisted, and that it is installed correctly on the seal ring. 4) After installing the floating seal, check that seal ring surface (C) is parallel with mating face (A) by measuring the distances (a) and (b), as illustrated. If these distances differ, correct the O-Ring (B) seating.

RIGHT

WRONG

SM0173

RIGHT

WRONG a

A

a

C B

b

b a=b

W1-1-3

a≠b

SM0174

E215B-E245B

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

ELECTRICAL EQUIPMENT — The disassembly of electrical equipment is not allowed. — Handle equipment with care so as not to drop it or bump it. — Connector should be removed by unlocking while holding the connector. Never stress in tension to the caulked section by pulling wire. — Check that connector is connected and locked completely. — Engine key off before removing and connecting connector. — Engine key off before touching terminals of starter and alternator. — Wash machine with care so as not to splash water on electrical equipment and connector. — When water has entered in the waterproofed connector, the removing of water is not easy. So check the removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before connecting. — Remove battery grounding terminal before beginning work close to battery and battery relay with tools.

WARNING Battery fluid is dangerous. The battery fluid is dilute sulfuric acid, and causes scald and loss of eyesight by adhering on eyes, skin and clothes. When the fluid has adhered on them, take an emergency measure immediately and see a doctor for medical advice. — When it has adhered on skin: wash with soap and water. — When it has got in eyes: wash in water for 10 minutes or more immediately. — When it was swallowed: drink milk or water.

W1-1-4

TIGHTENING TORQUE TORQUE CHART

WARNING Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use the correct tools. Avoid bodily injury caused by slipping wrenches. Bolt Types Tighten nuts or bolts correctly to torque specifications. Two kinds of bolts, hexagon bolts T and socket bolt, each made of different material, are used. Make sure to employ the correct bolts and tighten them to specification when assembling the machine or components. Hexagon T Bolt

Socket Bolt

SM0175

Specified Tightening Torque Chart

Bolt Dia.

Wrench Size

Hexagon Wrench Size

T Bolt, Socket bolt (Nm)

M18

13

6

29.5

M10

17

8

64

M12

19

10

108

M14

22

12

175

M16

24

14

265

M18

27

14

390

M20

30

17

540

M22

32

17

740

M24

36

19

930

M27

41

19

1370

M30

46

22

1910

M33

50

24

2550

M36

55

27

3140

W1-2-1

E215B-E245B

E215B-E245B

TIGHTENING TORQUE

IMPORTANT 1.

Apply lubricant (i. e. white zinc B dissolved into spindle oil) to nuts and bolts to stabilize their friction coefficients.

2.

Torque tolerance is ± 10%.

3.

Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force.

4.

The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application.

5.

Make sure that the nut and bolt threads are clean before installing. Remove dirt or corrosion, if any.

Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.

Equally tighten upper and lower alternately

Tighten diagonally 1

1.4

12

9

4

1

6

7

14

13

8

5

2

3

10

11

3

6 2.3

Tighten from center and diagonally

5

4 2

SM0176

W1-2-2

TIGHTENING TORQUE

E215B-E245B

Service Recommendations for Split Flange IMPORTANT 1.

Be sure to clean and inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component.

2.

Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file Oring surfaces. When installing an O-ring into a groove, use grease to hold it in place.

3.

Loosely assemble split flange halves. Make sure that the split is centrally located and perpendicular to the port. Hand-tighten the bolts to hold the parts in place. Take care not to pinch the O-ring.

4.

Tighten bolts alternately and diagonally, as shown, to ensure even tightening.

5.

Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to Orings or uneven tightening of bolts.

SM0177

WRONG

SM0178

Nut and Bolt Lockings •

SM0179

Lock Plate

IMPORTANT: do not reuse lock plates. Do not try to bend the same point twice. •

Cotter Pin

IMPORTANT: do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening. •

WRONG

RIGHT

Do not bend it round

Bend along edge sharply

RIGHT

RIGHT

WRONG

Lock Wire

IMPORTANT: apply wire to bolts in the bolttightening direction, not in the bolt-loosening direction. Bend along edge sharply

RIGHT

RIGHT Tighten

SM0180

WRONG

RIGHT

WRONG Loosen

SM0181

W1-2-3

E215B-E245B

TIGHTENING TORQUE

PIPING JOINT Pipe Thread Connection / Union Tightening Torque Specifications

Joint

4

1

5

3

2

Union Joint Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. Joint Body

SM0182

IMPORTANT 1.

2.

Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to specifications.

37° 37°

Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting /disconnecting.

Male Union Joint

Female Union Joint SM0183

Type 37° Union Joint

Wrench Size

Tightening Torque

Union Nut

Joint Body

(Nm)

19

17

29

22

19

39

27

22

78.5

36

30, 32

157

41

36

205

50

46

323.6

NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.

W1-2-4

TIGHTENING TORQUE

E215B-E245B

O-Ring Seal Joint O-Ring (6) seats against the end face of adaptor (7) to seal pressure oil.

7

9

6

IMPORTANT 1.

Be sure to replace O-Ring (6) with a new one when reconnecting.

2.

Before tightening union nut (9), confirm that ORing (6) is seated correctly in O-Ring groove (8). Tightening union nut (9) with O-Ring (6) displaced will damage O-Ring, resulting in oil leakage.

3.

Take care not to damage O-Ring groove (8) or sealing face (10). Damage to O-Ring (6) will cause oil leakage.

4.

If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-Ring (6) with a new one, then tighten union nut (9) after confirming that O-Ring (6) is securely seated in place.

Wrench Size

Tightening Torque

Union Nut

Joint Body

(Nm)

19

17

29.4

22

19

68.6

27

22

93

30

27

137.3

36

30

175

41

36

205

50

46

320

W1-2-5

8

10

Joint body SM0184

E215B-E245B

TIGHTENING TORQUE

Screwed-In Connection IMPORTANT: many types of screwed-in connections are used for hose connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. Male Tapered Thread

PT

PF 30°

Male Tapered Thread

Wrench Joint Body

Tightening Torque (Nm)

17, 19

34

22

49

27

93

36, 32

157

41

205

50

320

60

410

Male Straight Thread SM0185

Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap. •

Internal Thread

Clearance External Thread

SM0186

Application Procedure Confirm that the thread surface is clean, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.

Leave one to two pitch threads uncovered

Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. See below for correct tightening torque of each type of low-pressure-hose clamp.

SM0187

T-Bolt Type

Worm Gear Type

T-Bolt Type Band Clamp: 4.4 Nm (0.45 kgf m) Worm Gear Type Band Clamp: 5.9 a 6.9 Nm (0.6 a 0.7 kgf m)

SM0188

W1-2-6

SM0189

TIGHTENING TORQUE

E215B-E245B

Connecting Hose WARNING 1.

When replacing hoses, be sure to use only genuine parts. Using hoses other than genuine hoses may cause oil leakage, hose rupture or separation of fitting, possibly resulting in a fire on the machine.

2.

Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leakage, hose rupture or separation of fitting. Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked.

3.

If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care that hoses do not come into contact with moving parts or sharp objects.

RIGHT

WRONG

SM0190

WRONG

RIGHT

Rubbing Against Each Other

SM0191

RIGHT

WRONG Clamp

Clamp

Rubbing SM0192

WRONG

RIGHT

Rubbing Clamp SM0193

W1-2-7

E215B-E245B

TIGHTENING TORQUE

NOTE:

W1-2-8

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

1

3 2

SM0259

Disassembly and assembly of cover (1) and cover assy (2)

9

3 5

10 7

4

10

6

5 10 4

8

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.

9

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 (lbf·ft)

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.

1

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.

2

: 46 mm

4.

SM0264

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

3 5 6 7

4

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.

2

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.

7

: 46 mm

4 5.

Remove wire rope. Tighten the bolts (4) with a power wrench and torque wrench.

SM0265

1

: 46 mm : 1570+200 Nm -100

6.

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

4

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 Tightening torque: 177 Nm

4.

Disconnect the two hose (6). (F Port: PF1/4) : 19 mm Tightening torque: 29.4 Nm

A

B

C

D

B

F

F

F

E

D

F

D

F

C B A

E

E SM0268

W2-1-6

UPPERSTRUCTURE

E215B-E245B

SWIVEL JOINT LOWER SIDE HOSES

2

4

5

3

6

A

A

6

4

6

5

3

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

2

Attach two chain blocks (4) to the boom foot side.

1

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

M

5 SM0271

W2-1-8

UPPERSTRUCTURE 5.

E215B-E245B

Remove the 32 bolts (5) M20x100, the reamer bolt (6) M20, from the swing bearing.

A

: 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 Tightening torque: 392 Nm

5.

19,5°

X

Apply Loctite # 262 onto thread of reamer bolts (6) then, install reamer bolt. : 30 mm Tightening torque: 392 Nm

(*)

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. 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.

3.

Preparation 1.

Park the machine on a firm, level surface..

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure “Releasing the hydraulic pressure” at page T21-47.

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.

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

9

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

6

467

885 886

7

5

466

211

885

312 886 710

6

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 M20×210 (Q.ty Socket bolt M8×20 (Q.ty 4)

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

—

Socket bolt M6×55 (Q.ty 3) Socket bolt (Q.ty 2) Socket bolt (Q.ty 2) Socket bolt (Q.ty 2) Plug VP PF 1/4 (Q.ty 2) Plug VP PF 3/8 (Q.ty 2) Plug VP PF 3/4 (Q.ty 4) Plug nptf 1/16 (Q.ty 27) Tilt Pin m24×2 (Q.ty 2) Servo piston M24×2 (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 M16×30 (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).

5

435

: 8 mm SM0278

3.

Removing regulator. Remove the socket bolts (412) e (413), then remove regulator (9). : 6 mm

9

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

9

: 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

5

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

B

622

D

F

874 613

875 612

652

875

814

654

643

G

836 653

646 644

A

651

E

C

897

655

728

645

611

438

630

629 802 756

763

628

924 412 413

656 757

438

Y 418

D

X

E 601

722

496

755

W

Z

079 041 755

466

734 887

876 615

439

A

B

642 755

C

724 730 725

F 876

8-724 041 755

466

641

755

755 858

G

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 Socket bolt M8×50 (Q.ty 2) Socket bolt M8×70 (Q.ty 2) Socket bolt M5×12 (Q.ty 2) Socket bolt M6×20 (Q.ty Socket bolt M6×25 (Q.ty 5) 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 M30×1.5 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 (lbf·ft)

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 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 Ø 4×11.7 L Pin Ø 4×8 L (Q.ty 2) Pin Ø 5×8 L (Q.ty 2) Pin Pin Ø 4×19 L Pin Ø 7.5×11 L Socket bolt M8×20

E215B-E245B

PUMP DEVICE

Disassembly of regulator 1.

Proceed with disassembly operations in a clean place. Spread rubber sheet or cloth on work bench to protect parts from damaging.

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 (Ø 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 Socket bolt M10×20 (Q.ty 2)

SM0519

435 468 711 728 825 826 885 886

W2-2-21

—

Flange socket M10×20 (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.

Proceed with disassembly operations in a clean place. Spread rubber sheet or cloth on work bench to protect parts from damaging. 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.

1

2

: 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. 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.

3.

Preparation 1.

Park the machine on a firm, level surface.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure “Releasing the hydraulic pressure” at page. T21-47.

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.

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).

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

2

NOTE: control valve assembly mass: 232 kg.

4.

2

2

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.

1

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 (lbf·ft) Nm (lbf·ft) 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)

A

B

H

273×10

T2

P1 unload (Travel priotity)

Travel right

273×10

H

Travel left

C

USE FOR YN30V00101F1

C

PAL

PCb

PAr

PB1

Boom conflux (P2 unload)

D

D PBs

Boom

Swing

E

PBb

PCc

E

Pss

PBa1

Bucket

Arm 1

F

F PAo PA

PBa2

Arm 2

Option

MU

G

G K (P3)

PBp1

PBp2

K A

B

PAo

PBa2

PBp1

PBp2

274×4

275×4 (P4)

(P3)

213

212

PAa2

273×10

W2-3-5

PBo

273×10

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 N•m (lbf•ft)

No.

Parts Name

Q.ty

Tightening torque N•m (lbf•ft)

E215B-E245B

No.

Parts Name

Q.ty

101 Casing A

1

321 Spring

102 Casing B

1

322 Spring

4

3

323 Spring

3

220~250 (162~184) 154 Plug PF3/4

5

110~130 (81~96)

155 Plug PF1/2

2

324 Spring

3

20~24 (15~18)

159 Plug PT1/4

1

325 Spring

1

7.8~9.8

160 Plug PT1/16

5

326 Spring

1

161 O-ring

7

327 Spring

3

162 O-ring

15

328 Spring

1

163 O-ring

11

329 Spring

3

164 O-ring

19

331 Spring seat

24

333 Spacer bolt

12

169 O-ring 9,8~14 (7.2~13)

2

171 Socket bolt

336 Stopper

10

201 Cover

5

339 Stopper

1

202 Cover

4

340 Stopper

1

203 Cover

1

511 Poppet

11

204 Cover

1

205 Cover

7

512 Poppet

2

1

514 Poppet

2

1

515 Poppet

1

209 Cover

1

517 Boost check valve

1

211 Lock valve selector sub

2

518 Poppet

1

212 Plate

1

521 Spring

11

206 Cover Back pressure 207 valve cover 9.8~14 (7.2~13)

16~18 Loctite #262

check

213 Plate

1

522 Spring

2

215 Boom dowering valve

1

523 Spring

1

216 Piston

1

524 Spring

2

261 O-ring

12

527 Spring

1

264 O-ring

10

266 O-ring

4

528 Spring

1

25~34 (18~25)

273 Socket bolt

40

98~120 (72~89)

274 Socket bolt

4

98~120 (72~89

275 Socket bolt

4

25~34 (18~25)

278 Socket bolt

5

9.8~14 (7.2~13)

279 Socket bolt

3

301 Boom spool sub

1

302 Arm 1 spool 303 Swing spool

230~260 (170~192) 551 Plug 130~150 (96~111)

13

552 Plug

2

230~260 (170~192) 556 Plug

3

562 O-ring

2

69~78 (51~58)

601 Main relief valve

1

1

69~78 (51~58)

602 Over load relief valve

2

1

69~78 (51~58)

603 Over load relief valve

3

304 Bucket spool

1

69~78 (51~58)

604

305 Boom conflux spool

1

69~78 (51~58)

605 Over load relief valve

1

306 Travel spool

2

98~120 (72~89)

606 By-pass cut valve

2

307 Travel priority spool

1

140~180 (103~133) 973 Socket bolt

8

308 Arm 2 spool sub

1

140~180 (103~133) 974 Socket bolt

2

309 P1 unload spool

1

310 P2 unload spool

1

311 Option spool

1

W2-3-11

Plug assy for relief valve hole

2

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

1

b

Box and wrench

1 of each size

c

Allen wrench

1 of each size

d

Spanner

1

e

Loctite # 262

1

f

Spatula

1

g

Pincers

1

h

Adjustable wrench

1

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) 2.1 Loosen the socket bolts (273) and remove 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). IMPORTANT: when drawing out the spool assy, 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).

IMPORTANT: when drawing out the spool assy, use care so as not to score casing A (101).

SM0545

3.3 Fix the boom conflux spool with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (325), (326) and stopper (339) from boom conflux spool (305).

SM0546

4.

Disassembling the boom spool 4.1 Loosen socket bolts (273) and remove spring cover (203) for boom spool and Oring (261), (266). 4.2 Draw out the assy of boom spool (301), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing B (102).

IMPORTANT: when drawing out the spool assy, 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 protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from boom spool (301). Do not disassemble boom spool (301) further unless there is special reason.

SM0548

5.

Disassembling the swing spool 5.1 Loosen the socket bolts (273) and remove 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), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing A (101).

IMPORTANT: when drawing out the spool assy, use care so as not to score casing A (101).

SM0549

5.3 Fix the swing spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from swing spool (303).

SM0550

W2-3-16

CONTROL VALVE 6.

E215B-E245B

Disassembling bucket spool 6.1 Loosen socket bolts (273) and remove bucket spring cover (209) and O-ring (261).

SM0801

6.2 Draw out the assy of bucket spool (304), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing B (102). IMPORTANT: when drawing out the spool assy, use care so as not to score casing B (102).

SM0802

6.3 Fix the bucket spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (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).

IMPORTANT: when drawing out the spool assy, use care so as not to score 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 8.1 Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 2 spool. 8.2 Draw out the assembly which is consist of 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 protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (321, 328) and stopper (340) 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 9.1 Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of option spool. 9.2 Draw out the assembly which is consist of option spool (311), spring seat (331), spring (323, 324), stopper (336) and bolt (333) from casing A (101).

IMPORTANT: when drawing out the spool assy, use care so as not to score casing A (101).

SM0808

9.3 Fix the option spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (323, 324) and stopper (336) from option spool (311).

SM0809

10. Disassembling travel straight spool 10.1 Loosen the socket bolts (273) and remove 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). IMPORTANT: when drawing out the spool assy, 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 11.1 Loosen socket bolts (273), and remove spring cover (202) of P2 unload spool and O-ring (261). 11.2 Draw out the assembly which is consist of P2 unload spool (310), spring seat (331), spring (327, 329), stopper (336) and bolt (333) from casing A (101). IMPORTANT: when drawing out the spool assy, use care so as not to score 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 poppet (511) and spring (523). 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 Remove plug (551) and then remove poppet (515) and spring (521).

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. Remove plug (556) and then remove poppet (514) and spring (524). 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 Remove plug (552) and then remove poppet (512) and spring (522). 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 Attach poppet (511) and spring (523) in place, place O-ring (164) in plug (556) and tighten them to the specified torque. (1 place)

3.

Load check valve of arm 2 section Attach poppet (515) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified torque. (1 place)

4.

Lock valve section Attach poppet (514) and spring (524) in place, place O-ring (164) in plug (556) and tighten them to the specified torque. (2 places)

5.

Main relief valve section Attach poppet (512) and spring (522) in place, place O-ring (562) in plug (552) and tighten them to the specified torque. (2 places)

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, 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 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.

apply Loctite #262 when tightening bolt (333). 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 tighten socket bolt (273) to the specified torque.

Assembling arm 2 spool 1.

Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (328) and stopper (340) and tighten bolt (333) to the specified torque.

NOTE: • • 2.

apply Loctite #262 when tightening bolt (333). 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 socket bolt (273) to the specified torque.

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: • •

apply Loctite #262 when tightening bolt (333). 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 tighten socket bolt (273) to the specified torque.

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.), fit spring seat (331), springs (321), (322) 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 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 tighten socket bolt (273) to the specified torque.

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.), fit spring seat (331), springs (321), (322) 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 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 and tighten socket bolt (273) to the specified torque.

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.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.

NOTE: • apply Loctite #262 when tightening bolt (333). • 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 and tighten socket bolt (273) to the specified torque.

Assembling boom conflux spool 1.

Hold the mid section of boom conflux spool (305) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (325), (326) and stopper (339) and tighten bolt (333) to the specified torque.

NOTE: • apply Loctite #262 when tightening bolt (333). • 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 and tighten socket bolt (273) to the specified torque.

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.), fit spring seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) to the specified torque.

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 socket bolt (273) to the specified torque.

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, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.

NOTE: • apply Loctite #262 when tightening bolt (333). • 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 tighten socket bolt (273) to the specified torque.

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 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 1.

Park the machine on a firm, level surface.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure “Releasing the hydraulic pressure” at page T21-47.

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.

W2-4-1

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.

4

5

: 27 mm 3.

1

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.

8

8

7

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.

8

8

7

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

5

: 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

1

21 31 2 15 3 17 13-14 19 43 38

16 A

43

29

42

A

12 30 32 37

35 36 4

41 25

26

24

6 40

8 9

7

A-A

45 18 11

28

5

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.tà: 4) Swing motor casing Valve casing Plunger (q.ty 2) Spring (q.ty 2) Swing shockless valve (q.tà: 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).

3

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

7

8

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.

5

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).

8

6

9

7

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

8

7

4

19

2

28

16

6 20 3

10

15

12

18 17 5 9

23

22

31 32 25

26

13 24 27

21

11

1

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: 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

7

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.

2

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

4

8

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

1

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.

3

15

16 28

13. Disassembling #2 spider assy performing the following operations. 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

8

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

1

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 means of special tool (xxxxxxxxx).

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 means of special tool (xxxxxxxxx).

1

E215B-E245B

xxxxxxxxx

10

11. Attach retaining ring (20). 12. Assemble #1 Spider assy performing the following operations. 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

3

16 28

15

15

SM0733

W2-4-15

E215B-E245B

SWING DEVICE

13. Assemble #2 Spider assy performing the following operations.

A

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

8

9

18 5

15. Install #2 sun gear (4) directing the spline upward.

17

A 22 SM0734

8

SM0735

4

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.

x

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

7

2

3

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.

6

: 12 mm

SM0738

: 181 Nm 23

x x

25 27

SM0739

W2-4-17

E215B-E245B

SWING DEVICE

MAINTENANCE STANDARDS Swing motor

Unità: mm (poll.) Item

Standard dimension (mm)

Recommended value for replacement (mm)

0.027

0.052

0

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)

D

Replace piston or cylinder.

d

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

0.8—Z (Ra=0.2) (lapping)

3—Z (Ra=0.8)

Shoe plate

0.4—Z (Ra=0.1) (lapping)

3—Z (Ra=0.8)

Cylinder

1.6—Z (Ra=0.4) (lapping)

12.5—Z (Ra=3.2)

Valve plate

0.8—Z (Ra=0.2) (lapping)

6.3—Z (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

F

SM0740

Code

Item

Repairable level (mm)

A

Wear in #1 planetary shaft

0 Ø 39 -0.011

Wear in #2 planetary shaft

0 29 -0.009

Service Limit (mm)

No flaking B

Ø

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

C

Gears

D

Thickness of thrust washer

0 1,6-0.2

1.3

Replace

E

Thickness of thrust washer

0 2.0-0.2

1.6

Replace

F

Wear in shaft (diameter of part coming in contact with oil seal)

Ø 94.9

Replace

0 Ø 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 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. 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 1.

Park the machine on a firm, level surface.

“Releasing the hydraulic pressure” at page. T21-47.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure

3.

Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual 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.

7

: 5 mm

: 11.8 Nm (8.7 lbf·ft) 2.

7

Connect hoses to pilot valve body (9).

: 19 mm (Port: P)

3

3

60

: 29.4 Nm (22 lbf·ft) : 22 mm (Port: 1 to 8, T)

LEFT SIDE

: 49 Nm (36 lbf·ft) 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

2

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 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. 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 1.

Park the machine on a firm, level surface.

“Releasing the hydraulic pressure” at page. T21-47.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure

3.

Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual 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 lbf·ft)

2.

Connect pipes (from 3 through 6) to body (8). : 19 mm : 16.7 Nm (12.3 lbf·ft) : 22 mm : 30 Nm (22.0 lbf·ft)

3.

Connect pressure sensors (7) to body (8).

: 24 mm

: 16.7 Nm (12.3 lbf·ft) 4.

Install the levers tightening securing screws (2) and the pedals tightening securing screws (1).

: 17 mm : 46.1 Nm (34.1 lbf·ft)

: 13 mm

: 23.5 Nm (17.4 lbf·ft)

5.

Install the cover under the cab : 19 mm : 108 Nm (80.0 lbf·ft)

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 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” 1÷4 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) è 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 seat 2 (Q.ty 2) Spring seat 1 (Q.ty 2) Spring seat 2 (Q.ty 2) Spring seat 1 (Q.ty 2) 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 : 47.1±2.9 Nm (34.8±2.1 lbf·ft)

(

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 : 68.6±4.9 Nm (50±3.6 lbf·ft) : 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

O

T

7

U

X W 7

L 7 N 7 K

X W 7

M

X

W

U

T 7

/RFWLWH U

]

Z

7 aa 60

No.

Parts

NOTE: T=tightening torque Nm (lbf·ft) Q.ty No. Parts

5

Rubber boots

6

Foot pedal (Switch plate)

2 (2)

Q.ty

12-x Seal ø14×20×3

6

12-y Wiper ring

6

6-d

Switch plate

2

13

Damper spring

4

6-f

Regulation screw M8×28

4

14

Check valve kit

(2)

6-g

Set screw M5x8

4

14-q Plug M8

2

6-l

Damping screw

4

14-r Ball M6, 35

2

7

Retaining plate kit

7-h

Plate

7-i 7-j 7-k

(1)

15

Orifice

1

15-u Plug M6

Capscrew M10×20

2

15-t Orifice M6, ø0.6

Shaft

2

17

(4) 4 4

Shuttle valve kit

(2)

17-w’ Shuttle valve & orifice

2

Set screw M4×10

2

8

Flange kit

4

17-r Ball M6, 35

10

Control spool

4

17-z Orifice M5, ø0.8

11

Return spring

4

21

Plug

4

12

Damper flange kit

(4)

22

Valve body

1

12-o Damper plunger ø14

4

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 lbf·ft) 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 &

I

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 : • Apply a droplet of Loctite #262 on the locking screw thread. • Torque: 3 Nm 2.2 (lbf•ft) 2) Set the switch plate (6) horizontally 3) Screw on simultaneously both regulation screws (6-g) using a flat screw driver (5.5×150) 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 • The pilot control unit from the machine • 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 : • Apply a droplet of Loctite #262 on the screw thread. • Torque: 30 Nm (22 lbf•ft)

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). 4) Reassemble parts in reverse order. 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. Reassemble parts in reverse order. 6.

E215B-E245B

[

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[

&

‘

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.

Reassemble parts in reverse order.

60

7.

Throttle kit replacement 1) Remove • The pilot control unit from the machine • 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: • Apply a droplet of Loctite #262 on the 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: • Torque: 4 Nm (3 lbf•ft) 4) Repeat the operation for the other 3 assemblies. 5) Replace with new screws (15-u) and new throttles (15-t). 6) Reassemble parts in reverse order.

X

W 60

8.

Shuttle valve kit removal (17) 1) Remove the pilot control unit from the machine

NOTE: the pilot control unit does not need to be 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. • Apply a droplet of Loctite #242 on the shuttle valve thread (17-w). • Torque: 4 Nm (3 lbf•ft) 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. 7) Reassemble parts in reverse order.

60

W ]

Z

60

9.

Check valve kit removal (14) 1) Remove the pilot control unit from the machine

T

NOTE: the pilot control unit does not need to be 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 lbf•ft) 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. 6) Reassemble parts in reverse order.

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 lbf•ft)

8.

Repeat the operation for the other check valve plug.

T

W2-5-21

60

E215B-E245B

PILOT VALVE

NOTE:

W2-5-22

SECTION 3

E215B-E245B

UNDERCARRIAGE

CONTENTS Group 1 — Swing bearing Removal and installation of swing bearing ………………………………………….. W3-1-1

Group 2 — Travel device

Tool table ……………………………………….. W3-5-4

Group 6 — Upper and lower roller Removal and installation of upper roller ……………………………………………… W3-6-1

Removal and installation of travel device (E215B) ………………………………. W3-2-1

Removal and installation of lower roller ……………………………………………… W3-6-4

Disassembly travel device ……………….. W3-2-2

Upper roller disassembly…………………… W3-6-7

Disassembly and assembly of travel device (E215B) ……………………………… W3-2-3 Maintenance standard …………………. W3-2-61 Sprocket…………………………………….. W3-2-61

Upper roller assembly ………………………. W3-6-7

Removal and installation of travel device (E245B) ………………………………. W3-2-63 Disassembly procedure of travel device (E245B)…………………………………………. W3-2-67 Assembling procedure of travel device (E245B)…………………………………………. W3-2-80 Motor……………………………………………… W3-2-88 Tool table ……………………………………….. W3-2-98

Group 3 — Swivel joint Removal and installation of swivel joint . W3-3-1 Swivel joint disassembly and assembly . W3-3-4 Maintenance standard ……………………… W3-3-9

Group 4 — Track adjuster Removal and installation of track adjuster (with front idler) ………………………………. W3-4-1 Disassembly and assembly track adjuster …………………………………………. W3-4-2 Tool table ……………………………………….. W3-4-6

Group 5 — Front idler Disassembly and assembly front idler assy………………………………………………. W3-5-1 Maintenance standard ……………………… W3-5-4

Lower roller disassembly…………………… W3-6-11 Lower roller assembly ………………………. W3-6-13 Maintenance standard………………………. W3-6-15 Tool table ……………………………………….. W3-6-16

Group 7 — Tracks Removal and installation of tracks ……… W3-7-1 Maintenance standard………………………. W3-7-5 Tool table ……………………………………….. W3-7-7

SWING BEARING

E215B-E245B

REMOVAL AND INSTALLATION OF SWING BEARING WARNING Wear close-fitting clothing and safety equipment appropriate to the job. Use tools appropriate for the job to be performed. Always ensure that slings and chains used for lifting are adequate to the load and in good condition. Before removing the swing bearing, the upperstructure must be removed first. For removal and installation of the upperstructure, refer to “Remove and Install Main Frame” section. In this section, the procedure starts on the premise that the upperstructure has already been removed. Removal 1.

$

Put alignment marks on (A) swing bearing (1) and track frame (2).

60

2.

Remove screws M20 (3) (Q.ty 36) and the relevant washers (Q.ty 36). : 30 mm

60

IMPORTANT — Swing bearing weight: 251 kg (553 lbs). 3.

Attach lifting tools (380001026), hoist swing bearing (4) and remove it.

60

W3-1-1

E215B-E245B

SWING BEARING

Installation Clean the matching surfaces of swing bearing and the frame. 1.

Apply THREEBOND 1102 to the matching surfaces of swing bearing and track frame.

IMPORTANT — Swing bearing weight: 251 kg (553 lbs).

60

IMPORTANT — Inner race soft zone (S) and the ball filler port should be placed on the same position (right side of the frame). 2.

$ 6

Hoist the swing bearing. Align the swing bearing with the alignment mark on the track frame and install the swing bearing.

% NOTE — Apply Loctite #262 on the thread of the screws (3) before assembling. 60

A: Front Side B: Position of Plug

3.

Install screws M20 (3) (Q.ty 36) with the relevant washers (Q.ty 36) and tighten them to the prescribed torque. : 30 mm : 563 ± 56 Nm (415 ± 41 lbf·ft)

NOTE — Fill in greasebath with 8.6 ±0.86 kg of IP BIMOL 481 or equivalent grease.

60

TOOL TABLE TOOL NO.

DESCRIPTION

380001026

Lifting tools slewing ring

W3-1-2

TRAVEL DEVICE

E215B-E245B

REMOVAL AND INSTALLATION OF TRAVEL DEVICE (E215B) 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. 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 1.

Park the machine on a firm, level surface.

3.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure «Releasing the hydraulic pressure» at page. T2-1-47.

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. Removal The procedure starts on the premise that the track link has already been removed. 1.

2.

Loosen bolts M12 (7) to remove cover (6). Disconnect hoses (2), (3), (4) and (5). : 19 mm : 29.4 ±5 Nm (21.7 ± 3.7 lbf·ft) : 27 mm : 78.5 ±5 Nm (57.9 ± 3.7 lbf·ft) : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf·ft)

Attach the travel device to a crane using a wire rope. Remove any slack from the wire rope so as to secure the travel device when the mounting bolts are removed.

NOTE: Travel device weight: Approx. 300 kg (661.5 lbs). 3.

NOTE: Install caps on all disconnected hose and line ends.

W3-2-1

Remove bolts M16 (1). Remove the travel device using the crane. : 24 mm : 279 ±29 Nm (206 ± 21 lbf·ft)

E215B-E245B

TRAVEL DEVICE

DISASSEMBLY TRAVEL DEVICE

Installation 1.

Install the travel device using bolts (1).

2.

Connect hoses (2), (3), (4) and (5).

3.

Install cover (6) and fix it with screws (7) and washers (8) and (9). : 19 mm : 83.4 ±8.4 Nm (61.5 ± 6.2 lbf·ft)

Preliminary operations

IMPORTANT — After completing travel motor installation, be sure to fill the travel motor with hydraulic oil. After completing installation of the travel motor or the travel device, be sure to perform test driving to prevent motor seizure. Test drive as follows: 1. Run the engine with the engine control dial in the slow idle position. 2. Turn the travel speed mode switch to the slow speed position. 3. Test drive the machine back-and-forth for 0.5 m to 1 m in each direction five times or more.

In the case that it was necessary to undergo a (partial or total) revision, it will be necessary to dismount the gearmotor from the machine. As this is known as an out of the ordinary maintenance procedure, it is important that only personnel with specific skills and experience undertake it. It is also important that this procedure is undertaken in a workshop that is adequately tooled. As well as normal workshop tools it will be necessary to use special tools. In the following pages all the procedures for disassembling and reassembling the gearmotor are given, it is important to strictly adhere to them. Proceed with these operations using all the necessary safety measures, like for example: 1.

Cutting off all the hydraulic system connections on the gearmotor to avoid the introduction of any foreign parts in the circuit and the gearmotor.

2.

Making sure that the coupling surfaces are not damaged.

3.

Following the handling so as to be sure that there are no risks for human safety and to guarantee the reliability of the gearmotor.

4.

Making available a work area that is in line with work and health safety in the workplace guidelines.

5

4

3 2

8

1 6

7 9

NOTE: Initial inspection of hydraulic motor and gears, can be made without disassembling the track drive from the machine.

SM0300

Initial inspection of the gears, can be made without disassembling the track and the track drive from the machine. Before track drive disassembling, make sure that the oil is discharged.

W3-2-2

TRAVEL DEVICE

E215B

DISASSEMBLY AND ASSEMBLY OF TRAVEL DEVICE (E215B) Gearbox disassembling method By using a tackle place the gearbox unit (1) on a spacer (2).

2.

dz

dz

1.

60

Unscrew the nos. 2 plugs M22 x 1.5 (3) and the washers from the end cover (4).

60

3.

Unscrew the nos. 13 screws M10x30 (5), grade 12.9, from the end cover (4). 8 mm

60

W3-2-3

E215B 4.

TRAVEL DEVICE

Remove the end cover (4).

60

5.

Remove the O-ring seal (6) from its seat in the end cover (4).

60

6.

Remove the 1st stage sun gear (7).

60

7.

Remove the 1st reduction assembly (8).

60

W3-2-4

TRAVEL DEVICE 8.

E215B

Remove the 2nd reduction assembly (9).

60

9.

By using pliers remove the circlips (10) from their seats placed in the hydraulic motor’s pins (11).

60

10. By using a puller remove the planet assemblies of the 3rd reduction (12).

60

11. Take out the spacer (13).

60

W3-2-5

E215B

TRAVEL DEVICE

NOTE — in order to proceed with the gearbox disassembly, it is now necessary to remove it from the machine and bring it to a properly equipped workshop.

12. By using a drill remove the calkings on the ring nut (14).

60

13. By using a tackle place the torque multiplier (A) (XXXXXXXXX) on the ring nut (14) and, by using the torque multiplier, loosen the ring nut (14).

$

60

14. Take out the ring nut (14).

60

W3-2-6

TRAVEL DEVICE

E215B

NOTE: tighten nos. 2 screws M20x100-8.8 ISO 4017 (15) at 180° with nos. 2 washers 22x60x4 ISO 7093 in the thread holes of the gearbox housing (17) to avoid the housing comes out from the hydraulic motor (16) during the movement of the unit. Remove the screws when the unit is positioned.

60

15. By using a press, push on a metal stopper and remove the hydraulic motor (16) from the gearbox housing (17).

60

NOTE: In case of oil leakages, it might be necesary to check and eventuallu replace the lifetime seals (18), wich means both the metal rings parts and the O-ring seals.

16. By using a screwdriver remove the half seal (18) from the hydraulic motor (16).

60

W3-2-7

E215B

TRAVEL DEVICE

17. By using a puller and a metal stopper, remove the bearing inner raceway from the hydraulic motor (16).

60

18. Remove the bearing inner raceway (20) from the gearbox housing (17).

60

19. Remove the bearing balls (21) from the gearbox housing (17).

60

W3-2-8

TRAVEL DEVICE

E215B

Hydraulic motor disassembling method Disassembly of the flushing valve 1.

Unscrew the first plug (1) from the flushing valve (2).

NOTE: it is suggested to operate like that when motor is completely assembled.

60

2.

Remove th O-ring seal (3) from its seat in the first plug (1).

60

3.

Unscrew the second plug (4) from the flushing valve (2).

60

4.

Remove the O-ring seal (3) from its seat in the second plug (4).

60

W3-2-9

E215B 5.

TRAVEL DEVICE

Remove the spring (5) from the poppet (6).

60

6.

Take out the poppet (6) from the flushing valve (2).

60

7.

Unscrew the third plug (7) from the flushing valve (2).

60

8.

Remove the O-ring seal (3) from its seat in the third plug (7).

60

W3-2-10

TRAVEL DEVICE 9.

E215B

Remove the 1st spring (8) from the plunger assy (9).

60

10. Unscrew the fourth plug (10) from the flushing valve (2).

60

11. Remove the O-ring seal (3) from its seat in the fourth plug (10).

60

12. Remove the 2nd spring (11) from the plunger assy (9).

60

W3-2-11

E215B

TRAVEL DEVICE

13. Take out the plunger assy (9) from the flushing valve (2).

60

14. Take out the 1st spring seat (9) from the plunger assy (12).

60

15. Take out the 2nd spring seat (12) from the flushing valve (2).

60

16. Unscrew the nos. 4 socket head screws M10x30 (13), grade 8.8, of the flushing valve (2) by a male hex head wrench. : 8 mm

60

W3-2-12

TRAVEL DEVICE

E215B

17. Remove the flushing valve (2).

60

18. Remove the O-ring seals (14) from the flushing valve (2).

60

19. Unscrew the orifice M5 (15) from the flushing valve (2).

60

Disassembly of the two speed control 20. Unscrew the plug (16) from the base plate (17).

60

W3-2-13

E215B

TRAVEL DEVICE

21. Remove the O-ring seal (18) from its in the plug (16).

60

22. Remove the spring seat (19) from its seat in the base plate (17).

60

23. Remove the spring (20) from its seat in the base plate (17).

60

24. Unscrew the plug (21) from the base plate (17).

60

W3-2-14

TRAVEL DEVICE 25. Remove the O-ring seal (18) from its seat in the plug (21).

E215B

60

26. By using a screwdriver take out the two speed spool (22).

60

Disassembly of the relief valve assy 27. Unscrew the nos.2 relief valve kits (23).

60

28. Take out the free piston (24) from the relief valve (23).

60

W3-2-15

E215B

TRAVEL DEVICE

29. Remove the O-ring seal (25) and the backup rings (26) from their seats in the free piston (24).

60

30. Remove the O-ring seal (27) from relief valve (23). Repeate the same steps for the 2nd relief valve disassembly.

60

Disassembly of the counterbalance valve assy

31. Unscrew the nos. 4 socket head screws M12x40 (28), grade 12.9 of the first flanged plug assy (29) by a male hex head wrench. : 10 mm

60

32. Take out the first flanged plug assy (29) and the spring seat.

60

W3-2-16

TRAVEL DEVICE

E215B

33. Take out the spring seat (30) from the first flanged plug (29).

60

34. Remove the first spring (31).

60

35. Take out the first spring seat (32) from the counterbalance valve spool (33).

60

36. Remove the springs (34) from the base plate (17).

60

W3-2-17

E215B

TRAVEL DEVICE

37. Remove the O-ring seals (35) from the base plate (17).

60

38. Remove the check valves (36) from the base plate (17).

60

39. Unscrew the nos. 4 socket head screws M12x40 (28), grade 12.9, of the second flanged plug assy (29) by a male hex head wrench. : 10 mm

60

40. Take out the second flanged plug assy (29) and the spring seat.

60

W3-2-18

TRAVEL DEVICE 41. Take out the spring seat (30) from the second flanged plug (29).

E215B

60

42. Remove the second spring (31).

60

43. Take out the second spring seat (32) from the counterbalance valve spool (33).

60

44. Take out the counterbalance valve spool (33).

60

W3-2-19

E215B

TRAVEL DEVICE

Disassembly of flanged plug assy 45. Remove the O-ring seal (34) from the flanged plug (29).

60

46. Unscrew the plug (35) from the flanged plug (29).

60

47. Remove the O-ring seal (36) from the plug (35).

60

Disassembly of the base plate

48. Unscrew the plug (37) from the base plate (17).

60

W3-2-20

TRAVEL DEVICE

E215B

49. Remove the O-ring seals (38) from the plugs (39).

60

50. Unscrew the plug (40) from the base plate (17).

60

51. Unscrew the nos. 4 orifices M5 (41) from the base plate (17).

60

52. Remove the caulking with a M5 tap before unscrewing the orifices.

60

W3-2-21

E215B

TRAVEL DEVICE

53. Unscrew the nos. 2 orifices M5 (42) from the base plate (17).

60

54. Unscrew the nos. 10 socket head screws M14x40 (43), grade 12.9, that fix the base plate (17) to the flanged hub (44).

60

IMPORTANT: Remove carefully the base plate (17) until pins are completely out.

60

55. Remove the pins (45) from their seats.

60

W3-2-22

TRAVEL DEVICE

E215B

56. Remove the valve plate (46).

60

57. By using a puller, remove the bearing (47) from the base plate (17).

60

Disassembly of the motor shaft and cylinder block

58. Remove the O-ring seal (48) from its seat in the flanged hub (44).

60

59. Remove the O-ring seal (49) from brake pilot hole.

60

W3-2-23

E215B

TRAVEL DEVICE

60. Remove the O-ring seals (50) from speed shifting holes.

60

61. Remove the springs (51) from the brake piston (52).

60

62. Mark the position of the brake piston (52) as a reference for the reassembling step.

60

63. By using two screws M8, take out the brake piston (52).

60

W3-2-24

TRAVEL DEVICE

E215B

64. Remove the O-ring seals (53) from the brake piston (52).

60

65. Take out the 1st brake disc (54).

60

66. Remove brake discs pack (55).

60

67. Remove the cylinder block (56) from the flanged hub (44).

60

W3-2-25

E215B

TRAVEL DEVICE

68. Take out the spherical retainer plate holder (57).

60

69. Take out the nos. 3 pins (68) from their seats in the cylinder block (56).

60

70. Remove the pistons and the retainer plate (58) and (59) from the flanged hub (44).

60

71. Take out the pistons (58) from the retainer plate (59).

60

W3-2-26

TRAVEL DEVICE 72. Remove the swash plate (60) from the flanged hub (44).

E215B

60

73. Take out the nos. 2 steel balls (61) from their seats in the flanged hub (44).

60

74. Take out the nos. 2 pistons (62) from their seats in the flanged hub (44).

60

75. Take out the nos. 2 springs (63) from their seats in the flanged hub (44).

60

W3-2-27

E215B

TRAVEL DEVICE

76. By using a rubber hammer take out the motor shaft (64) from the the flanged hub (44).

60

77. By using a puller take out the bearing (65) from the motor shaft (64).

60

78. By using a screwdriver remove the seal ring from its seat in the flanged hub (44).

NOTE — Disassemble the seal ring only in case of replacement, because this will damage it. NOTE — The disassembly ends with the above operation. All items are now available for the necessary inspections.

60

W3-2-28

TRAVEL DEVICE Evaluation of the Pieces to be Replaced The pieces that are subject to general wear and tear are the following: — Gears. — Bearings. — All the seals. Replace the used or irregular parts respecting the following steps: 1.

Accurately remove dirt, and in particular properly clean the seals, bearings and locking rings seating.

2.

Lubricate the parts before connecting them.

3.

In the case of damaged gears, for example a planetary, do not proceed to replace the individual gear but the entire reduction assembly.

4.

When reconnecting a part always replace all the seals involved. Add some grease on the seats and on the new seals to make easier the reassembly.

5.

Replace all the damaged parts with original spare parts and doing so follow all the steps given by the manufacturer in sections 4.9.-4.10.

W3-2-29

E215B

E215B

TRAVEL DEVICE

Hydraulic motor reassembling method

Reassembly of motor shaft and cylinder block 1.

Assemble the back-up ring (66) inside its seat in the flanged hub (44).

60

2.

By using a plastic hammer and the stopper (B) (XXXXXXXXX), push the back-up ring into the flanged hub shoulder (44) until assembly is complete.

% 60

3.

Place the bearing outer ring (65) on the motor shaft (64).

60

By using a plastic hammer and a metal stopper, completely assemble together the bearing (65) and the motor shaft (64).

4.

60

W3-2-30

TRAVEL DEVICE 5.

Place the bearing-motor shaft sub-assembly (65-64) in the seat inside the flanged hub (44).

E215B

IMPORTANT — Be careful when inserting the shaft inside the motor seal (52).

60

6.

By using a plastic hammer and a metal stopper, completely assemble together the bearing-motor shaft sub-assembly into the flanged hub shoulder (44) until assembly is complete.

60

7.

Assemble the nos. 2 steel balls (61) into their seats inside the flanged hub (44).

60

8.

Assemble the nos. 2 springs (63) into their seats inside the pistons (62).

60

W3-2-31

E215B 9.

TRAVEL DEVICE

Assemble the nos. 2 pistons (62) into their seats inside the flanged hub (44).

NOTE — Be sure that the pistons (62) can move freely into the seats.

60

10. Insert the swash plate (60) inside the flanged hub (44) being careful that spherical housings matches with the 2 steel balls.

60

11. Assemble the nos. 3 pins (68) in their seats in the cylinder block (56).

60

12. Assemble the spherical retainer holder (57) on the cylinder block (56). NOTE — The two splines must be aligned together.

60

W3-2-32

TRAVEL DEVICE 13. The orifice of the piston (58) must be open and free of dust or dirt.

E215B

60

14. Assemble correctly the nos. 9 pistons (58) in the retainer plate (59).

60

15. Assemble the pistons-retainer plate sub assembly (58-59) in the cylinder block (56).

60

16. Assemble the cylinder block sub assembly (56) into the flanged hub (44) on the motor shaft spline (64).

60

W3-2-33

E215B

TRAVEL DEVICE

17. Assemble the brake discs package according to the following order: firstly, insert one brake disc (54) with internal teeth.

60

18. Then insert an externally toothed steel disc (55) Repeat the operation untill all nos. 3 brake discs and nos. 2 steel discs have been assembled.

60

19. Assemble the O-ring seals (53) into their seatsin the brake piston (52).

60

NOTE — Assemble the brake piston (52) respecting the markings set out previously and being careful not to damage the seals already fitted.

60

W3-2-34

TRAVEL DEVICE

E215B

20. Assemble the O-ring seal (48) into its seat in the flanged hub (44).

60

21. Assemble the O-ring seal (49) in the brake pilot hole of the flanged hub (44).

60

22. Assemble the O-ring seals (50) in the speed shifting holes of the flanged hub (44).

60

23. Insert the springs (51) in their seats in the brake piston (52).

60

W3-2-35

E215B

TRAVEL DEVICE

Reassembly of the base plate

24. Place the bearing (47) into its seat in the base plate (17).

60

25. By using a plastic hammer and a metal stopper, push the bearing into the base plate (17) shoulder until assembly is complete.

60

26. Place the valve plate (46) on the base plate (17).

IMPORTANT — Bronze layer surface must be upwards.

60

27. Assemble the pins (45) in their seats in the base plate (17).

60

W3-2-36

TRAVEL DEVICE

E215B

28. Place the base plate (17) on the flanged hub (44).

IMPORTANT: The base plate is centered by two pins (45) and the second speed oil passages must match together.

60

29. Fix the base plate (17) to flanged hub (44) using nos. 10 socket head screws M14x40 (43), grade 12.9, tightened by a torque wrench at 235 Nm torque. : 12 mm : 235 Nm (173 lbf·ft)

60

30. By using the tool (C) (XXXXXXXXX), fit the Oring seals in their seats in the plugs (39).

&

60

31. Insert the plugs (39) and tighten by a torque wrench at 36.8 ±2.5 Nm torque. : 36.8 ±2.5 Nm (27.1 ± 1.8 lbf·ft)

60

W3-2-37

E215B

TRAVEL DEVICE

32. Seal the thread of the orifices and the plugs (40) by «Teflon» tape. NOTE — Be sure that the tape is correctly winded around the plugs (40).

60

33. Insert the nos. 4 orifices M5 (41) in the base plate (17) and tighten by a torque wrench at 2.5 ±0.5 Nm torque. : 2.5 ±0.5 Nm (1.85 ± 0.35 lbf·ft)

60

34. Insert the plugs (40) in the base plate (17) and tighten by a torque wrench at 10 ±1 Nm torque. : 10 ±1 Nm (7.35 ± 0.7 lbf·ft)

60

35. Tighten the nos. 2 orifices M5 (41) in the base plate (17) by a torque wrench at 2.5 ±0.5 Nm torque. : 2.5 ±0.5 Nm (1.85 ± 0.35 lbf·ft)

60

W3-2-38

TRAVEL DEVICE 36. By using a punch and a hammer deform the thread hole (69).

E215B

60

Reassembly of the flanged plug assy 37. By using the stopper (D) (XXXXXXXXX), assemble the O-ring in its seat in the plug (35).

‘

38. Tighten the plugs (35) by a torque wrench at 20.6 ±1 Nm torque. : 20.6 ±1 Nm (15.2 ± 0.7 lbf·ft)

60

60

39. Assemble the O-ring (34) in its seat in the flanged plug (29).

60

W3-2-39

E215B

TRAVEL DEVICE

Reassembly of the counterbalance valve assy 40. Insert the counterbalance valve spool (33).

60

41. Insert the check valves (36) in the base plate (17).

60

42. Insert the O-ring seals (35) in the base plate (17).

60

43. Insert the springs (34) in the base plate (17).

60

W3-2-40

TRAVEL DEVICE 44. Insert the first spring seat (32) on the counterbalance valve spool (33).

E215B

60

45. Insert the first spring (31) on the counterbalance valve spool (33).

60

46. Assemble the spring seat (30) into its seat in the 1st flanged plug (29).

60

47. Assemble the first flanged plug assy (29).

60

W3-2-41

E215B

TRAVEL DEVICE

48. Tighten the nos. 4 socket head screws M12x40 (28), grade 12.9, of the first flanged plug assy (29) by a male hex head torque wrench at 108 ±10 Nm torque. : 10 mm : 108 ±10 Nm (79.7 ± 7.3 lbf·ft)

60

49. Insert the second spring seat (32) on the counterbalance valve spool (33).

60

50. Insert the second spring (31) on the counterbalance valve spool (33).

60

51. Assemble the spring seat (30) into its seat in the 2nd flanged plug (29).

60

W3-2-42

TRAVEL DEVICE

E215B

52. Assemble the second flanged plug assy (29).

60

53. Tighten the nos. 4 socket head screws M12x40 (28), grade 12.9, of the second flanged plug assy (29) by a male hex head torque wrench 108 ±10 Nm torque. : 14 mm : 108 ±10 Nm (79.7 ± 7.3 lbf·ft)

60

Reassembly of the relief valve assy

(

54. By using the stopper (E) (XXXXXXXXX), assemble the O-ring seal in its seat in the relief valve (23).

60

55. Assemble the first backup-ring (26) into its seat in the free piston (24).

60

W3-2-43

E215B

TRAVEL DEVICE

56. Assemble the O-ring seal (25) into its seat in thefree piston (24). After this step assembly the second backup ring as shown on the sketch.

60

57. Insert the free piston (24) in the relief valve (23) checking that the groove side is turned toward the inside of the motor.

60

58. Insert the relief valve (23) inside the base plate (17).

60

59. Tighten the relief valve (23) by a torque wrench at 373 ±20 Nm torque. : 373 ±20 Nm (275 ± 14.7 lbf·ft)

60

W3-2-44

TRAVEL DEVICE

E215B

Reassembly of the two speed control 60. By using the tool (F) (XXXXXXXXX), fit the Oring seal into its seat in the plug (44).

)

60

61. Insert the plug (44) and tighten by a torque wrench at 118 ±5 Nm torque. 118 ±5 Nm (87 ± 3.7 lbf·ft)

60

62. Insert correctly the two speed spool kit (22) in the base plate (17). NOTE: Two speed spool (22) have to move smoothly inside its seat in the base plate (17).

60

63. Insert the spring (20) in the second speed spool (22).

W3-2-45

60

E215B

TRAVEL DEVICE

64. Insert the spring seat (19) in the spring (20).

60

65. By using the tool (F) (XXXXXXXXX) fit the Oring seal into its seat in the plug (16).

)

60

66. Insert the plug (16) and tighten by a torque wrench at 118 ±5 Nm torque. : 118 ±5 Nm (87 ± 3.7 lbf·ft)

60

67. Correct assembling of the two speed control valve.

60

W3-2-46

TRAVEL DEVICE

E215B

Reassembly of the flushing valve 68. Insert the orifice M5 (15) in the flushing valve (2) and tighten by a torque wrench at 2.5 ±0.5 Nm torque. : 2.5 ±0.5 Nm (1.85 ± 0.35 lbf·ft)

69. Assemble the O-ring seals (14) into its seat in the flushing valve (2).

60

60

70. Assemble the flushing valve (2) to the base plate (17).

60

71. Fix the flushing valve (2) by using nos. 4 socket head screws M10x30 (13), grade 8.8, tightened by a male hex head torque wrench at 58 ±5 Nm torque. : 8 mm : 58 ±5 Nm (42.8 ± 3.7 lbf·ft)

60

W3-2-47

E215B

TRAVEL DEVICE

72. Slide the flushing spool valve (9) inside the flushing valve (2).

60

73. Insert the 1st spring seat (12) on the plunger assy (9).

60

74. Insert the 1st spring (11) on the plunger assy (9).

60

75. By using the tool (G) (XXXXXXXXX), fit the Oring seal in its seat in the plug (10).

*

60

W3-2-48

TRAVEL DEVICE 76. Insert the first plug (10) in the flushing valve (2) and tighten by a torque wrench at 67 ±5 Nm torque. : 67 ±5 Nm (49.4 ± 3.7 lbf·ft)

E215B

60

77. Insert the second spring seat (12) in the opposite side of the plunger assy.

60

78. Insert the second spring (8) on the plunger assy.

60

79. By using the tool (G) (XXXXXXXXX), fit the Oring seal in its seat in the plug (7).

*

W3-2-49

60

E215B

TRAVEL DEVICE

80. Insert the second plug (7) in the flushing valve (2) and tighten by a torque wrench at 67 ±5 Nm torque. : 67 ±5 Nm (49.4 ± 3.7 lbf·ft)

NOTE — it is suggest to operate like that when motor is completely assembled.

60

81. Slide the poppet (6) inside the flushing valve (2).

60

82. Insert the spring (5) in the flushing valve (2).

60

83. By using the tool (G) (XXXXXXXXX), fit the Oring seal in its seat in the plug (4).

*

60 W3-2-50

TRAVEL DEVICE 84. Insert the third plug (4) in the flushing valve (2) and tighten by a torque wrench at 67 ±5 Nm torque. : 67 ±5 Nm (49.4 ± 3.7 lbf·ft)

E215B

60

85. By using the tool (G) (XXXXXXXXX), fit the Oring seal in its seat in the plug (1).

*

86. Insert the fourth plug (1) in the flushing valve (2) and tighten by a torque wrench at 67 ±5 Nm torque. : 67 ±5 Nm (49.4 ± 3.7 lbf·ft)

60

NOTE — it is suggested to operate like that when motor is completely assembled.

60

87. Correct assembling of the flushing valve.

60

W3-2-51

E215B

TRAVEL DEVICE

Gearbox reassembling method

Reassembly of the gearbox 1.

Assemble the balls (1) to the plastic supports.

60

2.

Place the bearing inner ring (2) on a spacer (3).

Ɏ

3.

Place the gearbox housing (4) on the bearing inner ring (2).

60

4.

Assemble the bearing inner raceway (2) in the gearbox housing (4).

60

W3-2-52

TRAVEL DEVICE

E215B

Make ready of the lifetime seal: 1.

Carefully clean the seats (A and B) using, if necessary, metallic brushes or solvent (surfaces in contact with or (C) must be perfectly clean and dry).

2.

Make sure that sealing surfaces (D) of metal rings (E) are free from scratches, dinges or foreign substances; metallic ring surfaces (F) must be perfectly clean and dry. We suggest to dip the metallic rings in volatile solvent or industrial degreasing alcohol.

3.

Carefully clean the lapped surface (D) of metal rings (E) and remove dust or fingerprints. Then lubrificate them with a thin oil film, taking care not to oil the other components.

W3-2-53

60

E215B 5.

TRAVEL DEVICE

Fit the 1st half seals (5) on the tool (H) (XXXXXXXXX).

+ 60

6.

By means of the tool (H) (XXXXXXXXX), carry out the assembly of the 1st half seal (5) on the gearbox housing (4).

+

60

7.

Assemble, by using the same tool (H) (XXXXXXXXX), the 2nd half seal on the hydraulic motor (6).

+

60

W3-2-54

TRAVEL DEVICE

E215B

NOTE — Correct lifetime seal assembly check (5).

60

8.

Clean carefully the seal faces (5).

IMPORTANT: Apply a thin oil film on the entire metallic face of one or both seals. Oil must not contact surfaces other than the sealing faces.

60

W3-2-55

E215B

TRAVEL DEVICE

NOTE — By using a tackle, place the hydraulic motor (6) inside the gearbox housing (4).

9.

By using a press and a metal stopper, push the hydraulic motor (6) against the shoulder on the gearbox housing (4) untill assembling of the unit is complete.

60

NOTE: tighten nos. 2 screws M20x100-8.8 ISO 4017 (7) at 180° with nos. 2 washers 22x60x4 ISO 7093 in the thread holes of the gearbox housing (4) to avoid the housing comes out from the hydraulic motor (6) during the movement of the unit. Remove the screws when the unit is positioned.

60

10. Place the ring nut (8).

60

11. By using a tackle place the multiplier (A) (XXXXXXXXX) on the ring nut (8) and tighten by a torque wrench with an input multiplier torque of 143 ±5 Nm (105.5 ± 3.7 lbf·ft) corresponding to an output multiplier torque of 7250 ±250 Nm (5347 ± 184 lbf·ft).

$

60

W3-2-56

TRAVEL DEVICE

E215B

12. Stake the ring nut (8) near 2 seats of the hydraulic motor.

60

NOTE — Stake Ø 4÷5 mm (depth 1÷1,5 mm).

60

13. Assemble correctly the spacers (9) on the pins of the hydraulic motor (6).

60

14. Place the reduction planet assemblies of the 3rd reduction (10) on the pins of the hydraulic motor (6).

60

W3-2-57

E215B

TRAVEL DEVICE

IMPORTANT: Place correctly the reduction planet assemblies checking that the groove is towards the end cover (11).

60

15. By using a rubber hammer and a metal stopper, push the planet assemblies of the 2nd reduction (12) against the hydraulic motor pin shoulders (6).

60

16. By using pliers, assemble the circlips (13) in the hydraulic motor pin seats (6).

60

17. Insert the 2nd reduction assembly (14).

60

W3-2-58

TRAVEL DEVICE 18. Insert the 1st reduction assembly (15).

E215B

60

19. Insert the 1st reduction sun gear (16).

60

20. Assemble the O-ring (17) into its seat in the cover (18).

60

21. Place the end cover (18) on the gearbox housing (4).

60

W3-2-59

E215B

TRAVEL DEVICE

22. Tighten the nos. 13 socket head screws M10x30 (19), grade 12.9, by a torque wrench at 85 Nm torque. : 8 mm : 85 Nm (62.7 lbf·ft)

60

23. Fill the gearbox with the lubricant oil. Insert the washers and the plugs (20) into the oil draing-filling holes of the end cover (18). Tighten the plugs by a torque wrench at 35 ±5 Nm torque. : 35 ±5 Nm (25.8 ± 3.7 lbf·ft)

60

Final Test and Reinstallation Check the product by remounting it to the machine. Check the function of the transmission.

Dismantling and Destroying the Product When dismantling the gearmotor follow the indications given below. 1.

Remove the gearbox from the machine frame and let the lubricant oil flow.

2.

Completely dismount the gearbox and remove all oil and grease from its parts.

3.

Send all dangerous and/or polluted parts to the authorised demolishing centres whilst keeping in line with respective local rules and regulations.

W3-2-60

TRAVEL DEVICE

E215B

MAINTENANCE STANDARD Sprocket

% & ‘

(

$

60

IMPORTANT: Consult NEW HOLLAND KOBELCO S.p.A. for any inqueries concerning welding procedures. Standard mm (in)

Allowable Limit mm (in)

A

68 (2.67)

60 (2.36)

B

584.7 (22.80)

575 (22.42)

C

PCD644.6 (25.14)

—

D

659 (25.70)

648 (25.27)

E

190 (7.41)

—

W3-2-61

Remedy

Build up and finishing

E215B

TRAVEL DEVICE

NOTES

W3-2-62

TRAVEL DEVICE

E245B

REMOVAL AND INSTALLATION OF TRAVEL DEVICE (E245B) 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. 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 1.

Park the machine on a firm, level surface.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure «Releasing the hydraulic pressure» at page T2-1-47.

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.

INSTALL ASSY

LQ53D00010F1

No.

NAME

Q’TY

REMARKS

3

CAPSCREW

56

M16x55

4

TRAVEL MOTOR ASSY

2

LQ53D00011F1

APPLY LOCTITE #262 OR EQUIVALENT

4

60

W3-2-63

E245B

TRAVEL DEVICE

REMOVING Preparation for removal 1.

Remove crawler, lift up crawler frame using attachment, and put it on square timbers to float and stabilize.

Removing cover 2.

Remove sems bolt (6) M12x25 and also remove covers (1). : 19 mm

3.

6 1

60

Preparation of oil pan.

Removing hydraulic pipe 4.

Release pressure from travel circuit, and bleed air in hydraulic oil tank, then remove all pipes connecting to travel motor. Then plug up all pipes and joint section to protect them from entry of dust. : 19 mm : 27 mm : 41 mm

60

W3-2-64

TRAVEL DEVICE

E245B

Removing sprocket 5.

Removing thirty (one side) capscrews (3) M16x50. : 24 mm

3 60

Loosening travel motor attaching bolts 6.

Disconnect hoses (A). Apply match marks on travel motor and crawler frame, and remove seventeen (one side) capscrews (3) M20x60.

$

: 24 mm

3

60

Slinging travel motor assy 7.

Sling travel motor with nylon sling applied on the side close to sprocket installing section and remove the motor. Weight of motor: About 262 kg (578 lbs)

60

W3-2-65

E245B

TRAVEL DEVICE

INSTALLING Installing of the travel motor piping is performed in the reverse order of removal. 1.

Cleaning Check that contact surface of travel motor and crawler frame is free from burr and stain.

2.

Tightening torque Tighten capscrew and hydraulic pipes to the torque specified in «Tightening Torque»).

3.

Fill inside from motor drain port to casing with hydraulic oil before piping for drain. When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leakage and noise.

NAME

SIZE

TOOLS

No.

TIGHTENING TORQUE (N/m)

Bolts

M12

19

6

83.4 (61.5 lbf·ft)

Capscrew

M16

24

3

279 (206 lbf·ft)

Flareless nut for pipes, sleeve

Ø 10X1.5 Ø 18X2.5 Ø 28

19 32 41

—

49 (36.1 lbf·ft) 147 (108 lbf·ft) 275 (203 lbf·ft)

Hose cap

PF1/4 PF1/2

19 27

—

29.4 (21.7 lbf·ft) 78.5 (57.9 lbf·ft)

Connector

PF1/4 PF1/2 PF1

19 27 41

—

36.3 (26.8 lbf·ft) 108 (79.7 lbf·ft) 255 (188 lbf·ft)

W3-2-66

REMARKS Apply Loctite #262

TRAVEL DEVICE

E245B

DISASSEMBLY PROCEDURE OF TRAVEL DEVICE (E245B) Removing cap 1.

Fix the motor on a stable work bench, loosen eight socket bolts (13) and remove cap (11) with O-ring (12).

2.

Next, remove spring seat (10), spring (9) and spring seat (8).

3.

Then separate plug (15), O-ring (14), spring (34) and ball (33).

14,15,33,34

: 10 mm : 14 mm.

8 9 12

NOTE: cap (11) is pressed out by spring (9). Therefore, do the work, taking care of the following — Loosen socket bolts (13) evenly all round — Loosen socket bolts (13), holding down cap (11).

17

10

11 13

60

Removing double counterbalance plunger 1.

Push the end of plunger (3) lightly so part of plunger (3) comes out of base plate (2). Then, hold the end of plunger (3) by hand and draw out plunger (3) from base plate (2), while turning it by hand.

IMPORTANT: plunger (3) and base plate (2) have a very tight fit. Therefore, do the work, paying attention to the following: — case plunger (3) gets stuck halfway and does not come out, do not try to force it out. If it is pulled out by force, the bore surface of base plate (2) and the outer surface of plunger (3) are scored. — In case the plunger gets stuck halfway, do as follows: Put plunger (3) back into base plate (2) by lightly tapping the end face of it with a plastic mallet. Then make sure that the plunger (3) moves smoothly and draw out the plunger (3) once again, turning it by hand. — Do not disassemble plunger (3) unless it is necessary; the outer surface of it may be scored at disassembly.

W3-2-67

2 3 60

E245B

TRAVEL DEVICE

Removing relief valve assy 1.

Loosen plug (17-6) and remove relief valve assy (17). In that case, poppet seat (17-3) remains in base plate (2).

17-3

: 27 mm IMPORTANT: Relief valve assy (17) is set at certain pressure. The set pressure of it determines the starting power and the braking power of the motor. For this reason, do not do the following: — Do not loosen nut (17-16) and tamper with set screw (17-15). If the set screw is turned, the set pressure of the relief valve changes, making the motor unable to attain required performances. — Do not disassemble the relief valve assy. Otherwise, the set pressure changes and the motor is unable to attain required performances.

17-6

2

17-16 17-15 17 60

Removing poppet seat Separate poppet seat (17-3) from base plate (2), using the poppet seat removing jig. NOTE: Do not separate it unless it is necessary for special reason.

2 17-3 60

W3-2-68

TRAVEL DEVICE

E245B

Removing auto 2-speed select spool 1.

Loosen plugs (22), (25) and take off plugs (22), (25) and spring (21).

2.

Push out part of spool (19) from base plate (2) by pushing the end of spool.

3.

Draw spool (19) out of base plate (2), while holding the end of spool (19) by hand and turning it.

IMPORTANT: Spool (19) and base plate (2) are combined to a very small fit. For this reason, execute the work, paying attention to the following: — Do not disassemble spool (19) unless necessary. — In case the spool gets stuck halfway, do not force it out. If the spool is forced out, the bore surface of base plate (2) and the outer surface of spool (19) are scored. If it gets stuck, do as below: — Put spool (19) into base plate (2) once again by lightly tapping the end face of spool (19) with a plastic mallet. — Then, make certain that spool (19) moves smoothly and draw it out, turning spool (19) by hand.

4.

Do not remove orifice plug (18) unless necessary.

5.

Orifices (28), (29), (30) are caulked so they do not get loose. Do not disassemble them.

W3-2-69

21

25

2 19 22 60

E245B

TRAVEL DEVICE

Removing base plate 1.

Loosen socket bolts (52) and remove base plate (2). : 12 mm

52 2

59

60

NOTE: When removing base plate (2), do the work, taking care of the following: — Base plate (2) is pushed up by the action of spring (59). Therefore, loosen the cap screws evenly all round. — A positioning knock pin (60) is placed between base plate (2) and the main body. When removing base plate (2), do it upright toward the motor shaft center so knock pin (60) is not wrenched. In case it is wrenched, bring knock pin (60) back in place by lightly tapping base plate (2) with a plastic mallet and remove the knock pin. — When removing base plate (2), valve plate (62) comes with base plate (2). Since the moving surface of valve plate (62) tends to be scored, use care so valve plate (62) does not fall.

2

60 60

Removing valve plate 1.

When removing valve plate (62), take care of the following.

62

IMPORTANT: The moving surface of valve plate (62) tends to be scored. If the surface is scored, desired performances are not available; use care so as not to score it.

60

W3-2-70

TRAVEL DEVICE

E245B

Removing O-rings, knock pin and spring 1.

Take off O-rings (63), (64), and knock pin (60).

2.

Then take off spring (59).

59

60 63 64 60

Removing brake piston 1.

Attach a jet air nozzle to the oil path for the parking brake of flange (1), make brake piston (56) afloat by blowing jet air into the parking brake cylinder chamber and remove the brake piston.

2.

After removing brake piston (56), remove disk plate (54) and friction plate (55).

3.

Then separate O-rings (57), (58) from brake piston (56).

56

60

IMPORTANT: When removing brake piston (56), take care of the following: — When blowing in jet air from the parking brake oil path of flange (1), take measures so jet air does not leak. — If the jet air pressure is high when blowing in jet air from the parking brake oil path of flange (1), you may be injured as brake piston (56) pops out. For this reason, keep the air pressure less than 0.29 MPa (43 psi) and do the work, holding down brake piston (56) so brake piston (56) does not jump off.

56

54 54 55

55

54

58

57

60

W3-2-71

E245B

TRAVEL DEVICE

Removing cylinder block 1.

Take out cylinder block (37) from flange (1).

IMPORTANT: When drawing out cylinder block (37), use care of the following: — Hold cylinder block (37) by both hands and take it out slowly, while turning it both ways lightly; — Exercise care so as not to score the moving surface of cylinder block (37) in contact with valve plate (62). If the surface is scored, desired performances will not be attained. — Exercise care so as not to score the moving surface of the shoe of piston assy (38). Desired performances will not be attained if the surface is scored.

37 1

60

Disassembling cylinder block 1.

Give a matching mark to piston assy (38) and cylinder block (37) so they can be reassembled in the same positions.

2.

Then separate piston assy (38) and retainer plate (39) from cylinder block (37).

37

38 39

3.

Give a matching mark to piston assy (38) and retainer plate (39) so they can be reassembled in the same position.

4.

Then remove piston assy (38) from retainer plate (39).

60

39

38

W3-2-72

60

TRAVEL DEVICE 5.

E245B

Separate retainer holder (40) from cylinder block (37). Then take off pin (45) from cylinder block (37).

45

37 40

6.

Fix cylinder block (37) on a manual press bench so the moving surface faces upwards.

7.

Take off snap ring (41), push collar (44) with the jig, bend spring (43) and take off snap ring (41), using snap ring pliers.

60

41

%

37

60

IMPORTANT: When removing snap ring (41), take care as below, so as not to injure yourself: — If snap ring (41) is tight to remove with snap ring pliers, you may injure yourself when the snap ring comes off from the pliers; — Always use the removing jig to remove the snap ring and make certain that the claw of the pliers is set in the hole of the snap ring. 8.

Separate collar (44), spring (43) and spring seat (42) from cylinder block (37).

44 43 42

37

60

W3-2-73

E245B

TRAVEL DEVICE

Removing swash plate 1.

Separate swash plate (46) from flange (1).

IMPORTANT: Use care of the following when removing swash plate (46): — Take care so as not to score the sliding surface of swash plate (46). Desired performances will not be attainted if the surface is scored. — Swash plate (46) comes off with piston assy (38) and steel ball (47) in some cases. On that occasion, use care so piston assy (38) and steel ball (47) do not fall.

46

1

60

Removing travel 2-speed select piston assy and steel ball 1.

Separate piston assy (48) from flange (1).

2.

Then take off spring (61).

3.

Separate steel balls (47) from flange (1).

61

NOTE: Since steel balls (47) are hard to come off, do it as below: — Degrease steel balls (47) fixed in flange (1), using kerosene or thinner; — Separate steel balls (47) from flange (1), using a magnet.

48 47 1

60

Removing shaft 1.

Separate shaft (36) and ball bearing (49) from flange (1).

IMPORTANT: When removing shaft (36), use care of the following Use care so the spline of shaft (36) is not damaged. Exercise care so the sliding part of oil seal (53) in shaft (36) is not scored. If it is scored, oil leakage occurs.

36 49

1

60

W3-2-74

TRAVEL DEVICE

E245B

Draining lube oil from the reduction gear 1.

Next, before disassembling the reduction unit, put a screw in two tapped holes of flange (1) that are in diagonal positions and lift the reduction unit by crane.

2.

Remove two plugs (97) and drain lube oil from the reduction unit.

1

: 12 mm NOTE: Prepare an oil container before doing the work. Do not lift the reduction unit too high, but do the work at as low level as possible (height of your knees).

97

97

60

Removing cover 1.

Loosen bolts (96) and remove them.

2.

Then remove cover (95). : 8 mm

NOTE: Remove the cover as below. Liquid packing is applied between cover (95) and housing (72). For this reason, the cover is hard to come off. Loosen bolts (96) and tap the top and side faces of the removed cover (95) with a plastic mallet. Put a flat-blade screwdriver between cover (95) and housing (72) and take off cover (95).

96

72 95

W3-2-75

60

E245B

TRAVEL DEVICE

Removing thrust plate 1.

Separate thrust plate (94) from the top face of thrust plate (91).

91 94 60

Removing drive gear 1.

Remove drive gear (93).

93 60

Removing the 1st stage holder assy 1.

Remove the 1st stage holder assy that consists of holder B (85), planetary gear B (89), needle bearing (88), inner race (87), thrust plate (86), thrust plate (90), thrust plate (91) and screw (92). WARNING

Use care of the following when removing the 1st stage holder assy. Take care so you do not pinch your fingers at removing. 60

W3-2-76

TRAVEL DEVICE

E245B

Removing the 1st stage holder assy 1.

Fix the 1st stage holder assy in a vise and heat screw (92) with a hair dryer and loosen it.

2.

Separate screw (92), thrust plate (91), thrust plate (90), planetary gear B (89), needle bearing (88), inner race (87) and thrust plate (86), from the holder B, in that order.

92

: 8 mm

85 86

IMPORTANT: When loosening screw (92), exercise care of the following: Screw (92) is coated with Loctite and hard to get slack. If you loosen it by force, it is scored and can not be reused. Heat the screw with a hair dryer before loosening it.

89

88

87

90 91 60

Removing sun gear C 1.

Remove sun gear C (83).

83 60

W3-2-77

E245B

TRAVEL DEVICE

Removing planetary gear C 1.

Fix flange (1), loosen bolt (82) and remove it.

2.

Next, separate thrust plate (81), planetary gear C (80), needle bearing (79), inner race (78) and thrust plate (77), in that order.

1

: 17 mm

79

WARNING Bolt (82) is coated with adhesive Loctite to prevent it from loosening. Fix flange (1) securely for that reason. When loosening bolt (82), use a tool with a sufficiently long extension such as iron pipe. If you do not use it and try to loosen by force, you may injure your waist or other parts.

82

81

80

78

77 60

Removing holder C 1.

Fix flange (1) and loosen and remove bolt (76).

2.

Holder C (74) is fixed to flange (1) with pin (99).

3.

Attach the removing jig from the motor side and separate holder C (74) by the use of a press.

74

: 17 mm

WARNING

76

When loosening bolt (76), use care of the followin: Coat bolt (76) with screw locking agent to prevent it from loosening. For that purpose, fix flange (1) securely. To loosen bolt (76), use a tool with a sufficiently long extension such as an iron pipe. If you loosen it by force, you may injure your waist or yourself in some cases.

W3-2-78

99 60

TRAVEL DEVICE

E245B

Separating flange from housing 1.

Attach a jig to the end face on the outer flange of housing and separate flange (1) from housing (72) by pressing flange (1) by press.

&

1

99 72

1

72 60

Removing floating seal 1.

Remove floating seal (70) by pushing up the outer circumference of floating seal (70) with a flat-blade screwdriver.

70 60

Storage of parts This completes disassembly. Clean the disassembled parts thoroughly, coat them with a thick film of rust preventive oil, put them in plastic bags and store them in a cool, dark, dry place. NOTE: If the parts are stored in a hot humid place, they may be rusted even if rust preventive oil is applied. Keep the parts so no dust adheres to them.

W3-2-79

E245B

TRAVEL DEVICE

ASSEMBLING PROCEDURE OF TRAVEL DEVICE (E245B) Assembling floating seal into flange 1.

Confirm the below items concerning floating seal (70). Then assemble floating seal (70) to flange (1), using the floating seal fixing jig.

1 70

‘ 60

NOTE: Make certain that there is no dust on the surface of flange (1) in contact with floating seal (70). — Thoroughly degrease the surface where floating seal (70) of flange (1) is located. — Make sure that no dust is there on the O-ring of floating seal (70). — Thoroughly degrease the surface of the O-ring in floating seal (70).

71 72 71 (

(

60

2.

Assembling angular bearing (71) to housing (72).

3.

Press angular bearing (71) into housing (72), using a pressing (E) jig and a press.

4.

Make sure of the following as to floating seal (70). Then assemble floating seal (70) into housing (72), using the floating seal (D) fixing jig.

‘

70 NOTE: Make certain that there is no dust and foreign matter on the surface on which floating seal (70) in housing (72) is located. — Thoroughly degrease the surface where floating seal (70) in housing (72) is located. — Make sure that there is no dust and foreign matter on the O-ring of floating seal (70). — Thoroughly degrease the surface of the O-ring in floating seal (70).

W3-2-80

72

60

TRAVEL DEVICE

E245B

Assembling housing into flange 1.

Make sure of the below items and assemble housing (72) into flange (1), using a crane, so floating seal (70) of flange (1) matches floating seal (70) of housing (72).

NOTE: Make certain that there is no foreign matter on the moving surface of the seal ring located in floating seal (70). — Apply lubricating oil for the reduction unit or hydraulic oil to all sliding surface of seal ring located in floating seal (70). — When assembling housing (72) into flange (1), make sure that the shaft centers are aligned with each other.

1

72

60

Selecting the thickness of shim 1.

Press the end face of the inner race of angular bearing (71) at a load of 3000 kgf (6600 lbf), using the shim thickness (F) adjusting jig.

2.

In that case, measure the step H between the end face of the inner race of angular bearing (71) and the end face of flange (1).

3.

Measure the step h at holder (74).

4.

Select and combine the repair kit (t=0.05, 0.1, 0.3, 0.5, 1.0) of shims (73) so as to attain shim thickness that matches (H-h).

IMPORTANT: Do not reuse shims (73) that were once used. — Do this work without fail. If pre-load adjustment is not done well, the reduction unit may be broken during operation. — Clean the measuring surface thoroughly.

W3-2-81

74 h Press load: 3000 kgf )

H 71

1 60

E245B

TRAVEL DEVICE

Assembling holder C 1.

Fix flange (1) and erect pins (99) [four places] upright on flange (1).

2.

Bring the shims selected under (5) in contact with holder C (74), using grease, match the pin holes in holder C (74) to the pins and press it in by press.

3.

74 73

Fit washer (75) to holder C (74), coat bolts (76) with Loctite and tighten the bolts to a specified torque.

99

: 17 mm : 539 Nm (397.5 lbf·ft)

1

NOTE: Use care of the assembling direction of washer (75). Check correct direction in the picture on the right.

73 74

NOTE: Confirm that pins (99) are not inclined. — Washer (75) is equipped with a spike to prevent it from getting slack. Fit the spike to the seat of holder C (74). — Thoroughly clean the threads of bolt (76), degrease it and coat it with adhesive Loctite. — Thoroughly clean and degrease the inside of the screw threads of flange (1).

99 76

75

75

60

Assembling planetary gear C 1.

Assemble thrust plate (77) to planetary gear C (80).

2.

Next, fit needle bearing (79) to planetary gear C (80).

3.

Finally, attach inner race (78).

4.

Then install planetary gear C (80) by engaging the bore diameter of inner race (78) with trunnions (four) of holder C (74).

NOTE: Assemble thrust plate (77) to planetary gear C (80) so the draft of the thrust plate (77) is located on holder C (74) side. — When the planetary gears C (80) are installed finally to the holder C (74), mesh the inner gear of housing (72) with gear of planetary gear C (80). — Use care of the assembling direction of planetary gear C (80).

72 74

80 79

78

77

80 77 79 78

74 60

W3-2-82

TRAVEL DEVICE

E245B

Assembling thrust plate 1.

Install planetary gear C (80) so the chamfer side in the bolt hole of thrust plate (81) comes below the neck of bolt (82).

2.

After placing it, coat the screw threads of bolt (82) with Loctite, attach bolt (82) and tighten it to a specified torque. : 8 mm : 539 Nm (397.5 lbf·ft)

NOTE: Use care of the attaching direction of thrust plate (81). If the neck of the bolt is damaged, it breaks down. Clean the screw threads of bolt (82) thoroughly, degrease it and coat it with Loctite. Clean the screw threads in the tapped hole of holder C (74) thoroughly and degrease it thoroughly.

82

81

82

&

NOTE: Place so (C2) chamfer side comes on the seat side.

60

W3-2-83

E245B

TRAVEL DEVICE

Assembling sun gear C 1.

Make sure that snap ring (84) is fitted to sun gear (83).

2.

Then attach sun gear C (83) to four planetary gears C (80).

3.

Engage the teeth of planetary gear C (80) with those of sun gear C (83) and assemble them together.

80

84

83 60

Assembling holder B 1.

Engage the inner gear teeth of holder B (85) with the teeth of sun gear C (83) and assemble holder B (85) into sun gear C (83).

85

83 60

W3-2-84

TRAVEL DEVICE

E245B

Assembling planetary gear B 1.

Assemble thrust plate (86) to planetary gear B (89).

2.

Next, attach needle bearing (88) to planetary gear B (89).

3.

Finally, attach inner race (87), engage the bore with the trunnions (3 places) of holder B (85), and assemble planetary gear B (89) into holder B (85).

86 89 85

NOTE: Attach thrust plate (86) to planetary gear B (89) so the draft side (by press) of thrust plate (86) is located on the holder B side (85). — Finally, when assembling planetary gear B (89) to holder B (85), engage the inner gear teeth of housing (72) with the teeth of planetary gear B (89). — Be careful of the assembling direction of planetary gear B (89).

88

87 89

86 88 87

85 60

Assembling drive gear 1.

Attach thrust plate (90) to planetary gear B (89) and then attach thrust plate (91).

2.

Coat the threads of screw (92) with Loctite and tighten it to a specified torque.

91

90

89

: 8 mm : 58.8 Nm (43.4 lbf·ft) 3.

Assemble drive gear (93) to three planetary gears B (89) by directing the spline of drive gear (93) toward the motor assembling side.

4.

Then engage the teeth of planetary gear B (89) with the teeth of drive gear (93).

NOTE: Be careful about the assembling direction of thrust plate (90). Thoroughly clean and degrease the tapped hole in holder B (85) and the threads of screw (92).

W3-2-85

93

92

60

E245B

TRAVEL DEVICE

Attaching thrust plate 1.

Measure the step between the end face of housing (72) and thrust plate (94), using the thrust plate selecting jig, choose and attach thrust plate (94) according to the table below.

72 91 94

72 7

91 94 60

Unit: mm (in) Step dimension (T)

Thrust plate code

Shim thickness (t)

1.20 ~ 0.67 (0.0472 ~ 0.0264)

20941-62306

2.3

0.66 ~ 0.04 (0.0260 ~ 0.0016)

20941 — 62307

2.8

0.03 ~ -0.16 (0.00122 ~ -0.0063)

20941 — 62308

3.0

-0.174 ~ -0.41 (-0.00685 ~ -0.0161)

20941 — 62309

3.2

-0.42 ~ -0.80 (-0.0165 ~ -0.0315)

B0841 — 23017

3.6

NOTE: Align the hole in the center of thrust plate (94) with the convex part of drive gear (93) and assemble them together.

W3-2-86

TRAVEL DEVICE

E245B

Attaching cover 1.

Remove foreign matter completely from the matching surface between the end face of housing (72) and cover (95).

2.

Next, thoroughly degrease the matching surface between the end face of housing (72) and cover (95).

3.

Further, apply liquid packing to the corner of the spigot joint on the matching surface side of housing (72) of cover (95).

4.

Match the tapped holes in housing (72) with the bolt holes in cover (95) and place cover (95) in housing (72).

5.

Finally, attach bolts (96) and tighten them to specified torque.

72 95 96

60

: 8 mm : 73.4 Nm (54.1 lbf·ft)

Fitting plugs 1.

Take off O-ring (98) from plug (97), replace it with a new one and place it in plug (97).

2.

Then, attach plugs (97) to the oil inlet / outlet and the level ports (3 in all) of cover (95), and tighten them to specified torque. : 12 mm : 157 Nm (115.8 lbf·ft)

95

98 97

This completes the assy of the reduction unit. Next comes the assemble of the motor. Assemble it, referring to «Assembling the Motor».

60

W3-2-87

E245B

TRAVEL DEVICE

MOTOR Fitting oil seal 1.

Make sure that flange (1) is equipped with oil seal (53). If not, press oil seal (53) into flange (1), using the oil seal fixing jig (G).

IMPORTANT: Before attaching oil seal (53), apply grease to the bore surface of flange (1) (where the oil seal is placed) and outer diameter surface of oil seal (53). — Coat the lip of the bore of oil seal (53) with grease and put it in. — Push the oil seal upright. If it is tilted, the outer diameter of oil seal (53) will be scored. — Be careful so as not to score the lip of the bore of oil seal (53) when fixing it. If the lip is scored, oil leakage may occur and break the inside of the reduction gear while the motor is running.

*

1 60

Assembling piston 3 1. 2.

Place spring (61) in the hole where piston assy (48) of flange (1) is located.

48 61

Then, mount piston assy (48) to flange (1).

NOTE: Place spring (61) in the center of the hole. Install piston assy (48) with its cylindrical part facing downward. Before assembling piston assy (48), apply hydraulic oil to the bore of flange (1) and the outer surface of the cylindrical part of piston assy (48). After assembling piston assy (48), confirm that it moves smoothly.

1 60

W3-2-88

TRAVEL DEVICE

E245B

Fitting steel balls 1.

Fit steel balls (47) in the holes in the spherical surface of flange (1).

NOTE: Before fixing steel balls (47), apply hydraulic oil to the bore surface in the spherical part of flange (1) and steel balls (47).

47

1

60

Installing shaft 1.

Press ball bearing (49) into shaft (36), using the bearing fixing jig. Then mount shaft (36) into the center of flange (1).

36 49 ,

1

60

Installing swash plate 1.

Attach flange (1) so the inclined surface of swash plate (46) faces up.

46

NOTE: Assemble swash plate (46) by matching the holes in the rear spherical surface of the swash plate (46) to steel balls (47). After coating steel balls (47) with hydraulic oil and assemble swash plate (46). After assembling swash plate (46), make sure that the swash plate moves smoothly.

1

60

W3-2-89

E245B

TRAVEL DEVICE

Assembling cylinder block 1.

Place cylinder block (37) on a hand press bench so the sliding surface of valve plate (62) faces up.

2.

Assemble cylinder block (37) so the slope of spring seat (42) faces downward.

43

3.

Then mount spring (43) and collar (44) on spring seat (42), in that order.

42

4.

Press in the top face of collar (44), using a jig, and fix snap ring.

44

37

WARNING If snap ring (41) is tight, the snap ring pliers come off from the snap ring and you are injured by it, in some cases. When fixing the snap ring, always use a jig (J) and make sure that the claw of the snap ring pliers is engaged in the hole of the snap ring. If it is difficult to narrow the snap ring, use snap ring pliers one size larger. To press in collar (44), align the center of the cylinder block with that of the press.

60

41

—

60

5.

6.

Place cylinder block (37) on a work bench so the sliding surface of cylinder block (37) in contact with valve plate (62) faces downward.

45

Place three pins (45) into the slanted holes in cylinder block (37).

IMPORTANT: Before placing cylinder block (37) on a work bench, make certain that there is nothing on the work bench. Use care so as not to score the sliding surface of valve plate (62) in cylinder block (37). If the surface is scored, the motor performances are deteriorated which leads to a failure of the motor in an early stage. Before fixing pins (45), coat the pin holes with grease.

W3-2-90

37

60

TRAVEL DEVICE 7.

E245B

Install retainer holder (40) to cylinder block (37).

37 40 60

8.

Attach piston assy (38) [9 pcs.] to retainer plate (39) so the tapered face of retainer plate (39) faces downward.

39

38 60

9.

Install piston assy (38) to cylinder block (37).

NOTE: Coat the piston holes (9 pcs.) in cylinder block (37) with hydraulic oil, before installing piston assy (38). Coat the spherical surface of retainer holder (40) with hydraulic oil, before assembling it.

37

38 60

W3-2-91

E245B

TRAVEL DEVICE

Assembling cylinder block 1.

Engage the inner tooth splines of retainer holder (40) and cylinder block (37) with the outer tooth spline of shaft (36) so the sliding surface of cylinder block (37) in contact with valve plate (62) faces upwards.

2.

Then assemble cylinder block (37) into flange (1).

NOTE: At assy, use care so piston assy (38), retainer plate (39) and retainer holder (40) do not come off from cylinder block (37). Before assy, coat the surface of swash plate (46) and the sliding surface of piston assy (38) with hydraulic oil.

37

1

60

Attaching disk plate 1.

Engage the inner teeth of disk plate (54) with the outer teeth of cylinder block (37) and mount them to flange (1).

2.

Assemble the convex portion of the outer circumference of friction plate (55) with the concavity of flange (1) and install them to flange (1).

3.

In this way attach disk plate (54) and friction plate (55) to the flange, in that order.

54 55 54

55

54

NOTE: Disk plate (54) is a wet type disk. Before assmbly, immerse the disk plate (54) in hydraulic oil so disk plate (54) sucks in sufficient hydraulic oil. 60

W3-2-92

TRAVEL DEVICE

E245B

Installing brake piston 1.

Attach O-rings (57), (58) to brake piston (56).

2.

Next, mount brake piston (56) to flange (1) so the larger diameter side of the brake piston faces upward.

56 IMPORTANT: Coat O-rings (57), (58) with sufficient grease, before fixing them. Align the knock pin hole in flange (1) in contact with base plate with the knock pin hole in brake piston (56), using the positioning jig (K). Then install brake piston (56). Before fitting brake piston (56), coat the outer surface of the brake piston and the bore of flange (1) with grease. Assemble brake piston (56) by pressing it so it does not tilt. If the brake piston is assembled inclined, it develops trouble and tears off O-rings in some cases.

.

57 58

56 1 60

Fitting springs 1.

Fit springs (59) into eight holes in brake piston (56).

59

60

W3-2-93

E245B

TRAVEL DEVICE

Attaching valve plate 1.

Place base plate (2) on a work bench and press bearing (50) in the center of base plate (2), using the bearing fixing jig (L).

2.

Confirm that knock pin (60) is fixed in base plate (2) and attach valve plate (62) to base plate (2).

NOTE: Place valve plate (62) with the copper alloy side facing upward. Coat the matching face between base plate (2) and valve plate (62) with grease to prevent the valve plate from falling off. Use care so as not to score the copper alloy surface of valve plate (62).

W3-2-94

62 /

50

2

60

TRAVEL DEVICE

E245B

Attaching base plate 1.

Fit O-rings (64) and O-rings (63) [4 places] to the top face of flange (1).

2.

Fit knock pin (60) to base plate (2).

3.

Attach base plate (2) to flange (1) so the surface of valve plate (62) in contact with base plate (2) faces downward.

4.

Then tighten them with socket bolts (52).

60

2

52 60

: 12 mm : 205 Nm (151.2 lbf·ft)

63 64

NOTE: Coat O-ring (64) with grease. Do not coat O-ring (63) with grease. Fix knock pin (60) with its taper part upward. Coat the surface of valve plate (62) and the cylinder block (37) with hydraulic oil and install them to base plate (2). Since the surface of the base plate (2) in contact with base plate (2) faces downward, take care so the valve plate does not fall. When installing base plate (2) to flange (1), make sure of the location of O-ring (63) and the location of the oil passage hole in base plate (2). Before assmble, make sure of the knock pin (60) fixed in base plate (2), the hole in the base plate (2) into which spring (59) enters, the knock pin hole on the flange side (1), and the position of spring (59). Tighten socket bolts (52) evenly all round on the circumference.

W3-2-95

60

E245B

TRAVEL DEVICE

Assembling travel 2-speed select spool 1.

Attach spring (21) to spool (19).

2.

Then attach them to base plate (2).

3.

After placing spool (19), make certain that Oring (23) is set in plug (22), fit plug (22) to base plate (2) and tighten it to a specified torque.

4.

25 21 23

Next, make sure that O-ring (23) is fitted to plug (25), install spring guide (24) and washer (26), place plug (25) to base plate (2), and tighten it to a specified torque.

2 19

: 10 mm : 118 Nm (87 lbf·ft)

23 22 60

NOTE: Assemble spool A (19) into base plate (2) so that the pipe port surface of base plate (2) comes toward yourself and that the side of spool A (19) on which spring (21) is placed comes on the right. If the spool is assembled inversely, spool change may get out of order and other trouble may occur in some cases. Coat the outer surface of spool (19) with hydraulic oil, before assembling it. After spool (19) is placed, make certain that it moves smoothly.

W3-2-96

TRAVEL DEVICE

E245B

Assembling relief valve 1.

Make sure that poppet seat (17-3) is placed at the tip of relief valve (17).

2.

Then assemble relief valve (17) to base plate (2) and tighten them to a specified torque. : 27 mm : 373 Nm (275 lbf·ft)

17-17,18 NOTE: Replace O-ring (17-7) with a new one, before assembly. Make sure that O-ring (17-7) and backup ring (1718) are fitted to poppet seat (17-3). Coat O-ring (17-17) and backup ring (17-18) with grease, before assy.

2

17-3 17-7 17

60

Assembling counterbalance valve plunger 1.

Assemble plunger (3) to base plate (2).

NOTE: Assemble the plunger (3) to the base plate, while turning the plunger. Install plunger (3) straight. In case plunger (3) gets stuck, do not force it in, but tap it lightly with a plastic mallet. Coat the outer surface of plunger (3) with hydraulic oil before assmble.

2 3 60

W3-2-97

E245B

TRAVEL DEVICE

Attaching cap 1.

Attach spring seat (8) and spring (9), in that order, to plunger (3).

2.

Fit ball (33) and spring (34), O-ring (14), plug (15), in that order, into the hole beside the hole in base plate (2) in which cap (11) is placed.

3.

Finally, fasten capscrew (13) to a specified torque.

33,34,14,15

: 10 mm : 108 Nm (79.7 lbf·ft)

8

17

9 10

NOTE: Coat O-ring (12) with grease. Cap (11) is pushed up by the action of spring (9). When tightening up socket bolts (13), hold them down by hand. Tighten four socket bolts (13) evenly all round. If cap (11) is tightened up tilted, O-ring (12) is damaged, resulting in oil leakage.

11,12 13

60

This completes assy of the hydraulic motor.

TOOL TABLE REF.

TOOL NO.

A

XXXXXXXXX

DESCRIPTION Torque multiplier

B

XXXXXXXXX

Stopper back-up ring flanged hub

C

XXXXXXXXX

Stopper O-Rings plugs

D

XXXXXXXXX

Stopper O-Rings flanged plug

E

XXXXXXXXX

Stopper O-Rings relief valve

F

XXXXXXXXX

Stopper O-Rings two speed control

G

XXXXXXXXX

Stopper fitting O-Rings plug

H

XXXXXXXXX

Tool half seal gearbox housing

W3-2-98

TRAVEL DEVICE

E245B

MAINTENANCE STANDARD Sprocket

% & ‘

(

$

60

IMPORTANT: Consult NEW HOLLAND KOBELCO S.p.A. for any inqueries concerning welding procedures. Standard mm (in)

Allowable Limit mm (in)

A

66 (2.57)

58 (2.26)

B

586 (22.85)

575 (22.42)

C

PCD644.6 (25.14)

—

D

659 (25.70)

649 (25.31)

E

190 (7.41)

—

W3-2-99

Remedy

Build up and finishing

E245B

TRAVEL DEVICE

NOTES

W3-2-100

SWIVEL JOINT

E215B-E245B

REMOVAL AND INSTALLATION OF SWIVEL JOINT 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. 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. Preparation 1.

Park the machine on a firm, level surface.

2.

Cut-off the engine. Actuate the manual and pedal pilot valves to release any residual pressure from inside the hydraulic system. Press the valve located on the hydraulic oil tank to release any residual pressure present inside the tank itself.

3.

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.

Removal NOTE: Attach labels or tags to hoses and adapters, to aid in assembly. 1.

Remove tubes (2 and (PF1). : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf·ft)

Remove tube (5 and 6) (PF1/2). : 27 mm : 78.5 ±5 Nm (57.9 ± 3.7 lbf·ft)

2.

3.

4.

Remove tubes (3 and 4) (PF1/4). : 19 mm : 29.4 ±5 Nm (21.7 ± 3.7 lbf·ft)

Remove tubes (1 and 7) (PF1). : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf·ft)

60

W3-3-1

E215B-E245B 5.

SWIVEL JOINT

Remove drain hose (2).

: 27 mm : 78.5 ±5 Nm (57.9 ± 3.7 lbf·ft) 6.

Remove hoses (4 and 6). : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf·ft)

7.

Remove hoses (1 and 3). : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf·ft)

8.

Remove hose (5). : 19 mm : 29.4 ±5 Nm (21.7 ± 3.7 lbf·ft)

60

9.

Loosen the stop nut (7) M20 of swivel joint and remove the screw (8) M20x120.

: 36 mm : 157 Nm (115.8 lbf·ft)

60

10. Remove two adapters (9 and 10). : 19 mm : 36 Nm (26.6 lbf·ft)

60

W3-3-2

SWIVEL JOINT

E215B-E245B

11. Remove six screws (2) M10x25.

: 19 mm : 14.7 Nm (10.8 lbf·ft)

12. Remove clip (1). : 6.8 Nm (5.0 lbf·ft)

13. Remove seal (4).

60

14. Attach eye bolt (5), lift it up temporarily, and remove three screws (6) M12x35. : 19 mm : 108 Nm (79.7 lbf·ft)

NOTE: swivel joint mass: 31 kg (68.4 lbs).

60

Installation NOTE: refer to “Removal” section above for wrench sizes and tightening torque. 1.

Proceed with the re-installation of the centre joint following the operation in reversed order with respect to the removal.

NOTE: swivel joint mass: 31 kg (68.4 lbs).

W3-3-3

E215B-E245B

SWIVEL JOINT

SWIVEL JOINT DISASSEMBLY AND ASSEMBLY

View from X

Section G-G

60

1 2 3 4 5 6

—

Body Stem Thrust plate Cover Seal assy Seal assy

7 8 9 12 13

W3-3-4

—

O-Ring Socket Bolt (M8 x 20) Socket Bolt (M8 x 30) Plug O-ring

SWIVEL JOINT

E215B-E245B

Disassembly The part numbers used in this disassembly procedure correspond to those of a construction drawing in the figure on page W3-3-4. 1. Mark cover (4) and body (1) with matching marks for convenient reassembly. 2.

Place a ‘V’ (A) block on a work bench, place a swivel joint set on the side, fix it and loosen socket bolt (9) by means of a pipe and wrench. Alternately, the swivel joint may be fixed by holding stem (2) in a vise.

$

: 6 mm

60

3.

Remove cover (4) from body (1) and draw out O-Ring (7) from cover (4).

60

4.

Loosen socket bolt (8) fastening thrust plate (3), in the same manner as the removing of the above-mentioned cover (4).

— When removing thrust plate (3) by fixing body (1), support stem (2) so it may not fall down. : 6 mm

60

W3-3-5

E215B-E245B 5.

SWIVEL JOINT

Place body (1) on a ‘V’ (A)-block. Put a wooden block against stem (2) via the body so about half of the stem is covered by the wooden block (B) and knock it out using a mallet. By hitting out the stem over about 1/2 from the body, it can be easily pulled out by hand.

%

$

6.

Remove the back-up ring of the seals assemblies (5 and 6) by means of a spatula (E).

60

(

NOTE: Make sure the body (1) is not scored from the tip of the spatula (E).

60

7.

Take off the slip ring (B) of the seals assemblies (5 and 6) by means of pin of screwdriver (A) and remove them from the O-Ring grooves (D). The figure on side shows the use of only one pin of screwdriver, but by using two screwdriver pins, these can be extracted with more sureness.

NOTE: Make sure the body (1) is not scored from the screwdriver (A).

&

% $ ‘

60

W3-3-6

SWIVEL JOINT

E215B-E245B

Assembly Prior to assembly, clean each parts (excluding the O- Ring and slipper ring), and arrange in the sequence of assembly. 1. Make sure that oil and grease remains have been completely removed. 2.

Apply grease on the groove where are seated the O- Ring (6).

3.

Apply hydraulic oil to O-ring (13) thinly and insert it into O-ring groove. Check the twist of Oring.

4.

Slipper ring (B) is assembled, after first inserting the backup ring, by slightly-distorting the shape as shown in figure. Also after inserting all of the seals, be certain that these are installed in the seal groove by use of the spatula.

5.

Assemble seal (5) by the same procedure above mentioned, after removing grease, hydraulic oil and vaseline from the groove of the seal. Seals (5) have no back-up ring.

6.

Lightly coat the outer circumference of stem (2) and the inner surface of body (1) with grease or vaseline and slowly insert stem (2) into body (1).

%

60

NOTE: If stem (2) is pressed in too fast, the seal may be damaged. Do it slowly. The clearance between body (1) and stem (2) is about 0.1 mm. Push stem straight along the shaft center.

60

*A: Push with both hands

W3-3-7

E215B-E245B

SWIVEL JOINT

7.

While holding stem (2) and body (1), match the hole of thrust plate (3) and the stem (2) hole.

8.

Next, after removing any oil from the thread of socket bolt (8), coat it with Loctite 242 and tighten to stem (2).

: 6 mm : 30.4 Nm (22.4 lbf·ft)

60

9.

After installing O-Ring (7) to cover (4) and aligning the matching marks of the cover (4) and body (1), coat socket bolt (9) with Loctite 242 and tighten it which will then complete assembly.

$

: 6 mm : 30.4 Nm (22.4 lbf·ft)

60

W3-3-8

SWIVEL JOINT

E215B-E245B

MAINTENANCE STANDARD Allowable Limit (basis of judgment)

Item Sliding surface and sealed parts

Body, Stem

Sliding surface exception sealed parts

Sliding surface ring

Cover

Sliding surface ring

Remedy

Scored or something hurt it.

Replace

1.

Scored more than 0.1 mm.

Replace

2.

Scored less than 0.1 mm.

Repair with oil stone

1.

Wear more than 0.5 mm deep.

Replace

2.

Wear less than 0.5 mm deep.

Repair

3.

Scored less than 0.5 mm and able to repair.

Repair

1.

Wear more than 0.5 mm.

Replace

2.

Wear less than 0.5 mm.

Repair

3.

Scored less than 0.5 mm and able to repair.

Repair

1.

Protruded excessively from seal groove.

Replace (with back-up ring)

60

2.

Slipper ring narrower than 1.5 mm of seal groove, or narrower than back-up ring.

Replace (with back-up ring)

Slipper ring

PPPD[

60

3.

Worn unevenly more than 0.5 mm.

PPPD[

Replace (with back-up ring)

60

W3-3-9

E215B-E245B

SWIVEL JOINT

Inspection after assembly After completion of assembly, inspection for oil leakage, pressure resistance, etc., using a device as shown in the figure on right. 1. High pressure port (A, B, C, D and F port). Install a directional valve (8) and pressure gauge (1) to the stem side port and body side port respectively, and while watching the pressure gauge (for high pressure) installed on the body side and also by regulating high pressure relief valve (7), gradually increase the pressure. When the pressure has reached 1.5 times the maximum working pressure, close stop valve (3) and lock in the hydraulic oil in the swivel. At this time, keep stop valve (6) on the low pressure relief valve side closed for, at least, 3 minutes and check for any distortions, breakages or loosening. During the first minute, check for oil leakages and, in case of pressure drop, this shoul be the 10% of the pressure trapped. This check should be performed on each circuit. 2.

Low pressure port (E port). Similar to the high pressure port, install a directional valve and pressure gauge on each port of the stem side and body side. Open stop valve (6) on the side of low pressure relief valve (5) and while watching the pressure gauge (for low pressure) connected to the body side and also by regulating low pressure relief valve (5), gradually increase the pressure and check for outside leakage with a color check at a pressure of 0.49 MPa.

60

123456789-

W3-3-10

Pressure Gauge Swivel Joint Stop Valve Hydraulic source Relief Valve for low pressure Stop Valve Relief Valve for high pressure Directional Valve Piping, etc.

TRACK ADJUSTER

E215B-E245B

REMOVAL AND INSTALLATION OF TRACK ADJUSTER (WITH FRONT IDLER) Before removing the track adjuster, the tracks and the front idler must be removed first. For removal and installation of the tracks and the front idler, refer to applicable removal/installation sections. In this section, the procedure starts on the premise that the tracks and the front idler have already been removed. Removal NOTE: Track adjuster assembly weight: 214 kg (472 lbs) (E215B) — 250 kg (551 lbs) (E245B). WARNING Be sure cables are anchored and the anchor point is strong enough to handle the expected load. Keep exposed personnel clear of anchor point and cables or chain. 1.

After swinging superstructure to 90° related to machine longitudinal centerline for easier access to track components, remove the front idler and track adjuster assembly from track frame by prying it out, using a pry bar shown in figure.

60

Installation WARNING Be sure cables are anchored and the anchor point is strong enough to handle the expected load. Keep exposed personnel clear of anchor point and cables or chain. 1.

As shown in figure, install the front idler and track adjuster into spring guide on track frame.

60

W3-4-1

E215B-E245B

TRACK ADJUSTER

DISASSEMBLY AND ASSEMBLY TRACK ADJUSTER Disassembly Track Adjuster Be sure to thoroughly read «Precautions for Disassembly and Assembly» on page W1-1-1 before starting the disassembly work.

$

Be sure to use special tool (A) (380001029) for assembly / disassembly of the track adjuster. WARNING Prevent personal injury. The spring force of the track adjuster is extremely large. Thoroughly inspect the special tool for any damage. Carefully perform assembly work referring to the procedure below.

60

NOTE: Approximate weight of the track spring holder assembly: 229 kg (505 lbs) (E215B) — 265 kg (584 lbs) (E245B). 1.

Place a jack on the bottom of the track spring holder assembly (380001029).

2.

Loosen four nuts to remove the plate (A).

$

: 46 mm

60

NOTE: Track adjuster weight: 102 kg (225 lbs) (E215B) — 138 kg (304 lbs) (E245B). 3.

Connect the track adjuster to a hoist using a lifting strap. Put the track adjuster in the track spring holder assembly (380001029). Remove the lifting strap.

9

W3-4-2

60

TRACK ADJUSTER 4.

Draw out piston (6) from grease cylinder (1) of the idler adjuster assy.

5.

Removing oil seal (9), O-Ring (8) from grease cylinder (1).

6.

Set the idler adjuster assy on the stand of the jig, with its bracket side facing up.

E215B-E245B

60

7.

Fit retainer plate (A) to bracket (2), tighten holding-down nuts alternately, and secure idler adjuster assy.

: 46 mm

$

60

8.

Remove spring pin (4), press spring (5) lifting it with jack so that nut (3) can be turned freely, and remove nut.

: 46 mm : 75 mm

60

W3-4-3

E215B-E245B 9.

TRACK ADJUSTER

Allow the hydraulic jack to retract slowly till the spring is extended to its free length. Remove the retainer plate and take off bracket (2) and cover (11). : 46 mm

60

10. Hook lifting eye nut (W) to screw M48 on grease cylinder (1) top end and hoist it. Then, remove the set of grease cylinder (1) and spring (5) using crane from the jig. Remove spring (5), collar (7), grease cylinder (1), in that order.

:

60

W3-4-4

TRACK ADJUSTER

E215B-E245B

Assembly 1.

Insert grease cylinder (1) and collar (7) into spring (5) and attach lifting eye nut (W) to screw M48 at the tip of the grease cylinder. Lift the grease cylinder by crane and erect it in the center of the jig stand upright (380001029).

60

:

60

2.

Install bracket (2) and cover (11) on top of spring (5). Center the rod of grease cylinder (1) and the holes in bracket (2). Attach the retainer plate (13) and four holding-down nuts (12). Fasten the nuts evenly all round and fix the idler adjuster assy to the jig body (380001029).

: 46 mm 3.

Extend the hydraulic jack, compress spring (5) to a set length and screw in nut (3) to the screwed part at the tip of grease cylinder (1). Set length of the spring 432 mm (E215B) 440 mm (E245B)

4.

Tighten nut (3) till the holes for locking spring pins (4) are aligned. Then fit spring pin (4). : 46 mm : 75 mm

W3-4-5

60

E215B-E245B 5.

TRACK ADJUSTER

Remove idler adjuster assy from jig (380001029).

NOTE: Track adjuster weight: 102 kg (225 lbs) (E215B) 138 kg (304 lbs) (E245B).

60

6.

Apply grase on the oil seal (9) and O-Ring (8) then fit them to grease cylinder (1).

7.

Fill up grease in cylinder (1), remove the grease nipple from piston (6) in order to discharge the inside air, and press in the piston by hand.

8.

Direct grease nipple hole downward to make air discharge easier.

9.

Tighten grease nipple (X) to piston (6).

;

: 19 mm : 59 Nm (43.5 lbf·ft)

TOOL TABLE TOOL NO. 380001029

DESCRIPTION

Jig stand track adjuster

W3-4-6

60

FRONT IDLER

E215B-E245B

DISASSEMBLY AND ASSEMBLY FRONT IDLER ASSY Disassembly 1.

Remove plug (8) on the side of collar (3) to drain oil.

: 5 mm

60

2.

To remove pin (5) apply pin push bar (A) (380001051) to the top of pin, and push out striking bar lightly by hammer.

$

60

Put idler on repair stand. Apply push-out jig on shaft (B) (380001052), push out shaft (6) with collar (3), then remove collar (3).

3.

%

60

* : Push with press

W3-5-1

E215B-E245B

If removal of collar (3) on the opposite side is required, turn over front idler and proceed with the procedure described in the previous step.

4.

FRONT IDLER

%

60

* : Push with press 5.

With idler (1) mounted on the stand, tap bushing (C) (380001053) lightly by hammer, while placing the bushing drawing rod against the end face of bushing (2) evenly all round, till it comes out.

6.

Take out floating seals (4) from idler (1), collar (3). If you intend to re-use floating seals (4), confirm that there is no scoring and rusting on the contact surface and store the floating seals in pairs by placing card board between the sealing faces.

7.

Separate O-Ring from shaft.

&

60

W3-5-2

FRONT IDLER

E215B-E245B

Assembly Align inner hole of idler (1) and bushing (2) and press fit it vertically with press so that jig (D) (380001054) for bushing press-fitting is inserted into bushing.

‘

1.

60

* : Push with press 2.

Fit O-Ring (7) to O-Ring groove on shaft (6).

3.

Press fit the O-Ring installed side of shaft (6) into collar (3), and drive pin (5).

4.

Fit the half of floating seal (4) on each side of collar (3) and idler (1).

60

5.

6.

Install idler (1) on the shaft (6) with the floating seal (4) fitted into shaft (6) with the toward collar (3).

Fit floating seal (4) on the other side of idler (1).

60

7.

8.

Fit the half of floating seal (4) on the other collar (3), press fit it in shaft (6), and drive pin (5) in with hammer. Fill in 265 cm³ of engine oil AGIP SAE40RCL through the plug hole of collar (3), wind seal tape and tighten plug (8).

: 5 mm NOTE: After installing the idler assy to the idler adjuster assy, make certain that no oil leaks from floating seal and plug (8) and that idler (1) rotates smoothly. 60

W3-5-3

E215B-E245B

FRONT IDLER

MAINTENANCE STANDARD Front Idler

& ‘

( $ % 60

Unit: mm Standard

Allowable

A

84

66

B

159

—

C

500

482

D

540

—

E

20

—

Remedy

Buildup weld and finishing

IMPORTANT: Consult NEW HOLLAND KOBELCO for any inqueries concerning welding procedures.

Axle and Bushing Unit: mm Standard

Allowable

Axle

Outside Dia

75

74.2

Bushing

Inside Dia

75

76

Bushing

Flange thickness

2

1.2

TOOL TABLE TOOL NO.

DESCRIPTION

380001051

Pin push bar

380001052

Push-out jig

380001053

Punch for upper roller bushes

380001054

Bushing press-fitting jig

W3-5-4

Remedy Replace

UPPER AND LOWER ROLLER

E215B-E245B

REMOVAL AND INSTALLATION OF UPPER ROLLER Removal WARNING Do not loosen valve (1) quickly or loosen it too much as high-pressure grease in the adjusting cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (1). Never loosen grease fitting (2). 60

IMPORTANT: When gravel or mud is packed between sprockets and tracks, remove it before loosening. 1.

Loosen valve (1) to drain grease. : 19 mm

60

WARNING

Insert a piece of non-sliding rag between track frame (5) and hydraulic jack to prevent that the latter slides. 2.

Lift track chains (3) with the hydraulic jack to a height sufficient to remove upper roller (4).

60

3.

Insert a wooden block between tracks (3) and track frame (5).

W3-6-1

60

E215B-E245B 4.

UPPER AND LOWER ROLLER

Remove screws (2) from the support roller (1).

NOTE: Support roller mass 16.5 kg (36.4 lbs).

60

5.

Remove the upper roller (1) from the track frame (3).

NOTE: Support roller mass 16.5 kg (36.4 lbs).

60

Installation 1.

Install the support roller (1) and, after coating with Loctite #232, tighten screws (2). : 19 mm : 265 Nm (195.4 lbf·ft)

2.

Remove the wooden blocks and the hydraulic jack.

60

W3-6-2

UPPER AND LOWER ROLLER 3.

E215B-E245B

Supply grease to valve (3) throught nipple (4) to adjust tracks tension. Track sag specifications (A): 320 ÷ 350 mm : 19 mm : 59 Nm (43.5 lbf·ft)

NOTE: Check track sag after thoroughly removing soil stuck on the track area by washing.

60

60

4.

Add engine oil via plug (3) hole on cover (4). Apply sealant (Loctite 503 or equivalent) to plug (3). Tighten plug (3). Engine oil quantity: 0.2 kg : 6 mm : 23 Nm (17.0 lbf·ft)

W3-6-3

60

E215B-E245B

UPPER AND LOWER ROLLER

REMOVAL AND INSTALLATION OF LOWER ROLLER Removal

1.

Remove the roller guard and loosen bolts M18 (5). : 27 mm

60

2.

Lift the one side of the track frame high enough to remove the lower roller. Insert wooden blocks under track frame (2).

60

WARNING Do not loosen valve (3) quickly or loosen it too much as high-pressure grease in the adjusting cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (3). Never loosen grease fitting (4).

60

3.

Loosen valve (3) to drain grease enough to permit the roller removal. : 19 mm

W3-6-4

60

UPPER AND LOWER ROLLER

E215B-E245B

NOTE: Lower roller weight: 36.43 kg (80.3 lbs). 4.

Securely hold the lower roller using a fork lift. Remove lower roller (1).

60

Installation 1.

Securely hold the lower roller using a fork lift. Put lower rollers (1) on the tracks as illustration.

60

2.

Lower track frame (2) enough to allow bolts (4) to be installed into track frame (2).

60

3.

Align tapped holes in track frame (2). Tighten bolts M18 (5). : 27 mm : 400 Nm (295 lbf·ft)

60

W3-6-5

E215B-E245B 4.

UPPER AND LOWER ROLLER

Supply grease to valve (3) throught nipple (4) to adjust tracks tension. Track sag specifications (A): 320 ÷ 350 mm : 19 mm : 59 Nm (43.5 lbf·ft)

60

NOTE: Check track sag after thoroughly removing soil stuck on the track area by washing.

60

W3-6-6

UPPER AND LOWER ROLLER

E215B-E245B

UPPER ROLLER DISASSEMBLY 1.

Remove plug (3) and drain out oil.

: 6 mm 2.

Mount the end face inside upper roller (1) on stand jig (A) (XXXXXXXXX) and loosen bolts (12). : 19 mm

3.

Take off cover (9).

4.

Separeate O-Ring (11) from cover (9).

5.

Loosen two trust-washer bolts (13) and draw out trust-washer (10) from roller (1).

$

60

: 15 mm

6.

Put the extrusion jig (B) (XXXXXXXXX) against the end face of shaft (2) and push shaft with collar (8) to floating seals (6, 7) using a press or a hammer.

%

$

60

W3-6-7

E215B-E245B 7.

UPPER AND LOWER ROLLER

Take out floating seals (6, 7) from roller (1).

60

8.

Remove from collar (8) another floating seal (6) that is located on the side on which shaft (2) was disparted.

IMPORTANT: Collar (8) is press fitted into shaft (2) means of press. Therefore do not disassemble it.

60

9.

Since the bushings (4, 5) are thin, machine them on a lathe or scrape them off, exercise care so as not to damage the bore of roller (1). If the bushings are not worn much, mount upper roller (1) on jig (A) (XXXXXXXXX), and push out the bushings (4, 5) with punch (380001053) and hammer.

IMPORTANT: Hammer the surface of roller lightly so as not to damage the surface. Put the extrusion punch (380001053) uniformly over the circumference of bushings and extrude them perpendicularly little by little.

$

60

W3-6-8

UPPER AND LOWER ROLLER

E215B-E245B

UPPER ROLLER ASSEMBLY

&

1.

Assembly of the upper roller is done in the reverse order of disassembly.

2.

Place upper roller (1) on the top end face of jig (A) (XXXXXXXXX), with its floating seal setting side facing down.

3.

Confirm that the outer surface of bushing (5) is not seized and coat the outer surface of the inserting side of the bushing, with molybdenum disulfide grease.

Put jig (C) (XXXXXXXXX) into bushing (5) and press it in, using the bore of the bushing and the bore of the roller as guides.

4.

IMPORTANT: If you fail in this operation by pressing the bushing unevenly, the bushing is distorted and gets unserviceable. In that case, do not re-use the bushing as it may develop malfunctioning after assembly.

$

60

5.

Two floating seals (6) make a pair. Attach one floating seal to retainer fixed in shaft (2), and another to the inside of upper roller (1), placing O-rings (7). — Prior to placing floating seals (6), apply engine oil lightly to seal surface.

60

60

W3-6-9

E215B-E245B

UPPER AND LOWER ROLLER

6.

Coat shaft (2) with a thin film of oil and insert it into upper roller (1).

7.

Mount upper roller (1) on the stand jig (A) (XXXXXXXXX) and attach thrust-washer to the end face of the shaft (10) with bolt (13).

$

: 15 mm : 114.7 Nm (84.6 lbf·ft) 8.

Fit O-Ring (9) to the groove of cover (11). — Apply grease to O-Ring.

9.

Fit cover (9) to upper roller (1) and fix it with bolts (12).

: 19 mm 10. Fill in 0.2 cm3 of engine oil SAE40 through the plug hole in cover (3). 11. Wind seal tape around plug (3) and screw it into the plug hole of the upper roller (1). : 6 mm : 23 Nm (17.0 lbf·ft) — After assembling the upper roller, confirm that oil is not leaking from it and that it rotates smoothly by.

W3-6-10

60

UPPER AND LOWER ROLLER

E215B-E245B

LOWER ROLLER DISASSEMBLY

60

1.

Plug (Q.ty 2)

5.

Floating Seal (Q.ty 2)

2.

Collar (Q.ty 2)

6.

Bushing (Q.ty 2)

3.

Elastic pin (Q.ty 2)

7.

Roller

4.

O-Ring (Q.ty 2)

8.

Axle

W3-6-11

E215B-E245B

UPPER AND LOWER ROLLER

Disassembly Lower Roller Be sure to thoroughly read “Precautions for Disassembly and Assembly” on page W1-1-1 before starting the disassembly work. 1.

Remove plug (1) and elastic pins (3) from collars (2), and drain oil. : 6 mm

: 14 mm

60

2.

Press down axle (8) until O-Ring (4) comes out of collar (2). Remove collar (2) from axle (8).

3.

Remove O-Ring (4) from axle (8). Remove axle (8) from roller (7).

4.

Remove floating seal (5) from roller (7) and collar (2).

5.

Press out axle (8), and remove collar (2) and ORing (4) from axle (8).

60

6.

In case of replacing bushings (6), remove the bushings using a press and the special tool. Special Tool (380001030) (9).

60

W3-6-12

UPPER AND LOWER ROLLER

E215B-E245B

LOWER ROLLER ASSEMBLY

60

1.

Plug (Q.ty 2))

5.

Floating Seal (Q.ty 2)

2.

Collar (Q.ty 2)

6.

Bushing (Q.ty 2)

3.

Elastic pin (Q.ty 2)

7.

Roller

4.

O-Ring (Q.ty 2)

8.

Axle

W3-6-13

E215B-E245B

UPPER AND LOWER ROLLER

Assembly Lower Roller 1.

2.

Install bushings (6) (Q.ty 2) onto roller (7) using a press. Take care not to dent the flange surface of bushings. Apply a coat of grease to ORing (4) and install onto axle (8).

Install collar (2) onto axle (8), aligning the pin holes. Secure them using elastic pin (3). Take care not to damage O-Ring (4).

60

IMPORTANT: The elastic pin (3) has to be fitted with the slit oriented to the internal side of the roller.

IMPORTANT: For handling of floating seal (4), refer to the section “Precautions for floating seal handling” on page W1-1-3.

60

3.

Install floating seal (5) to roller (7) and to collar (2).

Insert axle (8) into roller (7). Install the other floating seal (5) to roller (7) and to collar (2). Install O-Ring (4) the other collar (2). Secure them using elastic pin (3).

IMPORTANT: The elastic pin (3) has to be fitted with the slit oriented to the internal side of the roller.

60

4.

Add engine oil via plug (1) hole on collar (2). Apply sealant (Loctite 503 or equivalent) to plug (1). Tighten plug (1). Engine oil quantity: 211 cm3

: 6 mm : 9.8 Nm (7.2 lbf·ft)

W3-6-14

60

UPPER AND LOWER ROLLER

E215B-E245B

MAINTENANCE STANDARD Upper Roller

&

$ %

60

Unit: mm Standard

Allowable Limit

A

84

—

B

150

—

C

140

130

Remedy Replace

Lower Roller

‘

$ %

&

&

60

Unit: mm Standard

Allowable Limit

A

172

181.5

B

218

—

C

23

11.5

D

150

132

W3-6-15

Remedy Buildup weld and finishing

E215B-E245B

UPPER AND LOWER ROLLER

Upper roller axle and bushing Unit: mm Standard

Allowable Limit

Axle

Outside Dia.

45

44.7

Bushing

Inside Dia.

45

45.3

Remedy Replace

Lower roller axle and bushing Unit: mm Standard

Allowable Limit

Outside Dia.

65

64.2

Bushing

Inside Dia.

65

66

Bushing

Flange Thickness

2

1.2

Axle

TOOL TABLE DESCRIPTION

TOOL NO. 380001053

Punch for upper roller bushings

XXXXXXXXX

Stand jig upper roller

XXXXXXXXX

Stopper shaft upper roller

XXXXXXXXX

Stopper bushings upper roller

380001030

Push-out jig bushings lower roller

W3-6-16

Remedy Replace

TRACKS

E215B-E245B

REMOVAL AND INSTALLATION OF TRACKS Removal WARNING Do not loosen valve (1) quickly on loosen too much since high-pressure grease in the adjusting cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (1). Never loosen grease fitting (2). 60

1.

Move the tracks so that master pin (3) is positioned over front idler (4). Put a wooden block under track shoes (5), as shown.

60

2.

To loosen the track tension, slowly turn valve (1) counterclockwise one turn; grease will escape from grease outlet. : 19 mm

W3-7-1

60

E215B-E245B

TRACKS

WARNING The front idler may jump out of position due to strong spring force when the tracks is disconnected. Especially, the strong spring force is always applied to the bolt part of the rod. If the rod and/or the bolt are damaged, metal fragments may fly off when the tracks is disconnected.

60

3.

Remove master pin (5) by using a special tool.

60

A: 380001008 B: 380001009 C: 380001013 (E215B); 380001010 (E245B) D: 380001012 (E215B); 380001011 (E245B) E: 380001015 (E215B); 380001016 (E245B) G: 380001019 5: MASTER PIN

‘ &

*

%

(

$ 60

4.

Slowly drive the machine in reverse until the whole length of the removing track comes on the ground.

60

5.

Rotate the upperstructure 90 degrees toward the removing track side, perpendicular to the tracks. Operate the boom and arm so that the angle between them is 90 to 110 degrees. Lower the boom with the bucket rolled-in to jack up the machine as illustrated.

ƒƒ

60

W3-7-2

TRACKS

E215B-E245B

Installation 1.

O OO

Jack up the machine and put the track under the lower roller. Be sure to position the track in correct direction, as illustrated. : Sprocket side : Idler side

60

2.

Lift the track, and place it on sprocket (1).

60

3.

Slowly turn the sprocket in forward direction.

60

4.

Turn sprocket (1) until end of track (4) comes on front idler (3). Lower the machine and put a wooden block as illustrated.

60

W3-7-3

E215B-E245B

TRACKS

IMPORTANT: hole surfaces, link holes and counterbore surfaces, bushing ends, shall be free from dust and rust. 5.

Install master pin (5), using a hammer and special tool. A: 380001008 B: 380001009 C: 380001013 (E215B); 380001010 (E245B) D: 380001012 (E215B); 380001011 (E245B) E: 380001015 (E215B); 380001016 (E245B) G: 380001019 5: MASTER PIN

60

IMPORTANT: inject rust preventive protective (ex. TECTYL165 G) between pin and bushing clearance.

IMPORTANT: if any links have been removed from the track, be sure to charge the grease into the clearance between the pin and bushing when reconnecting the links. Also, apply a coat of grease tothe ends of the bushing. Grease Charging Method: — Stand the bushing on a flat plate. — Fill the bushing bore with the grease. — Insert the pin into the bushing while pushing the bushing onto the plate (so that the bushing end stays on the plate). — Wipe off excess grease.

6.

‘ &

*

%

(

$ 60

Supply grease to the cylinder through the grease fitting to adjust the track tension. : 19 mm

When proper track sag is obtained, turn value clockwise and tighten.

60

Track sag specifications (A): 320 to 350 mm : 19 mm : 59 Nm (43.5 lbf·ft)

IMPORTANT: check track sag after thoroughly removing soil stuck on the track area by washing.

60

W3-7-4

TRACKS

E215B-E245B

MAINTENANCE STANDARD Link Pin and Track Bushing • •

Measure the length of four links, as illustrated, with the tension on the track. Do not measure the master-pin included part of the track.

$ 60

Unit: mm Standard A

Allowable Limit

E215B

E245B

E215B

E245B

761

760

774

778

Remedy Replace

Master Pin

(%

%

(%

$ 60

60

Unit: mm Standard E215B

Allowable Limit

E245B

E215B

E245B

A

207

220

200

—

B

38

39.7

36.5

37

W3-7-5

Remedy Replace

E215B-E245B

TRACKS

Master Bushing

%

&

$ 60

Unit: mm Standard

Allowable Limit

E215B

E245B

A

129.2

135

B

38

C

58.7

E215B

Remedy

E245B

—

—

40 ++00.87

39.5

42.8

60

54.1

57

Replace

Grouser Shoe

& % $ 60

Unit: mm Standard

Allowable Limit

E215B

E245B

E215B

E245B

A

220

222.5

—

—

B

9.5

12.5

—

—

C

25.5

28

15

14

W3-7-6

Remedy

Replace

TRACKS

E215B-E245B

TOOL TABLE DESCRIPTION

TOOL NO. 380001008

Tool fitting/pushing-out master pin

380001009

Tool fitting/pushing-out master pin

380001010

Tool fitting/pushing-out master pin (E245B)

380001011

Tool fitting/pushing-out master pin (E245B)

380001012

Tool fitting/pushing-out master pin (E215B)

380001013

Tool fitting/pushing-out master pin (E215B)

380001015

Tool fitting/pushing-out master pin (E215B)

380001016

Tool fitting/pushing-out master pin (E245B)

380001019

Tool fitting/pushing-out master pin

W3-7-7

E215B-E245B

TRACKS

NOTES

W3-7-8

SECTION 4

FRONT ATTACHMENT

CONTENTS Group 1 — Front attachment Front attachment removal and installation W4-1-1 Monoblock version ………………………. W4-1-1 Maintenance ………………………………. W4-1-6 Triple articulation version ……………… W4-1-7 Maintenance ………………………………. W4-1-12 Standard dimensions for arm and bucket connection……………………………………… W4-1-13 Replacement of bucket …………………….. W4-1-14 Removing the bucket ………………….. W4-1-14 Installing the bucket ……………………. W4-1-14 Bucket play adjustment………………… W4-1-14 Bucket teeth replacement …………….. W4-1-15 Cylinders removal and installation ……… W4-1-16 Bucket Cylinder removal ………………. W4-1-16 Bucket Cylinder installation…………… W4-1-18 Arm cylinder removal …………………… W4-1-19 Arm cylinder installation ……………….. W4-1-20 Boom cylinders removal ………………. W4-1-21 Boom cylinders installation ………….. W4-1-22 Positioner cylinder removal…………… W4-1-23 Positioner cylinder installation ………. W4-1-24 Cylinders assembly and disassembly …. W4-1-25 Bucket cylinder …………………………… W4-1-25 Arm cylinder ……………………………….. W4-1-28 Positioner cylinder ………………………. W4-1-31 Boom cylinders …………………………… W4-1-34 Special tools ………………………………. W4-1-37 Maintenance standard: rod …………… W4-1-38

E215B-E245B

FRONT ATTACHMENT

E215B-E245B

FRONT ATTACHMENT REMOVAL AND INSTALLATION Monoblock version WARNING Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries. Prevent this dangers by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes. Press the valve located on the hydraulic oil tank to bleed the residual pressure trapped inside the tank. Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns. Before starting any intervention, make sure that oil and components have cooled off. Always ensure that hooks and chains used for lifting are in good condition and adequate to the expected load. Metal fragments may fly off when a hammer is used to remove pins. Be sure to wear necessary protection.

Removal 1.

Park the machine on firm, level ground. Position the front attachment as illustated and lower the bucket to the ground.

2.

Disconnect lubrication hoses (1) from boom cylinder rod end. : 17 mm

3.

Loosen lock nuts (2), remove bolt (3) and stopper (4) from boom cylinder rod end. Carry out the same procedure for the other boom cylinder. : 24 mm

SM0200

5

4.

Attach each boom cylinder to a crane.

1

3

NOTE: boom cylinder weight: 176 kg Remove cylinder rod end pin (5) and shims (6) using a hammer and bar.

4 2 SM0201

3

5 4 2 2 6 4 3

W4-1-1

SM0202

E215B-E245B

FRONT ATTACHMENT

5.

Slowly lower the boom cylinder using the crane onto the wooden block.

6.

Press the valve located on the hydraulic oil tank to bleed the residual pressure inside the tank itself. Complete the bleeding of the residual pressure from the hydraulic system, making reference to «Procedure for the bleeding of the pressure from the hydraulic system» at page T2-1-47.

7.

Disconnect hoses (7) and (8) of bucket cylinder and arm cylinder.

SM0203

9

9

10

NOTE: if the machine is equipped with the hammer/ crusher, bucket rotation or anti-drop valves variants, disconnect the relevant hoses (9), (10) and (11). 8

11

11

: 41 mm

7

7 8

Bucket (7) and arm (8) cylinder hoses:

10

: 36 mm Hammer/crusher hoses (9): : 41 mm

SM0204

: 12 mm Bucket rotation hoses (10): : 27 mm

12

Anti-drop valves hoses (11): : 22 mm Close all openings with plugs to keep clean.

8.

Disconnect centralised lubrication hoses (12) located between the boom cylinders. : 17 mm

SM0205

14

9.

Remove panel (13) by removing securing screws (14). : 19 mm

13

SM0206

W4-1-2

FRONT ATTACHMENT

E215B-E245B

10. Remove work light and bracket by removing securing screws (15). : 17 mm

16 18

11. Disconnect fuel transfer pump hose (16). : 41 mm 15

12. Loosen lock nuts (17) and remove bolt (18). : 30 mm

17

SM0207

13. Sling the boom to a hoist. Slightly lift the boom. NOTE: approximate mass of the front equipment: 3450 kg.

SM0208

14. Pull out the boom lower pivot pin (20) to the frame using the appropriate puller (XXXXXXXX).

20

15. Lift the front attachment. Move the machine away from the front attachment and the hoist.

W4-1-3

SM0209

E215B-E245B

FRONT ATTACHMENT

Installation 1.

Lift the front attachment.

NOTE: approximate mass of the front equipment: 3450 kg 16

Install dust seals to boom foot. Align the boom foot boss with the main frame boss. Insert a thrust plate to both right and left sides of the boom foot boss to take out clearance between the boom foot boss and the main frame boss. 2. 3.

18

15

Install boom foot pin (20) using a hammer and bar.

20 17

Install bolt (18) and tighten lock nuts (17). SM0210

: 30 mm : 200 Nm 4.

14

Install fuel transfer pump hose (16).

13

: 41 mm : 30 Nm 5.

Install work light and bracket by removing securing screws (15). : 17 mm : 15 Nm

6.

Install panel (13) by tightening securing screws (14).

SM0206

: 19 mm : 80 Nm 7.

Connect hoses (7) and (8) of bucket cylinder and arm cylinder.

NOTE: if the machine is equipped with the hammer/ crusher, bucket rotation or anti-drop valves variants, connect the relevant hoses (9), (10) and (11).

9

9

10

8 11

Bucket (7) and arm (8) cylinder hoses:

7

7 8

10

11

: 41 mm : 206 ± 21 Nm : 36 mm SM0204

: 177 ± 18 Nm Bucket rotation hoses (10):

Hammer/crusher hoses (9):

: 27 mm

: 41 mm

: 78 ± 5 Nm

: 206 ± 21 Nm

Anti-drop valves hoses (11):

: 12 mm

: 22 mm

: 150 ± 10 Nm

: 49 ± 5 Nm

W4-1-4

FRONT ATTACHMENT 8.

E215B-E245B

Attach the boom cylinder to a crane.

NOTE: boom cylinder weight: 176 kg Lift the boom cylinder and align the boom cylinder rod with the pin hole on the boom. NOTE: for easy alignment, start the engine and use the boom control lever.

9.

Install shims (6) and insert pin (5).

10. Install stopper (4), tighten bolts (3) and lock nuts (2):

SM0211

: 24 mm : 147 Nm

3

11. Connect lubrication hoses (1) to boom cylinder rod.

5 4 2

: 17 mm : 20 Nm

2 6

12. Connect centralised lubrication hoses (12) located between the boom cylinders.

4 3

: 17 mm

SM0202

: 20 Nm Using a grease gun, inject grease via nipples (21) (boom) and (22) (boom cylinders).

5 1

3

NOTE: fill the hydraulic oil tank with hydraulic oil to the specified level. Run the engine at idle. Check hose connections for any oil leakage.

4

IMPORTANT: bleed air from hydraulic circuit.

2 SM0201

12

22

21

22

SM0212

W4-1-5

E215B-E245B

FRONT ATTACHMENT

Maintenance: monoblock version

A

B

H

G

E

F

J

C

D

K

I SM0213

Unità di misura: mm Standard

Allowable limit

Pin

90

89

Bushing

90

91.5

Pin

85

84

Boss (Main Frame)

85

86.5

Bushing (Boom Cylinder)

85

86.5

Pin

85

84

Parts name A

B

C

D

E

F

G

H

I J K

Bushing (Boom Cylinder)

85

86.5

Foro (Boom)

85

86.5

Pin

90

89

Bushing

90

91.5

Pin

85

84

Boss (Arm)

85

86.5

Bushing (Arm Cylinder)

85

86.5

Pin

85

84

Boss (Boom)

85

86.5

Bushing (Arm Cylinder)

85

86.5

Pin

80

79

Boss (Arm)

80

81.5

Bushing (Bucket Cylinder)

80

81.5

Pin

80

79

Bushing

80

81.5

Bushing (Bucket Cylinder)

80

81.5

Pin

70

69

Bushing

70

71.5

Pin

80

79

Bushing

80

81.5

Pin

80

79

Bushing

80

81.5

IMPORTANT: be sure to install front attachment bushings using a press.

W4-1-6

Remedy

Replace

FRONT ATTACHMENT

E215B-E245B

Triple articulation version WARNING Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries. Prevent this dangers by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes. Press the valve located on the hydraulic oil tank to bleed the residual pressure trapped inside the tank. Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns. Before starting any intervention, make sure that oil and components have cooled off. Always ensure that hooks and chains used for lifting are in good condition and adequate to the expected load. Metal fragments may fly off when a hammer is used to remove pins. Be sure to wear necessary protection.

Removal 1.

Park the machine on firm, level ground. Position the front attachment as illustated and lower the bucket to the ground.

2.

Disconnect lubrication pipes (1) from boom cylinder rod end. : 17 mm

3.

Loosen lock nuts (2), remove bolt (3) and stopper (4) from boom cylinder rod end. Carry out the same procedure for the other boom cylinder. : 24 mm

SM0215

3

4.

Attach each boom cylinder to a crane.

1

5

NOTE: boom cylinder weight: 176 kg Remove cylinder rod end pin (5) and shims (6) using a hammer and bar.

2

4

SM0216

3

5 4 2

2 6 4 3

W4-1-7

SM0217

E215B-E245B

FRONT ATTACHMENT

5.

Slowly lower the boom cylinder using the crane onto the wooden block.

6.

Press the valve located on the hydraulic oil tank to bleed the residual pressure inside the tank itself. Complete the bleeding of the residual pressure from the hydraulic system, making reference to «Procedure for the bleeding of the pressure from the hydraulic system» at page T2-1-47.

7.

Disconnect hoses (12), (7) and (8) of positioner cylinder, bucket cylinder and arm cylinder.

NOTE: if the machine is equipped with the hammer/ crusher, bucket rotation or anti-drop valves variants, disconnect the relevant hoses (9), (10) and (11).

SM0218

9

10

9

Positioner cylinder hoses (12) (from the control valve): : 30 mm

8

Bucket (7) and arm (8) cylinder hoses:

8 11

: 41 mm : 36 mm

7

7

11 12

12 SM0219

Hammer/crusher hoses (9): : 41 mm : 12 mm

13

Bucket rotation hoses (10): : 27 mm Anti-drop valves hoses (11): : 22 mm Close all openings with plugs to keep clean. SM0220

8.

9.

Disconnect centralised lubrication hoses (13) located between the boom cylinders. : 17 mm

15 14

Remove panel (14) by removing securing screws (15). : 19 mm

SM0221

W4-1-8

FRONT ATTACHMENT

E215B-E245B

10. Remove work light and bracket by removing securing screws (16). : 17 mm

17 19

11. Disconnect fuel transfer pump hose (17). : 41 mm 16

12. Loosen lock nuts (18) and remove bolt (19). : 30 mm

18

SM0222

13. Sling the boom to a hoist. Slightly lift the boom. NOTE: approximate mass of the front equipment: 4100 kg.

SM0223

14. Pull out the boom lower pivot pin (21) to the frame using the appropriate puller (XXXXXXXX).

21

15. Lift the front attachment. Move the machine away from the front attachment and the hoist.

W4-1-9

SM0224

E215B-E245B

FRONT ATTACHMENT

Installation 1.

Lift the front attachment.

NOTE: approximate mass of the front equipment: 4100 kg 16

Install dust seals to boom foot. Align the boom foot boss with the main frame boss. Insert a thrust plate to both right and left sides of the boom foot boss to take out clearance between the boom foot boss and the main frame boss. 2.

Install boom foot pin (20) using a hammer and bar.

3.

Install bolt (18) and tighten lock nuts (17).

18

15

20 17

: 30 mm SM0210

: 200 Nm 4.

Install fuel transfer pump hose (16).

14

: 41 mm

13

: 30 Nm 5.

Install work light and bracket by removing securing screws (15). : 17 mm : 15 Nm

6.

Install panel (13) by tightening securing screws (14). : 19 mm : 80 Nm

7.

SM0206

Connect bucket cylinder hoses (7), positioner cylinder hoses (12) and arm cylinder hoses (8).

NOTE: if the machine is equipped with the hammer/ crusher, bucket rotation or anti-drop valves variants, connect the relevant hoses (9), (10) and (11).

9

10

9

Positioner cylinder hoses (12) (from the control valve): : 30 mm

8

: 83 ± 5 Nm

8

Bucket (7) and arm (8) cylinder hoses:

11

: 41 mm : 206 ± 21 Nm

11 12

: 36 mm

Bucket rotation hoses (10):

: 177 ± 18 Nm

: 27 mm

Hammer/crusher hoses (9):

: 78 ± 5 Nm

: 41 mm

Anti-drop valves hoses (11):

: 206 ± 21 Nm

: 22 mm

: 12 mm

: 49 ± 5 Nm

: 150 ± 15 Nm

W4-1-10

7

7

12 SM0219

FRONT ATTACHMENT 8.

E215B-E245B

Attach the boom cylinder to a crane.

NOTE: boom cylinder weight: 176 kg Lift the boom cylinder and align the boom cylinder rod with the pin hole on the boom. NOTE: for easy alignment, start the engine and use the boom control lever.

9.

Install shims (6) and insert pin (5).

10. Install stopper (4), tighten bolts (3) and lock nuts (2): : 24 mm : 147 Nm

3

11. Connect lubrication hoses (1) to boom cylinder rod.

5 4 2

: 17 mm : 20 Nm

2

12. Connect centralised lubrication hoses (12) located between the boom cylinders. : 17 mm

6 4 3

SM0217

: 20 Nm Using a grease gun, inject grease via nipples (21) (boom) and (22) (boom cylinders).

3 1

5

NOTE: fill the hydraulic oil tank with hydraulic oil to the specified level. Run the engine at idle. Check hose connections for any oil leakage. IMPORTANT: bleed air from hydraulic circuit.

2

4

SM0216

12

22

21

22

SM0212

W4-1-11

E215B-E245B

FRONT ATTACHMENT

Maintenance: triple articulation version

E

F

A

B

L

C

G

M

H

D

N

J

K

I SM0238

Unità di misura: mm Standard

Allowable limit

Pin

90

89

Bushing

90

91.5

Pin

90

89

Boss (Main Frame)

90

91.5

Bushing (Boom Cylinder)

90

91.5

Pin

85

84

Parts name A-D-N

B

C

E

F

G

H

I J-K

L

M

Bushing (Boom Cylinder)

85

86.5

Boss (Boom)

85

86.5

Pin

90

89

Boss (Positioner)

90

91.5

Bushing (Positioner Cylinder)

90

91.5

Pin

90

89

Boss (Boom)

90

91.5

Bushing (Positioner Cylinder)

90

91.5

Pin

80

79

Boss (Arm)

80

81.5

Bushing (Bucket Cylinder)

80

81.5

Pin

80

79

Bushing

80

81.5

Bushing (Bucket Cylinder)

80

81.5

Pin

70

69

Bushing

70

71.5

Pin

80

79

Bushing

80

81.5

Pin

85

84

Boss (Positioner)

85

86.5

Bushing (Arm Cylinder)

85

86.5

Pin

85

84

Boss (Arm)

85

86.5

Bushing (Arm Cylinder)

85

86.5

IMPORTANT: be sure to install front attachment bushings using a press. W4-1-12

Remedy

Replace

FRONT ATTACHMENT

E215B-E245B

STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION o

q

p

g h

k

i j Section A d

l m

B c

n

e b

a

Section B

f

A

SM0214

E215B-E245B

E215-E245

a (*)

419

→

b (*)

31

23

c

630

→

d

610

→

e

430

→

f

1464

→

g

433

→

h

326

→

i

80

→

j

428.7

→

k

33

→

l

433

→

m

307

→

n

80

→

o

20°

→

p

3.73°

→

q

449

→

(*) Arm: 2940 mm

Unit: mm

W4-1-13

E215B-E245B

FRONT ATTACHMENT

MAINTENANCE TO BE PERFORMED WHEN REQUIRED REPLACEMENT OF BUCKET

CAUTION — Replace the bucket on firm level ground. Pay close attention to safety. — When aligning the pin bores, DO NOT INSERT YOUR HAND OR FINGERS into the bores. It may cause severe injury. Align the bores visually or using a tool. — Hold the removed bucket in the stable condition. Removing the bucket • Place the machine on a firm and flat surface and rest the bucket on the ground in a stable position. • Place O-rings (1) out of the relevant seats. Remove the pins and the retaining rings of the pins. • Remove pin (E) and pin (B); then remove the bucket.

Installing the bucket • Using a suitable hoist, place the bucket on the same level as the tracks. • Position the O-Rings (1)outside their seats. • Using the arm cylinder control and boom cylinder control make small vertical and horizontal movements to insert pivot pin (B) connecting the bucket to the arm into hole (A). • Use the bucket cylinder control to align the connecting rod (C) to hole (D)and insert pivot pin (E). • Secure pivot pins using lock pins and retaining rings and reposition the O rings into their seats.

IMPORTANT: during the removal of the bucket, take care that the pin are not contaminated by dirt, sand etc. After the reinstallation of the bucket, provide grease to the pins through the appropriate fittings.

Bucket play adjustment Bucket play (g) is adjusted by opportunely changing total shims installed. NOTE: bucket play (g) should be 0.5 to 1.5 mm. If bucket play (g) exceeds the specified value, increase adjust shims as follows: • loosen the three bolts (2) taking care to retrieve the washers. Slide out the ring (1); • Add adjust shims (3) until compensating the play (g); • Install the ring (1), and tighten securing bolts (2).

W4-1-14

FRONT ATTACHMENT Bucket teeth replacement

WARNING Keep people not involved in the maintenance work outside the working area. Wear adequate personal clothes and glasses with side shields as a protection against flying debris.

• Ensure the machine is parked on a level surface. • Rest the bucket to the ground. • Switch off the Auto-Idle, fully turn the engine speed manual control anticlockwise, stop the engine, remove the ignition key and move the safety lever in the locked position (LOCK). • Use a hammer and punch to push lock pin (1) out of its seat and remove the tip of bucket tooth (2). NOTE: to push lock pin (1) out of its seat, strike it with a punch on its upper side. • Install a new rubber insert (3) inside lock pin (1). • Clean the surface of bucket tooth (4) and insert a new tip. • Insert lock pin (1) into its seat using a punch and hammer, until it is fully mounted.

W4-1-15

E215B-E245B

E215B-E245B

FRONT ATTACHMENT

CYLINDERS REMOVAL AND INSTALLATION WARNING Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries. Prevent this dangers by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes. Press the valve located on the hydraulic oil tank to bleed the residual pressure trapped inside the tank. Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns. Before starting any intervention, make sure that oil and components have cooled off. Always ensure that hooks and chains used for lifting are in good condition and adequate to the expected load. Metal fragments may fly off when a hammer is used to remove pins. Be sure to wear necessary protection.

Bucket Cylinder removal 1.

Park the machine on firm, level ground. Position the front attachment as illustated and lower the bucket to the ground.

2.

Press the valve located on the hydraulic oil tank to bleed the residual pressure inside the tank itself.

3.

Insert wooden block (3) between bucket cylinder (1) and arm (2). SM0200

4.

Complete the bleeding of the residual pressure from the hydraulic system, making reference to «Procedure for the bleeding of the pressure from the hydraulic system» at page T2-1-47.

1

3

IMPORTANT: Pin (6) end of the link will drop when pin is removed, possibly resulting in personal injury. Be sure to secure the link using a wire before removing pin (6).

2

SM0226

5.

Loosen lock nuts (4) and remove bolt (5). Pull-out pin (6) with the help of a mallet and a bar so that the end of the cylinder is free, then remove adjusting shims (7).

7

4

6

: 24 mm 5

SM0227

W4-1-16

FRONT ATTACHMENT 6.

E215B-E245B

Disconnected hoses (8) from bucket cylinder (1).

9

12

: 10 mm

11

: 36 mm Put plugs on cylinder pipes and hoses.

10 1

NOTE: bucket cylinder weight: 153 kg

7.

Using a hoist, slightly lift bucket cylinder (1). Loosen locking nuts (9) remove screw (10) and pull-out pin (11) with the help of a mallet and a bar so that the end of the cylinder is free, then remove adjusting shims (12).

8

8

: 24 mm

8.

Remove bucket cylinder (1).

SM0228

W4-1-17

E215B-E245B

FRONT ATTACHMENT

Bucket Cylinder installation NOTE: bucket cylinder weight: 153 kg

9

12

1.

2.

11

Connect bucket cylinder (1) to a crane using a sling belt. Align the hole of the bucket cylinder with the pin hole on the arm-tip bracket. Install adjusting shims (12) and insert pin (11). Install screw (10) and tighten lock-nuts (1).

10 1

: 24 mm

8

: 147 Nm 3.

Connect two hoses (8) to bucket cylinder (1).

8

: 10 mm : 83 ± 5 Nm : 36 mm : 177 Nm NOTE: fill the hydraulic oil tank with hydraulic oil to the specified level. Run the engine at idle. Check hose connections for any oil leakage. 4.

SM0228

Align the bucket cylinder rod with bucket links (13) and (14). Install shims (7) and pin (6).

NOTE: for easy alignment, start the engine and use the arm control lever. 7

5.

4

6

Install bolt (5) onto pin (6) then tighten lock nuts (4). : 24 mm

5

: 147 Nm

14

IMPORTANT: if link (13) has been disconnected from the arm, be sure to insert shims (7) when connecting it. Bleed air from hydraulic circuit.

13

SM0229

W4-1-18

FRONT ATTACHMENT

E215B-E245B

Arm cylinder removal 1.

Insert a wooden block (3) between arm cylinder (1) and boom (2). 1

2.

3.

Press the valve located on the hydraulic oil tank to bleed the residual pressure inside the tank itself. Complete the bleeding of the residual pressure from the hydraulic system, making reference to «Procedure for the bleeding of the pressure from the hydraulic system» at page T2-1-47.

3 2 SM0230

Loosen lock nuts (4), remove bolt (5) and pullout pin (6) with the help of a mallet and a bar so that the end of the cylinder is free, then remove adjusting shims (7).

7

6

4

: 24 mm 5

4.

Disconnected hoses (8) and (9) from arm cylinder. Put plugs on cylinder pipes and hoses. : 10 mm : 36 mm SM0231

5.

Disconnect lubrication hose (10). : 17 mm

8

NOTE: arm cylinder weight: 255 kg

6.

Using a hoist, slightly lift arm cylinder (1). Loosen locking nuts (11) remove screw (12) and pull-out pin (13) with the help of a mallet and a bar so that the end of the cylinder is free, then remove adjusting shims (14).

10

9

: 24 mm

7.

SM0232

14

Remove arm cylinder (1).

11

13

12

SM0233

W4-1-19

E215B-E245B

FRONT ATTACHMENT

Arm cylinder installation NOTE: arm cylinder weight: 255 kg 1.

Using a crane, align the hole of the arm cylinder with the pin hole on the boom-tip bracket.

2.

Install adjusting shims (14), pin (13), install screw (12) onto pin (13) and tighten lock-nuts (11).

14

13

11

: 24 mm : 147 Nm 12

3.

Connect lubrication hoses (10) and hoses (8) and (9) to the arm cylinder. : 10 mm : 83 ± 5 Nm : 36 mm : 177 Nm

SM0233

NOTE: fill the hydraulic oil tank with hydraulic oil to the specified level. Run the engine at idle. Check hose connections for any oil leakage. 4.

Slightly lift arm cylinder and align the arm cylinder rod with the pin hole on the arm.

NOTE: for easy alignment, start the engine and use the arm control lever. 5.

8

10

9

Install adjusting shims (7), pin (6), install screw (5) onto pin (6) and tighten lock-nuts (4).

SM0232

: 24 mm : 147 Nm

7

4

6

IMPORTANT: bleed air from hydraulic circuit. 5

SM0231

W4-1-20

FRONT ATTACHMENT

E215B-E245B

Boom cylinders removal 1.

2.

Park the machine on firm, level surface and lower the bucket teeth and arm top to the ground with the arm and bucket cylinders fully retracted.

5 1

3

Disconnect lubrication hoses (1). : 17 mm

3.

Loosen lock nuts (2), remove bolt (3) and stopper (4) from boom cylinder rod end. : 24 mm

4 2 SM0201

NOTE: boom cylinder weight: 176 kg 3

4.

Attach boom cylinder to a crane.

5.

Slowly lower the boom cylinder using the crane onto the wooden block.

6.

Press the valve located on the hydraulic oil tank to bleed the residual pressure inside the tank itself. Complete the bleeding of the residual pressure from the hydraulic system, making reference to «Procedure for the bleeding of the pressure from the hydraulic system» at page T2-1-47.

7.

5 4 2 2 6 4 3

SM0202

Disconnect hoses (7) of boom cylinder. Put plugs on cylinder pipes and hoses. : XX mm

: 30 mm 7

8.

Disconnect centralised lubrication hoses (10) located between the boom cylinders. : 17 mm

9.

9 8

Remove securing screws (8) complete with washers, then remove pin (9) and adjusting shims (10).

SM0234

: 24 mm 10. Using a hoist, lift boom cylinder. Remove the other boom cylinder following the same procedure.

10

10

SM0235

W4-1-21

E215B-E245B

FRONT ATTACHMENT

Boom cylinders installation NOTE: boom cylinder weight: 176 kg 1.

Using a crane, install the boom cylinders to the main frame.

2.

Install adjusting shims and pin (9), then tighten securing screws (8) complete with washers.

7

: 24 mm : 540 Nm 3.

4.

9 8

Connect lubrication hose (7) to boom cylinder. : 30 mm

: 36 mm

: 137 Nm

: 206 Nm

SM0234

Connect centralised lubrication hoses (10) located between the boom cylinders.

10

10

: 17 mm : 20 Nm 5.

Install shims (6) and insert pin (5).

6.

Install stopper (4), tighten bolts (3) and lock nuts (2): : 24 mm : 147 Nm

7.

SM0235

Connect lubrication hoses (1) to boom cylinder rod.

3

: 17 mm : 20 Nm 5 4 2

8.

Using a grease gun, inject grease via nipples (10).

2

Install the other boom cylinder following the same procedure. NOTE: fill the hydraulic oil tank with hydraulic oil to the specified level. Run the engine at idle. Check hose connections for any oil leakage.

6 4 3

SM0202

5

IMPORTANT: bleed air from hydraulic circuit.

1

3

4 2 SM0201

W4-1-22

FRONT ATTACHMENT

E215B-E245B

Positioner cylinder removal 1.

Insert a wooden block (3) between positioner cylinder (1) and boom (2).

2.

Press the valve located on the hydraulic oil tank to bleed the residual pressure inside the tank itself. Complete the bleeding of the residual pressure from the hydraulic system, making reference to «Procedure for the bleeding of the pressure from the hydraulic system» at page T2-1-47.

1

3 2

3.

Loosen lock nuts (4), remove bolt (5) and pullout pin (6) with the help of a mallet and a bar so that the end of the cylinder is free, then remove adjusting shims (7).

SM0236

7

6

4

: 24 mm 5

4.

Disconnected hoses (8) and (9) from arm cylinder. Put plugs on cylinder pipes and hoses. : 10 mm : 36 mm SM0237

5.

Disconnect lubrication hose (10). : 17 mm

8

NOTE: positioner cylinder weight: 220 kg

6.

Using a hoist, slightly lift positioner cylinder (1). Loosen locking nuts (11) remove screw (12) and pull-out pin (13) with the help of a mallet and a bar so that the end of the cylinder is free, then remove adjusting shims (14).

10

9

: 24 mm

7.

SM0232

14

Remove positioner cylinder (1).

11

13

12

SM0233

W4-1-23

E215B-E245B

FRONT ATTACHMENT

Positioner cylinder installation NOTE: positioner cylinder weight: 220 kg 1.

Using a crane, align the hole of the positioner cylinder with the pin hole on the boom-tip bracket.

2.

Install adjusting shims (14), pin (13), install screw (12) onto pin (13) and tighten lock-nuts (11).

13

11

14

: 24 mm : 147 Nm 12

3.

Connect lubrication hoses (10) and hoses (8) and (9) to positioner cylinder. : 10 mm : 83 ± 5 Nm : 36 mm

SM0233

: 177 Nm NOTE: fill the hydraulic oil tank with hydraulic oil to the specified level. Run the engine at idle. Check hose connections for any oil leakage. 4.

8

Slightly lift positioner cylinder and align the positioner cylinder rod with the pin hole on the arm.

NOTE: for easy alignment, start the engine and use the arm control lever.

10

9

SM0232

5.

Install adjusting shims (7), pin (6), install screw (5) onto pin (6) and tighten lock-nuts (4). 7

: 24 mm

4

6

: 147 Nm IMPORTANT: bleed air from hydraulic circuit.

5

SM0237

W4-1-24

FRONT ATTACHMENT

E215B-E245B

CYLINDERS ASSEMBLY AND DISASSEMBLY Bucket cylinder

13 20

19 15

16 18 19

17 16 20 21

24 23

22 11

12 1 2 8

3 4 7

5 6 9 10

SM0240

12345678-

Wiper Ring Backup Ring Seal Seal Bushing Snap Ring Cylinder Head Socket Bolt (q.ty 12)

9 — Backup Ring 10 — O-Ring 11 — Cylinder Rod 12 — Cylinder Tube 13 — Cushion Bearing 15 — Piston 16 — Backup Ring (q.ty 2) 17 — Seal Ring

W4-1-25

18 — O-Ring 19 — Slide Ring (q.ty 2) 20 — Slide Ring (q.ty 2) 21 — Shim 22 — Set Screw 23 — Steel Ball 24 — Nut

E215B-E245B

FRONT ATTACHMENT

Bucket cylinder disassembly

6.

Loosen nut (24) using special tool (xxxxxxxxx). Remove piston (15), shim (21) cushion bearing. Socket to loosen nut (24): — bucket cylinder: 90 mm (XXXXXXXX)

7.

Remove seal ring (17), slide rings (19) and (20), O-ring (18) and backup rings (16) from piston (15).

8.

Remove cylinder head (7) from cylinder rod (11).

9.

Remove O-Rings (10), backup rings (9) and (2) from cylinder head (7), then remove wiper ring (1), seal (3), buffer ring (4), snap ring (6), and bushing (5).

Be sure to thoroughly read all the precautions for disassembly/assembly work on page W1-1-1 before starting the disassembly procedure. The disassembly procedure below starts on the premise that the hydraulic lines and the line securing bands have been removed. NOTE: bucket cylinder mass: 153 kg 1.

2.

Lift and securely place the cylinder on a workbench using a crane. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

Fully extend cylinder rod (11). Secure the rod end using a crane. Remove socket bolts (8) from cylinder head (7). : 14 mm

IMPORTANT: be sure to pull cylinder rod (11) straight so as not to damage the sliding surfaces.

3.

Pull out cylinder head (7) from cylinder tube (12) by tapping with a plastic hammer.

4.

Secure cylinder rod (11) on special tool (xxxxxxxxx). Put matching marks between cylinder rod (11) and nut (24).

5.

Remove set screw (22) and steel ball (23). : 10 mm

NOTE: cut away its mushroomed portion using a drill first, as set screw was mushroomed with a punch and hammer at two places after it had been screwed in.

W4-1-26

FRONT ATTACHMENT 9.

Bucket cylinder assembly 1.

Install bushing (5) to cylinder head (7) using a press. Special tools for bushing installation (5): — Bucket cylinder: Ø 80 mm (XXXXXXXX)

IMPORTANT: be sure that the rings are installed correctly.

2.

Install seal (3), back-up ring (2), elastic ring (6) and seal (4) on the cylinder front sleeve (7).

3.

Install wiper ring (1) to cylinder head (7) using a plastic hammer.

4.

Install O-Rings (10) and backup ring (9) to cylinder head (7).

E215B-E245B

Align the holes on cylinder rod (11) and nut (24). Insert steel ball (23) into the hole, and tighten set screw (22) into the hole. Mushroom the head of set screw (22) at two places using a punch and hammer. : 10 mm : 56.9 ± 10.7 Nm

IMPORTANT: be sure to align cylinder rod (11) with the center of cylinder tube (12) when inserting, in order to avoid damaging the rings.

10. Secure cylinder tube (12) horizontally using a work bench. Insert cylinder rod (11) into cylinder tube (12).

11. Install cylinder head (7) to cylinder tube (12). Tighten socket bolts (8). : 14 mm : 267 Nm

5.

Install O-Ring (18), backup ring (16) (Q.ty 2), seal ring (17), slide ring (19) (Q.ty 2), (20) (Q.ty 2) to piston (15). Special tools for seals assembly: — Bucket cylinders: (XXXXXXXX)

6.

Install cylinder head (7) to cylinder rod (11). Special tools: — Bucket cylinders: (XXXXXXXX)

IMPORTANT: be sure that the cushion seal slit faces toward the piston and that the cushion bearing oil groove faces the correct direction.

7.

Install cushion bearing (13) to cylinder rod (11). Install piston (15) to cylinder rod (11).

8.

Install shim (21) to cylinder rod (11). Tighten nut (24) using special tool (xxxxxxxxx). Be sure to align the machine mark on the rod with that on the nut. Socket to tighten nut (24): — bucket cylinder: 90 mm (XXXXXXXX) : 7280 Nm

W4-1-27

E215B-E245B

FRONT ATTACHMENT

Arm cylinder

14 13 19 20 15 23 17 16 20 19 27

22 16 18 11

25 26 28

12

1 2 8

3 4 7

5 6 9 10

SM0241

12345678-

Wiper Ring Backup Ring Seal Seal Bushing Snap Ring Cylinder Head Socket Bolt (q.ty 12) 9 — Backup Ring

10 — O -Ring 11 — Cylinder Rod 12 — Cylinder Tube 13 — Cushion Bearing 14 — Cushion Seal 15 — Piston 16 — Backup Ring (q.ty 2) 17 — Seal Ring 18 — O -Ring

W4-1-28

19 — Slide Ring (q.ty 2) 20 — Slide Ring (q.ty 2) 22 — Set Screw 23 — Steel Ball 25 — Snap Ring 26 — Cushion Seal 27 — Cushion Bearing 28 — Stopper

FRONT ATTACHMENT Arm cylinder disassembly

7.

Remove seal ring (17), slide rings (19) and (20), O-ring (18) and backup rings (16) from piston (15).

8.

Remove cylinder head (7) from cylinder rod (11).

9.

Remove O-Rings (10), backup rings (9) and (2) from cylinder head (7), then remove wiper ring (1), seal (3), buffer ring (4), snap ring (6), and bushing (5).

Be sure to thoroughly read all the precautions for disassembly/assembly work on page W1-1-1 before starting the disassembly procedure. The disassembly procedure below starts on the premise that the hydraulic lines and the line securing bands have been removed. NOTE: arm cylinder mass: 251 kg 1.

2.

Lift and securely place the cylinder on a workbench using a crane. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

10. Remove stopper (28) from cylinder rod (11) using a screw driver. Remove cushion bearing (27), cushion seal (26), and snap ring (25).

Fully extend cylinder rod (11). Secure the rod end using a crane. Remove socket bolts (8) from cylinder head (7). : 14 mm

IMPORTANT: be sure to pull cylinder rod (11) straight so as not to damage the sliding surfaces.

3.

Pull out cylinder head (7) from cylinder tube (12) by tapping with a plastic hammer.

4.

Secure cylinder rod (11) on special tool (xxxxxxxxx). Put matching marks between cylinder rod (11) and piston nut (15).

5.

Remove set screw (22) and steel ball (23). : 10 mm

NOTE: cut away its mushroomed portion using a drill first, as set screw was mushroomed with a punch and hammer at two places after it had been screwed in.

6.

E215B-E245B

Loosen piston (15) using special tool (xxxxxxxxx). Remove shim (21) cushion bearing (13) and cushion seal (14). Piston nut (15) Turning Special Tool: — 110 mm (XXXXXXXX)

W4-1-29

E215B-E245B

FRONT ATTACHMENT 9.

Arm cylinder assembly 1.

Install bushing (5) to cylinder head (7) using a press. Special tools for bushing installation (5): (XXXXXXXX)

IMPORTANT: be sure that the rings are installed correctly.

2.

3.

Align the holes on cylinder rod (11) and piston nut (15). Insert steel ball (23) into the hole, and tighten set screw (22) into the hole. Mushroom the head of set screw (22) at two places using a punch and hammer. : 10 mm : 56.9 ± 10.7 Nm

IMPORTANT: be sure that the cushion seal slit faces toward the piston and that the cushion bearing oil groove faces the correct direction.

Install seal (3), back-up ring (2), elastic ring (6) and seal (4) on the cylinder front sleeve (7).

Install wiper ring (1) to cylinder head (7) using a plastic hammer.

4.

Install O-Rings (10) and backup ring (9) to cylinder head (7).

5.

Install O-Ring (18), backup ring (16) (Q.ty 2), seal ring (17), slide ring (19) (Q.ty 2) and (20) (Q.ty 2) to piston (15). Special tools for seals assembly: (XXXXXXXX)

10. Install snap ring (25) and cushion seal (26) to cylinder rod (11). Install cushion bearing (27) and stopper (28) to cylinder rod (11). IMPORTANT: be sure to keep cylinder rod (11) aligned with the center of cylinder tube (12) when inserting, in order to avoid damaging the rings.

11. Secure cylinder tube (12) horizontally using a vise. Insert cylinder rod (11) into cylinder tube (12).

12. Install cylinder head (7) to cylinder tube (12). Tighten socket bolts (8). 6.

Install cylinder head (7) to cylinder rod (11). Special tools for cylinder head installation: (XXXXXXXX)

IMPORTANT: be sure that the cushion seal slit faces toward the piston and that the cushion bearing oil groove faces the correct direction.

7.

Install cushion seal (14) to cylinder rod (11). Install cushion bearing (13) and piston (15) to cylinder rod (11).

8.

Install shim (21) to cylinder rod (11). Tighten piston nut (15) using special tool (xxxxxxxxx). Be sure to align the machine mark on the rod with that on the nut. Nut Turning Special Tools (24): -110 mm (XXXXXXXX) : 10280 Nm

W4-1-30

: 14 mm : 367 Nm

FRONT ATTACHMENT

E215B-E245B

Positioner cylinder (triple articulation version)

20

19 15

16 18 19

17 16 20 21

24 23

22 11

12 1 2 8

3 4 7

5 6 9 10

SM0242

12345678-

Wiper Ring Backup Ring Seal Seal Bushing Snap Ring Cylinder Head Socket Bolt (q.ty 12)

9 — Backup Ring 10 — O -Ring 11 — Cylinder Rod 12 — Cylinder Tube 15 — Piston 16 — Backup Ring (q.ty 2) 17 — Seal Ring 18 — O -Ring

W4-1-31

19 — Slide Ring (q.ty 2) 20 — Slide Ring (q.ty 2) 21 — Shim 22 — Set Screw 23 — Steel Ball 24 — Nut

E215B-E245B

FRONT ATTACHMENT

Positioner cylinder disassembly

8.

Remove cylinder head (7) from cylinder rod (11).

Be sure to thoroughly read all the precautions for disassembly/assembly work on page W1-1-1 before starting the disassembly procedure.

9.

Remove O-Rings (10), backup rings (9) and (2) from cylinder head (7), then remove wiper ring (1), seal (3), buffer ring (4), snap ring (6), and bushing (5).

The disassembly procedure below starts on the premise that the hydraulic lines and the line securing bands have been removed. NOTE: positioner cylinder mass: 220 kg 1.

Lift and securely place the cylinder on a workbench using a crane. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

2.

Fully extend cylinder rod (11). Secure the rod end using a crane. Remove socket bolts (8) from cylinder head (7). : 17 mm

IMPORTANT: be sure to pull cylinder rod (11) straight so as not to damage the sliding surfaces.

3.

Pull out cylinder head (7) from cylinder tube (12) by tapping with a plastic hammer.

4.

Secure cylinder rod (11) on special tool (xxxxxxxxx). Put matching marks between cylinder rod (11) and nut (24).

5.

Remove set screw (22) and steel ball (23). : 12 mm

NOTE: cut away its mushroomed portion using a drill first, as set screw was mushroomed with a punch and hammer at two places after it had been screwed in.

6.

Loosen nut (24) using special tool (xxxxxxxxx). Remove piston (15) and shim (21). Socket to loosen nut (24) -110 mm (XXXXXXXX)

7.

Remove seal ring (17), slide rings (19) and (20), O-ring (18) and backup rings (16) from piston (15). W4-1-32

FRONT ATTACHMENT

E215B-E245B

Positioner cylinder assembly 1.

Install bushing (5) to cylinder head (7) using a press. Special tools for bushing installation (5): (XXXXXXXX)

IMPORTANT: be sure that the rings are installed correctly.

2.

Install seal (3), back-up ring (2), elastic ring (6) and seal (4) on the cylinder front sleeve (7).

IMPORTANT: be sure to align cylinder rod (11) with the center of cylinder tube (12) when inserting, in order to avoid damaging the rings.

10. Secure cylinder tube (12) horizontally using a work bench. Insert cylinder rod (11) into cylinder tube (12).

11. Install cylinder head (7) to cylinder tube (12). Tighten socket bolts (8). : 17 mm : 520 Nm

3.

Install wiper ring (1) to cylinder head (7) using a plastic hammer (7).

4.

Install O-Rings (10) and backup ring (9) to cylinder head (7).

5.

Install O-Ring (18), backup ring (16) (Q.ty 2), seal ring (17), slide ring (19) (Q.ty 2), (20) (Q.ty 2) to piston (15). Special tools for seals assembly: (XXXXXXXX)

6.

Install cylinder head (7) to cylinder rod (11). Special tools: (XXXXXXXX)

7.

Install piston (15) to cylinder rod (11).

8.

Install shim (21) to cylinder rod (11). Tighten nut (24) using special tool (XXXXXXXX). Be sure to align the machine mark on the rod with that on the nut. Nut Turning Special Tools (24): — 110 mm (XXXXXXXX) : 9900 Nm

9.

lign the holes on cylinder rod (11) and nut (24). Insert steel ball (23) into the hole, and tighten set screw (22) into the hole. Mushroom the head of set screw (22) at two places using a punch and hammer. : 12 mm : 56.9 ± 10.7 Nm

W4-1-33

E215B-E245B

FRONT ATTACHMENT

Boom cylinders

13 20

19 15

16 18 19

17 16 20 21

24 23

22 11

12 1 2 8

3 4 7

5 6 9 10

SM0240

12345678-

Wiper Ring Backup Ring Seal Seal Bushing Snap Ring Cylinder Head Socket Bolt (q.ty 12)

9 — Backup Ring 10 — O-Ring 11 — Cylinder Rod 12 — Cylinder Tube 13 — Cushion Bearing 15 — Piston 16 — Backup Ring (q.ty 2) 17 — Seal Ring

W4-1-34

18 — O-Ring 19 — Slide Ring (q.ty 2) 20 — Slide Ring (q.ty 2) 21 — Shim 22 — Set Screw 23 — Steel Ball 24 — Nut

FRONT ATTACHMENT Boom cylinders disassembly

7.

Remove seal ring (17), slide rings (19) and (20), O-ring (18) and backup rings (16) from piston (15).

8.

Remove cylinder head (7) from cylinder rod (11).

9.

Remove O-Rings (10), backup rings (9) and (2) from cylinder head (7), then remove wiper ring (1), seal (3), buffer ring (4), snap ring (6), and bushing (5).

Be sure to thoroughly read all the precautions for disassembly/assembly work on page W1-1-1 before starting the disassembly procedure. The disassembly procedure below starts on the premise that the hydraulic lines and the line securing bands have been removed. NOTE: boom cylinder mass: 176 kg 1.

Lift and securely place the cylinder on a workbench using a crane. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

2.

Fully extend cylinder rod (11). Secure the rod end using a crane. Remove socket bolts (8) from cylinder head (7). : 14 mm

IMPORTANT: be sure to pull cylinder rod (11) straight so as not to damage the sliding surfaces.

3.

Pull out cylinder head (7) from cylinder tube (12) by tapping with a plastic hammer.

4.

Secure cylinder rod (11) on special tool (xxxxxxxxx). Put matching marks between cylinder rod (11) and nut (24).

5.

Remove set screw (22) and steel ball (23). : 10 mm

NOTE: cut away its mushroomed portion using a drill first, as set screw was mushroomed with a punch and hammer at two places after it had been screwed in.

6.

E215B-E245B

Loosen nut (24) using special tool (xxxxxxxxx). Remove piston (15), shim (21) cushion bearing (13). Socket to loosen nut (24): — boom cylinder: 90 mm (XXXXXXXX)

W4-1-35

E215B-E245B

FRONT ATTACHMENT 9.

Boom cylinders assembly 1.

Install bushing (5) to cylinder head (7) using a press. Special tools for bushing installation (5): — Boom cylinders: Ø 85 mm (XXXXXXXX)

IMPORTANT: be sure that the rings are installed correctly.

2.

Install seal (3), back-up ring (2), elastic ring (6) and seal (4) on the cylinder front sleeve (7).

3.

Install wiper ring (1) to cylinder head (7) using a plastic hammer (7).

4.

Install O-Rings (10) and backup ring (9) to cylinder head (7).

Align the holes on cylinder rod (11) and nut (24). Insert steel ball (23) into the hole, and tighten set screw (22) into the hole. Mushroom the head of set screw (22) at two places using a punch and hammer. : 10 mm : 56.9 ± 10.7 Nm

IMPORTANT: be sure to align cylinder rod (11) with the center of cylinder tube (12) when inserting, in order to avoid damaging the rings.

10. Secure cylinder tube (12) horizontally using a work bench. Insert cylinder rod (11) into cylinder tube (12).

11. Install cylinder head (7) to cylinder tube (12). Tighten socket bolts (8). : 14 mm : 267 Nm

5.

Install O-Ring (18), backup ring (16) (Q.ty 2), seal ring (17), slide ring (19) (Q.ty 2), (20) (Q.ty 2) to piston (15). Special tools for seals assembly: — Bucket cylinders: (XXXXXXXX)

6.

Install cylinder head (7) to cylinder rod (11). Special tools: — Boom cylinders: (XXXXXXXX)

IMPORTANT: be sure that the cushion seal slit faces toward the piston and that the cushion bearing oil groove faces the correct direction.

7.

Install cushion bearing (13) to cylinder rod (11). Install piston (15) to cylinder rod (11).

8.

Install shim (21) to cylinder rod (11). Tighten nut (24) using special tool (xxxxxxxxx). Be sure to align the machine mark on the rod with that on the nut. Socket to tighten nut (24): — Boom cylinder: 90 mm (XXXXXXXX) : 5470 Nm

W4-1-36

FRONT ATTACHMENT Special tools Piston nut socket wrench: XXXXXXXXX for boom cylinders (90 mm) XXXXXXXXX for bucket cylinder (90 mm) XXXXXXXXX for arm cylinder (110 mm) XXXXXXXXX for positioner arm cylinder (110 mm) (triple articulation version) Use nut loosening/tightening workbench: XXXXXXXXX Tools kit seals installation: XXXXXXXXX for boom cylinders XXXXXXXXX for bucket cylinder XXXXXXXXX for arm cylinder XXXXXXXXX for positioner arm cylinder (triple articulation version)

Tool for the installation and removal of the rod guide bushing: XXXXXXXXX for boom cylinders (Ø 85 mm) XXXXXXXXX for bucket cylinder (Ø 80 mm) XXXXXXXXX for arm cylinder (Ø 95 mm) XXXXXXXXX for positioner arm cylinder (Ø 90 mm) (triple articulation version) Head installation tool: XXXXXXXXX for boom cylinders XXXXXXXXX for bucket cylinder XXXXXXXXX for arm cylinder XXXXXXXXX for positioner arm cylinder (triple articulation version)

W4-1-37

E215B-E245B

E215B-E245B

FRONT ATTACHMENT

Maintenance standard: rod

A

SM0243

Cylinders

STANDARD (A)

Boom

85 ± 0.03

Arm

95 ± 0.03

Bucket

80 ± 0.03

Positioning (*)

90 ± 0.03

(*) Triple articulation version

Remedy

Replace or plate with chromium

Unit: mm

W4-1-38

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