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M0103
E215B-E245B
Group 1
Group 2
Group 3
Group 4
Introduction
Standard Performances
Test Procedures
Mechatro Controller
SECTION 4
OPERATIONAL PERFORMANCE
TEST
CONTENTS
Group 1 - Introduction
How to Use the Maintenance Standard
and Cautions to Be Exercised ........... T4-1-1
Preparation for Performance Tests......... T4-1-2
E215B-E245B
INTRODUCTION
E215B-E245B
Terminology
STANDARD VALUES
Values to be used to condition or assemble a new
machine. Where special notes are not given, these
values represent standard specifications (machine
with standard attachments and standard shoes).
REFERENCE VALUES FOR REMEDY
Values at which readjustment is required. In order to
ensure performance and safety it is strictly
prohibited to use the machine over the specified
values.
SERVICE LIMIT
This is the limit value at which reconditioning is
impossible without replacement of parts. If the value
is expected to exceed the service limit before next
inspection and correction are performed, replace
the parts immediately. The operation over the
specified values causes increase of damage and
requires the down time of machine, and also causes
safety problems.
Rubber products, such as, hydraulic hoses, ORings, and oil seals deteriorate with time; replace
them at regular intervals or at overhauls.
PARTS REQUIRING REGULAR REPLACEMENT
Out of critical hoses that are necessary to secure
safety, we designate Very Important Parts (V.I.P)
and recommend that they should be replaced
regularly.
INSPECTION AND REPLACEMENT OF OILS AND
GREASES
In performing maintenance, it is necessary for the
user to familiarize himself with how to handle the
machine safely, cautions to be exercised and
inspection/lubrication procedures. Refer to the
operators manuals as well.
T4-1-1
E215B-E245B
INTRODUCTION
Test area
1.
2.
3.
SM1231
Precautions
1.
2.
3.
4.
in
2.
3.
T4-1-2
SM1232
STANDARD PERFORMANCES
E215B-E245B
Measuring Position
Inspection Item
Standard
Value
Unit
Adjusting
Point
NAS 9
or less
Class
Sampling
Tank surface
50 5
Radiator surface
75 15
Atmospheric
temp
50 C ~ -10 C
Position
Water temperature
H mode Hi idle
Measure the engine speed at
multi display on the gauge
cluster, or measure with diesel
speed meter
Auto-Idle
B mode Hi idle
ATT Travel
Power
boost
Bucket
Arm
Swing
Travel
RH
LH
P1
a1
P2
a2
P1
a1
P2
a2
a1
R
H
R
H
R
LH
RH
Forward
Reverse
Forward
Reverse
Main pump
Main relief
valve pressure
1050 50
2000 50
1800 50
Boom
2000 50
S mode Hi idle
a5
PF 1/4
a1
Adjustment
not
required Perform all
measurement with the
air-conditioner OFF
PR1
HI idle
34.3 +0.7
MR1
Boom up
37.8 +1.0
MR1
-0
-0,5
-0.5
39.7 +0
-5.9
OR3
Boom up
37.8 +0
OR4
Boom down
39.7
OR1
Bucket digging
OR2
Bucket dump
OR7
Arm in
OR8
Arm out
OR5
Swing LH
OR6
Swing RH
37.8
-4.0
+0
-5.9
+0
-4.0
+0
-4.0
39.8 +0
-5.9
a2
+6.0
29.0 +0
a1
34.3 +0,7
a2
34.3 +0,7
T4-2-1
min-1
5.0 +0,5
37.8
a2
Low throttle
2000 50
G pump
1000 50
A mode Hi idle
Port
H mode Lo idle
Engine speed
Size
Measuring
Condition
-0,5
-0,5
MPa
Simultaneous
Operation of travel RH
and LH
E215B-E245B
STANDARD PERFORMANCES
Inspection Item
Standard value
Sprocket revolution
(RH, LH)
E215B
1st speed
32~28
2nd speed
50~45
Sprocket revolution
(RH, LH)
E245B
1st speed
28~24
nd
45~40
speed
Operating speeds
Arm
Operating time
of cylinder
Positioner
Swing speed
Travel speed
E215B
Travel speed
E245B
Performance
Bucket
In
3.0~3.6
Out
2.3~2.9
Digging
2.2~2.8
Dumping
1.7~2.3
In
2.9~3.5
Out
4.1~4.7
RH - LH
4.2~5.4
st
1 speed
Iron shoe
25.2~28.2
2nd speed
Iron shoe
16.9~18.9
1st speed
Iron shoe
29.5~32.5
Iron shoe
18.5~21.5
nd
speed
Amount of travel
deviation
2nd speed
15 Gradient
Performance of Swing
brake
Measuring
condition
Unit
min-1
min-1
(At no load)
s / 3 rev
0~240
mm / 20 m
mm / 5 min
55~75
degree
15 Gradient
mm
80
Boom cylinder
Arm cylinder
30~50
mm / 5 min
mm
Bucket digging
5.
Swing left
2.
Bucket dump
6.
Swing right
3.
Boom up
7.
Arm in
4.
Boom down
8.
Arm out
T4-2-2
(At no load)
(8)
(5)
(4)
(6) (1)
(7)
(2)
(3)
TEST PROCEDURES
E215B-E245B
2.
3.
4.
5.
GAUGE CLUSTER
BUZZER STOP
SWITCH
WASHER
SWITCH
WIPER
SWITCH
SCREEN CHANGE SWITCH
NO.2 ENG
G-3 SPEED SET
MEAS
G-5 ENG PRS.
WATER TEMP
MODE
H-1 ACCEL VOLT.
POS.
G-1 MOTOR STEP
POS.
COIL A
COIL B
G-2 LIMIT SW.
SM0851
1000
1000
LIVE
20 C OFF
H
0.3 V
0%
30
0%
1.5 A
1.5 A
OFF
SM0852
T4-3-1
E215B-E245B
TEST PROCEDURES
MEASUREMENT OF HYDRAULIC
PRESSURE
Preparing to measure hydraulic pressure
HYDRAULIC EQUIPMENT
6.9 MPa (1000psi) pressure gauge: 1unit
49 MPa (7100psi) pressure gauge: 2 units
Pressure measuring equipment and instrument for
analysis: 1 set
a5
B3
Dr3
A3
PSV2
WARNING
After releasing air in the hydraulic oil tank, open the
cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the
measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.
T4-3-2
(PSV1)
a1
a2
SM0853
TEST PROCEDURES
E215B-E245B
ARM (R)
OR8
PLUG FOR
OPTIONAL RELIEF
FRONT
MACHINE
MAIN RELIEF
(ATT & TRAVEL)
BOOM (H)
OR3
BUCKET (R)
OR2
BOOM (R)
OR4
SM0854
BUCKET (H)
OR1
MACHINE
FRONT
ARM (H)
OR7
View from the bottom of the machine
T4-3-3
PLUG FOR
OPTIONAL RELIEF
SM0855
E215B-E245B
TEST PROCEDURES
B3
A3
PR1
a5
Dr3
SM0856
SWING RIGHT
OVERLOAD RELIEF
OR6
SWING LEFT
OVERLOAD RELIEF
OR5
(A)
(B)
PB
PA
SM0857
a5
B3
Dr3
A3
A2
(A1)
PSV2
(PSV1)
a1
T4-3-4
a2
SM0853
TEST PROCEDURES
E215B-E245B
1 turn
311
LOCK NUT HEX24
SM0858
4 3
: 32 mm
: 27.4~31.4 Nm (20~23 lbfft)
SM0859
: 22 mm
: 27.4~31.4 Nm (20~23 lbfft)
: 19 mm Adjust screw
: 6 mm
1 turn
1
SM0860
T4-3-5
E215B-E245B
TEST PROCEDURES
: 30, 38 mm
: 118 Nm (87 lbfft)
: 12 mm
1 turn
Approx. 10 (1450)
SM0861
: 17 mm
: 6 mm
2
SM0862
T4-3-6
TEST PROCEDURES
E215B-E245B
SM0863
REFLECTION
PANEL
Hi idle
1st speed and 2nd
speed
Right and left
Measuring points:
Method, example 1:
Measure revolution with a stroboscope
Method, example 2:
Measure the revolutions per minute visually.
SM0864
E215B
Unit: min-1
Sprocket revolution
Measurement
item
H mode 1st
speed
RH&
LH
H mode
2nd speed
Standard
value
Reference
value for
remedy
Service
limit
32~28
25.2~22.8
20.4 or
less
50~45
39~35.3
32.5 or
less
E245B
Unit: min-1
Sprocket revolution
Measurement
item
H mode 1st
speed
RH&
LH
H mode
2nd speed
Standard
value
Reference
value for
remedy
Service
limit
28~24
22~19
17 or less
45~40
34~31
29 or less
T4-3-7
E215B-E245B
TEST PROCEDURES
Deviation of travel
PURPOSE
Measure the amount of deviation at 20m (66ft) travel
and confirm the horizontal balance between the
hydraulic pump and the travel motor of the travel
drive system.
CONDITION
Hydraulic oil temperature:
45~55 C
(113~131F)
RH and LH crawler are tensioned evenly.
Firm, level ground
Engine revolution:
Hi idle.
Approx. 30~40 cm
PREPARATION
SM0865
1.
2.
MEASUREMENT
1.
2.
Travel deviation
A
20m
Measuring
position
Standard
value
Reference value
for remedy
Service
limit
240 (9.45)
or less
480 (18.9)
720 (28.4)
SM0866
T4-3-8
TEST PROCEDURES
E215B-E245B
PREPARATION
Place an angle meter on the shoe plate and confirm
that it makes an angle more than 15 degree.
Hang a perpendicular in parallel with the guide
frame rib on the track frame and put a mark
(matching mark) on the shoe plate.
15 degree slope
SM0867
MEASUREMENT
Five minutes after the engine stops, measure the
movement distance of the matching mark.
Parking brake
Measuring
position
Standard
value
Reference value
for remedy
Service
limit
1 (0.04)
2 (0.08)
GUIDE FRAME
ANGLE METER
SM0868
T4-3-9
E215B-E245B
TEST PROCEDURES
45~55C
(113~131F)
Hi idle
PREPARATION
1.
2.
3.
90 o 10
(3.54") (0.394")
FORWARD
o 22 PIPE
(0.866")
RIB "A"
40
(1.57")
150
(5.91")
STOPPER
"B"
ROTARY DIRECTION
o 80
(3.15")
SM0869
WARNING
Unless you observe the rotary force direction at
travel lock, rib "A" may be broken by stopper "B" in
some cases.
1.
2.
Standard
value
Reference value
for remedy
Service limit
Drain rate
9 (2.4)
16 (4.2)
23 (6.1)
E245B
Unit: (gal)
L/30 s
Standard
value
Reference value
for remedy
Service limit
Drain rate
7 (1.6)
14 (3.5
21 (4.6)
T4-3-10
SM0870
TEST PROCEDURES
E215B-E245B
45~55C
(113~131F)
Hi idle
PREPARATION
Put the bucket empty and extend the boom, arm and
bucket cylinder fully.
And the machine becomes a position of minimum
reach.
MEASUREMENT AT TRAVEL LOCK
Swing the machine by bringing the swing lever to its
full stroke. Measure the time required to make two
turns after one turn of preliminary run and calculate
the time required for one turn.
Swing speed
Unit : sec/rev
Measuring
position
Standard
value
Reference value
for remedy
Service limit
Swing speed
at min. reach
4.2~5.4
5.4~6.9
7.2~
T4-3-11
SM0871
E215B-E245B
TEST PROCEDURES
ARM TOP
PIN
CONDITIONS
Hydraulic oil temperature:
Firm, level ground
Engine revolution:
45~55C
(113~131F)
Hi idle
SM0872
PREPARATION
1.
2.
2.
Swing
angle ()
drift
Amount of deflection of
matching marks [m (ft-in)]
Circumferenzial lenght of
swing race [m (ft-in)]
x 360
MATCHING MARKS
ON INNER RACE
SM0873
Unit : degree
Measuring
position
Standard
value
Reference value
for remedy
Service limit
Swing 180
75
85
90
T4-3-12
TEST PROCEDURES
E215B-E245B
SM0874
Performance of swing
parking brake
Unit : mm(in)/5min
Measuring
position
Standard
value
Reference value
for remedy
Service limit
1 (0.04)
2 (0.08)
T4-3-13
MATCHING MARKS
ON INNER RACE
SM0875
E215B-E245B
TEST PROCEDURES
45~55C
(113~131F)
Hi idle
PREPARATION
1.
2.
3.
4.
2.
3.
Unit : L(gal)/30sec
Measuring
position
Standard
value
Reference value
for remedy
Service limit
Drain rate
2.1 (0.55)
5.2 (1.4)
6.2 (1.6)
T4-3-14
SM0876
TEST PROCEDURES
E215B-E245B
45~55C
(113~131F)
Engine revolution:
Hi idle
Operating time excluding the cushion stroke.
PREPARATION
Firm level ground with the bucket empty.
MEASUREMENT
Measurement 1 ; Boom up and down
30cm (1ft)
Unit : sec
Measuring
position
Standard
value
Reference value
for remedy
Service limit
2.2~2.8
2.8~3.6
3.8~
1.7~2.3
2.2~2.9
3.0~
2.5~3.1
3.2~4.0
4.2~
2.2~2.8
2.8~3.6
3.8~
3.5~4.1
4.4~5.9
5.5~
2.6~3.2
3.3~4.1
4.3~
3.0~3.6
3.8~4.6
5.0~
2.3~2.9
2.9~3.7
3.9~
2.9~3.5
3.7~4.4
4.6~
10
4.1~4.7
5.2~6.0
6.3~
30cm (1ft)
10
SM0877
T4-3-15
E215B-E245B
TEST PROCEDURES
B
BOOM FOOT PIN
CONDITIONS
Hydraulic oil temperature:
45~55C
(113~131F)
Unit: mm(in)/5min
Measuring
position
Standard
value
Reference value
for remedy
Service limit
7 (0.28)
11 (0.43)
14 (0.55)
6 (0.24)
9 (0.35)
11 (0.43)
80 (3.1)
120 (4.7)
160 (6.3)
T4-3-16
D
ARM TOP PIN
SM0878
TEST PROCEDURES
E215B-E245B
2.
LOCATION OF BEARING
MOUNTING BOLTS
SWING BEARING
A
DIAL INDICATOR
LOWER FLAME
MEASUREMENT
Measuring position 1 and 2
Measure the displacement of the outer race in the
axial direction in position 1 [The arm at 90~110
and the crawler front is lifted by attachment about
30cm (1ft)] and in position 2, using a dial indicator.
Axial play of swing bearing
SM0879
Unit: mm (in)
Measuring
position
Standard
value
Reference value
for remedy
Service limit
0.8~1.8
(0.03~0.07)
2.3~3.3
(0.09~0.13)
3.6 (0.14)
90 ~100
30cm
SM0879
Position 1
BOOM FOOT
PIN
ARM TOP
PIN
SM0872
Position 2
T4-3-17
E215B-E245B
TEST PROCEDURES
Measuring position 3
Retract the arm cylinder fully and extend the bucket
cylinder fully. And move the boom so that the arm
top pin is positioned at same height with boom foot
pin. Then swing the bucket right and left by man
power.
But in this case, the gap of the attachment is
included.
Right and left movement of
the tip of bucket
BOOM FOOT
PIN
ARM TOP
PIN
Unit: mm (in)
Measuring
position
Standard
value
Reference value
for remedy
Service limit
Benna
30~50
(1.18~1.97)
80 (3.15)
120 (4.72)
T4-3-18
SM0872
Position 3
MECHATRO CONTROLLER
E215B-E245B
M-2:
GOVERNOR MOTOR
C-2:
GAUGE CLUSTER
E-1:
FUSE&RELAY
BOX
ENGINE SPEED
SENSOR
STARTER
SWITCH
C-1:
MECHATRO CONTROLLER
ACCEL
POTENTIO METER
ENGINE
PUMP
PROPORTIONAL
VALVE
SM0881
T4-4-1
E215B-E245B
MECHATRO CONTROLLER
ENGINE CONTROL
Engine control assy
3
1
11
3
3
5
Section A-A
10
HIGH
LOW
LOW
HIGH
2
4
2
Section B-B
Detail aa
9
Section C-C
1 - Governor motor
2 - Lever assy
3 - Sems-Bolt M8x25 (Q.ty 4) 23.5 Nm (17.3 lbf x ft)
4 - Bracket
5 - Capscrew (Q.ty 3) 19.6 Nm (14.5 lbf x ft) Apply Loctite #242
6 - Rod
7 - Nut M10 10.7 Nm (7.89 lbf x ft)
8 - Nut M10 10.7 Nm (7.89 lbf x ft)
9 - Nut M8 (Q.ty 2) 23.5 Nm (17.3 lbf x ft)
10 - Sems-Bolt M6x16 (Q.ty 2) 4.4 Nm (3.25 lbf x ft)
11 - Sems-Bolt M6x20 9.6 Nm (7.08 lbf x ft)
T4-4-2
SM0882
MECHATRO CONTROLLER
E215B-E245B
2.
3.
OIL SEAL
OUTPUT
SHAFT
CAM
LIMIT
SWITCH
SM0883
Speed sensor
Installing place: engine flywheel housing.
Sensor attaching procedure: push it into place and
fix with partially self-sealing cylindrical screw
M6x12, tightening torque 82 Nm.
CN-136F
SM0884
WORK MODE
SELECT SWITCH
SM0885
T4-4-3
E215B-E245B
MECHATRO CONTROLLER
ADJUSTMENT OF MECHATRO
CONTROLLER OUTPUT (A-B-C
ADJUSTMENT)
Purpose of the adjustment
There are 3 kinds of adjustment of mechatro
controller as shown below; every adjustment is an
essential function to ensure performance of
machine.
1.
2.
3.
Mechatro controller
2.
Engine
3.
4.
Unloading proportional
unloading valve.
valve,
spool
of
Preparation
1.
2.
3.
T4-4-4
MECHATRO CONTROLLER
E215B-E245B
Adjusting procedure
MULTI DISPLAY
WASHER SWITCH
WIPER SWITCH
SELECT SWITCH
SM0886
2.
3.
T4-4-5
SM0887
E215B-E245B
4.
5.
MECHATRO CONTROLLER
FINISH ENG
ENGINE SPEED
2000rpm
PUMP PRESSURE
C-1 2.0M C-2
STEP
400
2.0M
SM0888
ADJUSTMENT OF PUMP
("B" ADJUSTMENT)
PROCEDURE
1.
2.
T4-4-6
FINISH PUMP
ENGINE SPEED
2000rpm
PUMP PRESSURE
C-1 35.0M C-2
PROPO-VALVE
E-1 300mA E-2
35.0M
300mA
SM0889
MECHATRO CONTROLLER
E215B-E245B
2.
MEMORY UNLOAD
ENGINE SPEED
2000rpm
PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
D-1 300mA D-2 300mA
T4-4-7
E215B-E245B
2.
MECHATRO CONTROLLER
SM0891
Judging condition 2:
the adjustment does not complete although the
pump proportional valve current reaches to the
specified value.
The P1 and P2 pump pressures usually
increase to 33~38MPa. When the pressure
does not increase:
a. Identify the reason why the pressure does
not increase,
Check that the relief valve operates
normally.
Check that the hydraulic circuit is free from
leak of pressure.
Check that the pressure sensor functions
normally. And so on.
b. Identify the reason why the actual flow rate
does not increase,
Check that the pump proportional valve
operates normally.
Check that the pump regulator operates
normally. And so on.
3.
T4-4-8
SM0892
MECHATRO CONTROLLER
E215B-E245B
OTHER PRECAUTIONS
1.
2.
2.
3.
4.
T4-4-9
MULTI DISPLAY
(EXAMPLE)
SM0893
E215B-E245B
5.
6.
MECHATRO CONTROLLER
T4-4-10
MEMORY UNLOAD
ENGINE SPEED
2000rpm
PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
D-1 300mA D-2 300mA
SM0894