E175B

E195B
Workshop
Manual

Workshop
Manual

Print No. 87690582A

English - Printed in Italy

E175B
E195B

PROVEN PERFORMANCE

E175B
E195B
WORKSHOP MANUAL

M0103

All the information and data contained in this manual are based upon most recent information available at the
time of its publication.
NEW HOLLAND KOBELCO has the right to implement, at any time, any modification without providing any
communication.

NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. - Product Support

Print No. 87690582A
Edition - June 2007

INTRODUCTION

E175B-E195B

TO THE READER
- If you have any questions or comments, or if you
found any errors regarding the contents of this
manual, please contact:

This manual is written for an experienced

technician to provide technical information
needed to maintain and repair this machine.

NEW HOLLAND KOBELCO

CONSTRUCTION MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 0077357

- Be sure to thoroughly read this manual for

correct information concerning the service
procedures.

ADDITIONAL REFERENCES
Please refer to the materials listed below in
addition to this service manual:
- Operation
Manual

and

Maintenance

Instruction

- Parts Catalog

WORKSHOP MANUAL COMPOSITION

- The Operational Performance Test part includes
the information needed to carry out the machine
operational performance test.

The Workshop Manual consists of five parts:

- Safety Precautions
- Operational Principle
- Operational Performance Test

- The Troubleshooting part includes the technical

information needed for troubleshooting and
malfunction detection.

- Troubleshouting
- Repair Instructions
- The Safety Precaution part includes the
recommended procedures that, if followed, can
avoid the risk of accident for operator and for staff
related to the work and maintenance machine
operations.

- The Repair Instruction part includes information

needed for maintenance and repair of the
machine, tools and devices needed for
maintenance and repair, maintenance standards,
removal/installation and assembly/disassembly
procedures.

- The Operational Principle part includes the

technical information concerning the operation of
main devices and systems.

IN - 1

E175B-E195B

INTRODUCTION

PAGE NUMBER
Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:
Example: T 1-2-3
Consecutive page number for each group
Group number (if exist))
Section number
T:

Technical Manual

W: Workshop Manual
SYMBOLS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential
for personal injury or machine damage.
This is the safety alert symbol.
When you see this symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed along with the safety alert symbol.
The safety alert symbol is also used to draw attentio in to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting
heavy parts.

UNITS USED
SI Units (International System of Units) are used in this manual.
MKSA system units and English units are also indicated in parentheses just behinds SI units.
Example: 24.5 MPa (250 kgf/cm2)
A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

To convert from
(SI)

Into
(Others)

Multiply by

Quantity

To convert from
(SI)

Into
(Others)

Multiply by

Lenght

mm

in

0.03937

Pressure

MPa

kgf/cm2

10.197

mm

ft

0.003281

MPa

psi

145.0

US gal

0.2642

kW

CV-PS

1.360

US qt

1.057

kW

HP

1.341

m3

yd3

1.308

Temperature

C x 1.8 + 32

Mass

kg

lb

2.205

Velocity

km/h

mph

0.6214

Force

kgf

0.10197

min-1

rpm

1.0

lbf

0.2248

L/min

US gpm

0.2642

N.m

kgf.m

0.10197

mL/rev

cc/rev

1.0

N.m

lbf.ft

0.7375

Volume

Torque

Power

Flow rate

IN - 2

INDEX

E175B-E195B

MANUAL INDEX
SAFETY PRECAUTIONS

Page

Section 1 GENERALITIES ..................................................................... S1

Section 2 SAFETY PRECAUTIONS ..................................................... S2
Section 3 SAFETY PLATES .................................................................. S3

OPERATIONAL PRINCIPLE
Section 1 GENERAL
Group 1

Specifications................................................................................. T1-1

Section 2 SYSTEM
Group 1
Group 2
Group 3

Mechatro control system................................................................ T2-1

Hydraulic System........................................................................... T2-2
Electrical System ........................................................................... T2-3

Section 3 COMPONENT OPERATION

Group 1
Group 2
Group 3
Group 4
Group 5
Group 6
Group 7
Group 8

Hydraulic Pump Assy..................................................................... T3-1

Pilot Valve ...................................................................................... T3-2
Control Valve ................................................................................. T3-3
Swing Device ................................................................................. T3-4
Travel Device ................................................................................. T3-5
Swivel Joint.................................................................................... T3-6
Cylinders........................................................................................ T3-7
Air Conditioner system................................................................... T3-8

OPERATIONAL PERFORMANCE TEST

Section 4 OPERATIONAL PERFORMANCE TEST
Group 1
Group 2
Group 3
Group 4

Introduction ................................................................................... T4-1

Standard Performances ................................................................. T4-2
Test Procedures ............................................................................ T4-3
Mechatro Controller ....................................................................... T4-4

TROUBLESHOOTING
Section 5 TROUBLESHOOTING
Group 1
Group 2
Group 3

Troubleshooting (by error codes)................................................... T5-1

Troubleshooting (by trouble) .......................................................... T5-2
Troubleshooting (trouble diagnosis mode)..................................... T5-3

E175B-E195B

INDEX

REPAIR INSTRUCTIONS
Section 1 GENERAL INFORMATION
Group 1
Group 2

Precautions for Disassembly and Assembly.................................W1-1

Tightening Torque ........................................................................W1-2

Section 2 UPPERSTRUCTURE
Group 1
Group 2
Group 3
Group 4
Group 5

Upperstructure ..............................................................................W2-1
Pump Device.................................................................................W2-2
Control Valve ................................................................................W2-3
Swing Device ...............................................................................W2-4
Pilot Valve .....................................................................................W2-5

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

Swing Bearing ..............................................................................W3-1

Travel Device ...............................................................................W3-2
Swivel Joint ..................................................................................W3-3
Track Adjuster ..............................................................................W3-4
Front Idler .....................................................................................W3-5
Upper and Lower Roller ...............................................................W3-6
Tracks ...........................................................................................W3-7

Section 4 FRONT ATTACHMENT

Group 1

Front attachment...........................................................................W4-1

SAFETY PRECAUTIONS

M0103

SAFETY PRECAUTIONS

E175B-E195B

INDEX
Section 1

GENERALITIES

Section 2

SAFETY PRECAUTIONS

Section 3

SAFETY PLATES

GENERALITIES

E175B-E195B

SAFETY PRECAUTIONS
GENERALITIES
Do not leave the machine until it has come to a
complete stop.

Read the Operation and Maintenance Instruction

Manual carefully before starting,
operating,
maintaining, fuelling or servicing the machine.

Always check height, width and weight limitations

which may be encountered in the working site and
ensure the machine does not exceed them.

Carefully read the explanation to each and all safety

signs in the special section of this Manual before
starting, operating, maintaining, fuelling or servicing
the machine.

Assess exact paths of gas ducts, water mains,

telephone lines, sewers, overhead and underground
electric lines and all other possible obstacles.

Machine-mounted safety plates are colour coded

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

Such paths should be opportunely defined by

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

It is fundamental that all machine operators know

very well the meaning of each safety plate as this
considerably decreases operating hazards and
accidents.

Never exceed machine lifting capacity.

Remain within the limits shown in the loading
capacity chart which located on the machine.

Do not allow unauthorised personnel to operate or

service this machine.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get
caught in moving parts. Wear certified safety clothes
such as: hard hat, no-slip footwear, heavy gloves, ear
protection, safety glasses, reflector vests, respirators
every time the job requires it. Ask your employer
about safety regulations in force and protective
equipment.

STARTING
Never start or operate a failed machine. Walk all
around the machine before mounting.
Before operating the machine, make sure that any
possible dangerous condition has been properly
removed. Before starting machine, check that
steering and attachment controls are in the neutral
position and the safety lever is in the LOCK position.
Immediately report any malfunction of parts or
systems to the maintenance managers for proper
action.

Always keep the operators compartment, step

plates, grab-rails and handles clean and clear of
foreign objects, oil, grease, mud or snow to minimise
the danger of slipping or stumbling. Remove mud or
grease from your shoes before operating the
machine.

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

drivers seat for maximum riding comfort and control
accessibility. Prior to operating the machine and/or
its attachments, check that bystanders are outside
the machine operating range. Sound the horn.

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

hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Do not use controls or hoses as hand holds. Hoses
and controls are movable parts and do not provide
solid support. Besides, controls may be inadvertently
moved and cause unexpected movement of the
machine or its attachments.

Obey all hand signals, safety indications and signs.

Never operate the machine or its attachments from

any position other than sitting in the drivers seat.
Keep head, body, limbs, hands and feet inside the
operators compartment at all times to reduce
exposure to external hazards.

Ensure that nobody is within the excavator operating

area before starting the machine, swinging the upper
structure or moving in any direction.

Be careful of possible slippery conditions of the steps

and hand rails as well as of the ground around the
machine. Wear protective boots or shoes with the
soles made of highly no-slip rubber

Ensure that engine speed is appropriate to the job to

be carried out.

Due to the presence of flammable fluids, never

check fuel level, refuel, charge the batteries in the
presence of smoking materials, open flames or
sparks.

Adjust all rear-view mirrors for maximum visibility of

the area behind the machine.

S1 - 1

E175B-E195B

GENERALITIES

If any hydraulic control or system exhibits erratic

performance or responds abnormally, have the
machine checked for air in the system.

properly protected against possible backlash in

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

Air in these circuits may cause incorrect movements

with consequent accident hazard. Refer to the
Operation and Maintenance Instruction Manual
about corrective action to be taken.

In darkness, check area of operation carefully before

moving in with the machine. Use all lights provided.
Do not move into low visibility areas.
If the engine tends to slow down and stall for
whatever reason under load or at idle, immediately
report this problem to the maintenance managers for
proper action.

OPERATING
Do not run the engine of this machine in closed
buildings without proper ventilation capable to
remove harmful exhaust gases which concentrate in
the air.

Do not operate the machine until this condition is

corrected. Regularly check all exhaust system
components, as exhaust fumes are toxic for the
operator.

Keep the operators compartment free of foreign

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

Operators must know the performance of the

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

Do not carry riders on the machine. Study and

familiarise with escape routes alternative to normal
exit routes. For your personal safety, do not climb on
or off the machine while it is in motion.

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

hours at the operators ear, wear approved ear
protection in compliance with local regulations.

Make sure that bystanders are clear of the machine

operating range before starting the engine and
operating the attachment. Sound the horn.
Obey all hand signals, safety indications and signs.

Do not operate the machine if you are extremely tired

or feel ill. Be especially careful towards the end of the
working shift.

When backing, always look to where the machine is

to be moved.

Where removable counterweights are provided, do

not operate the machine if they have been removed.

Be alert of the position of bystanders. Should

someone enter the work area, stop the machine.
Maintain a safe distance from other machines or
obstacles to ensure required visibility conditions.

When operating the machine, keep in mind height

limits of overhead doors, arches, overhead cables
and lines as well as width limits of corridors, roads
and narrow passages.

Always give way to loaded machines.

Also, get to know load limits of the ground and

paving type of the ramps you are to work on.

Maintain a clear vision of the surroundings of the

travel or work area at all times. Keep cab windows
clean and repaired.

Beware of fog, smoke or dust that obscure visibility.

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

When pulling loads or towing through a cable or

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

Whenever possible, avoid crossing over obstacles

such as very rough terrain, rocks, logs, steps,
ditches, railroad tracks.

Always wear heavy gloves when handling chains or

cables.

When obstructions must be crossed, do so with

extreme care and at a square angle, if possible. Slow
down.

Chains and cables should be securely anchored

using suitable hooks. Anchor points should be strong
enough to withstand the expected load.

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

point slowly and ease down the other side also using
the attachment, if necessary.

Keep anyone clear of anchor points and cables or

chains.

To overcome deep trenches or sinking ground, place

the machine perpendicular to the obstacle, drastically
reduce ground speed and start crossing using also

Do not pull or tow unless the operators

compartments of the machines involved are
S1 - 2

GENERALITIES

E175B-E195B

the attachment if necessary, only after assessing that

ground conditions allow the traverse safely and
without risks.

The load must always be properly arranged in the

bucket; move with extreme care when transporting
oversize loads.

The gradient you may attempt to overcome is limited

by factors such as ground conditions, load being
handled, machine type and speed, and visibility.
There is no substitute for good judgement and
experience when working on slopes.

Do not lift and move the bucket overhead where

persons are standing or working, nor downhill when
working on a slope as this would decrease machine
stability. Load the bucket from the uphill side.
Loads to be raised using the machine should be
exclusively hooked to the hitch specially provided.

Avoid operating the attachment too close to an

overhang or high wall, either above or below the
machine. Beware of caving edges, falling objects
and landslides. Remember that such hazards are
likely to be concealed by bushes, undergrowth and
such.

The excavator is no lifting and transportation means,

therefore it should not be used to position loads
accurately. Should it be exceptionally used to lift and
lay building components, special caution must be
taken as follows:

Avoid faggots, bushes, logs and rocks. Never drive

over them, nor over any other surface irregularities
that discontinue adherence or traction with the
ground, especially near slopes or drop-offs.

- The machine must be equipped compulsorily with

the appropriate variant provided upon request.
- Secure the loads to be raised using cables or
chains fastened with appropriate hooking
mechanisms.

Be alert to avoid changes in adherence conditions

that could cause loss of control. Work with extreme
care on ice or frozen ground and on stepped slopes
or near drop-offs.

- Nobody should be allowed to remain under the

raised load or within the excavator operating range
for any reason whatever.

The word bulldozing generally refers to work in

virgin rough terrain, characterised by the presence of
all the perils and risks listed above. We emphasise
the danger represented in these conditions by large
tree limbs (possibly falling on the machine) and large
roots (which may act as a leverage under the
machine when up-rooted and cause the unit to
overturn).

Never exceed specified loading capacity. Incorrect

fastening of slings or chains may cause boom/arm
failure or failure of the lifting means with consequent
bodily injuries and even death.
Always ensure that slings and chains used for lifting
are adequate to the load and in good condition.

Position the machine dependent upon the loading

and unloading areas in order to swing leftwards to
load to obtain best visibility.

All loading capacities are referred to the machine

on a level surface and should be disregarded
when working on a slope.

Never use the bucket or attachment as a man lift

or carry riders. Never use the machine as a work
platform or scaffolding. The machine must not be
improperly used for works not consistent with its
features (such as pushing railway cars, trucks or
other machines).

Avoid travelling across slopes. Proceed from uphill

downhill and vice-versa. If machine starts slipping
sideways when on a slope, lower the bucket and
thrust bucket teeth into the ground.
Working on slopes is dangerous. Grade the working
area if possible. Reduce work cycle time if it is not
possible to grade the working area.

Always pay attention to people within the machine

operating range.
Never move or stop the bucket, other loads or the
attachment above ground personnel or truck cabs.

Do not move full bucket or a load from uphill downhill

as this would reduce machine stability. Do not work
with the bucket turned to the uphill side.

Ensure the truck driver is in a safe place before

loading the truck.

Do not work with the bucket turned uphill as

counterweights protruding downhill would reduce
machine stability on the slope and increase risk of
overturning.

Load trucks from side or rear.

Use only the type of bucket recommended
considering machine type, materials to be handled,
material piling up and loading characteristics, ground
type and other typical conditions of the work to be
performed.

We recommend to work on slopes with the bucket

downhill, after checking machine stability with the
bucket empty and attachment retracted, by slowly
swinging the upper structure by 360.

When transporting a loaded bucket, keep it as

rolled-back as possible. Keep boom and arm as low
as possible.

Position the carriage at a right angle relative to

slopes, hanging walls, etc. to exit the working area
easily.

Ground speed should be adequate to the load and

ground conditions.

Standard use, provides for the travel controls at the

front and travel motors at the back. Should travel
S1 - 3

E175B-E195B

GENERALITIES
- Look up the in the telephone directory.

motors be positioned at the front with regard to the

actual travel direction. Remind relative to travel
direction that controls are reversed.

- Define together with the Company representative

which precautions should be taken to guarantee
work safety.

Always check travel motor position before moving off.

- All electric lines should be considered as operative

live lines even though it might be well known that
the line in question is out of work and visibly
connected to the ground.

Properly judge ground conditions with particular

attention to consistency of the area you are going to
work on.
Keep the machine sufficiently
edge.

far from the ditch

- The Electric Power Company, if previously advised

and involved in the work, as well as machine
Operator, Owner and/or any natural person or legal
entity having rent orleased the machine or being
responsible at the time by contract or by law, are
liable for the adoption of the necessary
precautions.

Never dig under the machine.

Should it be necessary to dig under the machine,
always ensure that digging walls are opportunely
propped up against landslide to prevent the machine
from falling into the trench.
Do not swing the upperstructure, raise the load or
brake abruptly if not required. This may cause
accidents.

- Decrease work speed. Reaction time could be too

slow and distance evaluation wrong.
- Warn all ground personnel to keep clear of the
machine and/or load at all times. If the load has to
be guided down for laying, consult the Electric
Power Company to know which precautions should
be taken.

Prior to beginning the work near gas distribution

mains or other public utilities:
- Contact the company owner of the gas mains or its
nearest branch before starting the work. Look up
the number in the telephone directory.

- Appoint a person in charge of signalling duties.

This person will have the responsibility of observing
the machine, any part of it and/or the load
approaching the electric lines from a standpoint
more favourable than the Operators. This signal
man (flag-man) must be in direct communication
with the Operator and the Operator must pay
undivided attention to the signals supplied.

- Define together which precautions should be taken

to guarantee work safety.
- Decrease work speed. Reaction time could be too
slow and distance evaluation wrong.
- When working near gas mains or other public
utilities installations, appoint a person in charge of
signalling duties. This person will have the
responsibility of observing the machine, any part of
it and/or the load approaching the gas mains from
a standpoint more favourable than the Operators.
This signal man (flag-man) must be in direct
communication with the Operator and the Operator
must pay undivided attention to the signals
supplied.

When working in or near pits, in ditches or very high

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

- The gas distributing Company, if previously

advised and involved in the work, as well as
machine Operator, Owner and/or any natural
person or legal entity having rent or leased the
machine or being responsible at the time by
contract or by law, are liable for the adoption of the
necessary precautions.

When digging, there is the risk of cave-ins and

landslides.
Always check ground conditions and conditions of
the material to be removed. Support everywhere it is
required to prevent possible cave-ins or landslides
when:
- Digging near previous trenches filled with material.

Working near electric lines can be very dangerous,

therefore some special precautions must be
observed.

- Digging in bad ground conditions.

- Digging trenches subject to vibration from
railroads, working machines or highway traffic.

Within this Manual, work near electric lines means

when the attachment or load raised by the excavator
(in any position) may reach the minimum safety
distance established by local or international Safety
Regulations.

STOPPING

To work without risks, keep maximum possible

distance from electric lines and never trespass
minimum safety distance.

When the machine is to be stopped for whatever

reason, always check that all controls are in the
neutral position and that the safety lever is on the lock
position to guarantee risk-free start-up.

- Contact the Company owner of the electric lines or

its nearest branch before starting the work.
S1 - 4

GENERALITIES

E175B-E195B

Read all safety plates mounted on the machine and

observe instructions they contain before starting,
operating, repairing, fuelling or servicing the
machine.

Never leave the machine unattended with the engine

running.
Prior to leaving the drivers seat, and after making
sure that all people are clear of the machine, slowly
lower the attachment until resting it safely to the
ground. Retract possible auxiliary tools to the closed
safety position.

Do not allow unauthorised personnel to repair or

service the machine.
Follow all recommended maintenance and service
procedures.

Check that all controls are in the neutral position.

Move engine controls to the shut-down position.
Switch off the key-start switch. Consult the Operation
and Maintenance Instruction Manual.

Do not wear rings, wrist watches, jewellery, loose or

hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get
caught in moving parts. Wear certified safety clothes
such as: hard hat, no-slip footwear, heavy gloves, ear
protection, safety glasses, reflector vests, respirators
when required. Ask your employer about safety
regulations in force and protective equipment.

Park the machine in a non-operating and no-traffic

area. Park on firm level ground. If this is not possible,
position the machine at a right angle to the slope,
making sure there is no danger of uncontrolled
sliding.

Do not use controls or hoses as hand holds. Hoses

and controls are movable parts and do not provide
solid support. Besides, controls may be inadvertently
moved and cause unexpected movement of the
machine or its attachments.

If parking in traffic lanes cannot be avoided, provide

appropriate flags, barriers, flares and other signals as
required to adequately warn the oncoming drivers.
Always switch off the key-start switch before
cleaning, repairing, or parking the machine to prevent
accidental unauthorised start-up.

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

hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.

Never lower the attachment or auxiliary tools other

than from sitting in the operators seat. Sound the
horn. Make sure that nobody is within the machine
operating range. Lower the attachment slowly.

Never service the machine with someone sitting in

the drivers seat, unless this person is an authorised
operator assisting in the maintenance being carried
out.

Securely block and lock the machine every time you

leave it unattended. Return keys to the safe place
previously agreed upon. Perform all necessary
operations for stopping as detailed in the Operation
and Maintenance Instruction Manual.

Keep the operators compartment, step plates, grab

rails and handles clear of foreign objects, oil, grease,
mud orsnow to minimise the danger of slipping or
stumbling.

Drive the machine far from pits, trenches, rocky

hanging walls, areas with overhead electric lines, and
slopes before stopping it at the end of the working
day.

Clean mud or grease from your shoes before

climbing on the machine or driving it.
Never attempt to operate the machine or its
attachments from any position other than sitting in the
operators seat.

Align the upperstructure to the tracks in order to allow

to easily get on and off the drivers compartment.

Keep the drivers seat free from foreign objects,

especially if these are not secured.

Move all controls to the position specified for machine

stopping. Refer the Operation and Maintenance
Instruction Manual.

Should it be necessary to move the attachment for

maintenance purposes, do not raise or lower the
attachment from any other position than sitting in the
operators seat. Before starting the machine or
moving its attachment, sound the horn and require
that nobody remains near the machine.

Never park on an incline without accurately blocking

the machine to prevent unexpected movement.
Follow stopping instructions contained in the
Operation and Maintenance Instruction Manual.

Raise the attachment slowly.

Always lock all moving components or parts of the
machine that must be lifted for maintenance
purposes using adequate external means as
required by local and national regulations. Do not
allow anyone to pass or stay near or below a raised
attachment. If you are not absolutely sure about your
safety, do not stay or walk under a raised attachment.

MAINTENANCE
GENERALITIES
Carefully read the Operation and Maintenance
Instruction Manual before starting, operating,
maintaining, fuelling or servicing the machine in any
manner.

Do not place head, body, limbs, hands, feet or fingers

near articulated cutting edges deprived of the
necessary guards, unless they are suitably and
safely locked.
S1 - 5

E175B-E195B

GENERALITIES
flammable fluids to clean parts. Use proprietary
certified non-flammable, non-toxic solvents only.

Never lubricate, repair or adjust the machine with the

engine running, except when this is specifically
required by the Operation and Maintenance
Instruction Manual.

When using compressed air to clean parts, wear

safety glasses with side shields. Limit pressure to
max. 2 bars, in accordance with local and national
safety regulations in force.

Do not wear loose clothing, jewellery near rotating

parts.

Do not run the engine of this machine in closed

buildings without proper forced ventilation capable to
remove toxic exhaust gases concentrating in the air.

When service or maintenance require access to

areas that cannot be reached from the ground, use a
ladder or step platform conforming to local or national
regulations to reach the working area. If such means
are not available, use machine grab rails and steps.
Always perform all service or maintenance work with
the greatest care and attention.

Do not smoke, nor allow open flames or sparks

nearby while refuelling the unit or handling highly
flammable materials.
Do not use open flames as light sources to look for
leaks or inspect anywhere on the machine.

Shop and/or field service platforms or ladders should

be manufactured and maintained in accordance with
local or national safety regulations in force.

Make sure that all mechanical tools provided are in

good condition at all times. Never use tools with
mushroomed or damaged heads. Always wear eye
protections with side shields.

Disconnect batteries and label all controls to warn

that service work is in progress, according to local
and national safety regulation requirements.

Move with extreme care when working under, on or

near the machine or its attachments.

Block the machine and all attachments to be raised

according to local and national safety regulation
requirements.

In case of attachment tests during which the engine

should be kept running, a qualified operator must sit
in the drivers seat at all times while the mechanic is
at work.

Do not check or fill fuel tanks or install batteries near

burning or smoking materials and open flames due to
the presence of flammable vapours.

Keep hands and clothes far off moving parts.

The fuel filler pipe nozzle must be constantly kept in

contact with the filler neck and this even before fuel
starts flowing in. Keep this contact from the beginning
to the end of the fuelling operation to avoid possible
generation of sparks due to static electricity.

Stop the engine and move the safey lever to the lock
position before starting adjusting or repairing an
assembly.
Do not carry out any work on the attachment without
prior authorisation. Observe maintenance and repair
procedures.

Use a truck or trailer to haul a failed machine. Should

it be necessary to tow it, provide for suitable danger
signals as required by the local norms and
regulations and observe recommendations given in
the Operation and Maintenance Instruction Manual.
Load/unload the machine on firm level ground
providing safe support to the wheels of the truck or
trailer. Use strong access ramps, with adequate
height and angle. Keep the trailer flatbed free of mud,
oil or slippery materials. Tie the machine securely to
the trailer and block carriages and upperstructure.

In case of field service, move the machine to level

ground and block it. If work on an incline cannot be
avoided, securely block the machine and its
attachments. Move the machine to level ground as
soon as possible.
Do not twist chains and cables. Never use a twisted
chain or cable for lifting or pulling. Always wear safety
gloves to handle chains or cables.
Be sure chains and cables are firmly fastened and
that the anchor point is strong enough to withstand
the expected load.

Never align holes or slots using your fingers;

alwaysuse appropriate aligning tools.
Remove all sharp edges and burrs from re-worked
parts.

Keep all bystanders clear of the anchor point, cables

or chains. Do not pull or tow unless the operators
compartments of the machines involved are
fitted with proper guards against cable or chain
backlash.

Use only approved and effectively grounded auxiliary

power sources for heaters, battery chargers, pumps
and similar equipment to reduce electrical shock
hazard.

Keep the maintenance area clean and dry at all

times.

Lift and handle heavy components using hoisting

devices of appropriate capacity. Ensure the parts are
supported by appropriate straps and hooks.

Clean immediately all water and oil spillage.

Do not pile up oily or greasy rags as they represent a
major fire hazard. Always store them in closed metal
containers.

Use lifting eyes provided to this aim.

Pay attention to bystanders near the lifting area.

Before starting the machine or its attachment, check,

adjust and lock the operators seat. Also ensure that
nobody is within the machine or attachment

Never pour gasoline or diesel fuel into open

containers. Never use gasoline, solvents or other
S1 - 6

GENERALITIES

E175B-E195B

injuries are most likely to occur. Pay attention to

prevent possible part movements by means of
blocks or by keeping clear of such zones when
motion may take place during maintenance or repair.

operating range before starting or operating the

machine and/or its attachments.
Sound the horn.
Rust inhibitors are volatile and flammable.

Move the hydraulic system lock safety lever to the

lock position when stopping the machine for
whatever reason.

Prepare parts in well ventilated areas. Keep open

flames away.
Do not smoke.

Always install the safety stays for the hood and other
hinged covers before performing any maintenance or
repair work in the engine compartment.

Store containers in a cool well ventilated place where

they could not be reached by unauthorised people.
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
safety shoes and gloves, safety glasses when
splinters or other particles may be ejected.

TRANSFERS AND TRANSPORTATION

Before moving or transporting the machine, block
upperstructure swing to prevent accidental
movement.

Wear the appropriate welders equipment such as

dark safety glasses or mask, hard hat, protective
clothing, safety gloves and footwear always while
welding or arc-cutting. Wear dark safety glasses
when you are near a welding in progress.

Pay particular attention during transfer on inclines,

both uphill and downhill. Keep the bucket in a position
to provide a possible anchor point into the ground in
case of slipping.

Do not look the welding arc without proper eye

protection.

During transfers on inclines, both uphill and downhill,

keep the upperstructure aligned with the carriages.
Do not travel across the slope.

Become acquainted with all your jacking equipment

and their capacity.
Ensure that the jacking point on the machine is
appropriate for the load applied. Also, be sure the
supports under the jack and between the jack and the
machine are appropriate and stable.

Never transfer the machine in the working site, in a

crowded area, or near people without having at least
one person charged with hand-signals who could
guide the Operator.

Any equipment supported by a jack represents a

possible hazard. Always support the load onto
appropriate blocking means as a safety measure
before proceeding with service or maintenance work,
in compliance with local or national safety
regulations.

Sound the horn to inform that you are about to move

off.
It is necessary to know load limits of bridges and
dimensional limits of tunnels. Such limits must never
be exceeded. You should also know machine height,
width, and weight. Have a signal-man help you when
clearances are limited.

Metal cables produce steel splinters. Always wear

certified protection clothes such as safety gloves and
glasses while handling them.

Check distance between boom/arm and dimensional

limits during transfer or transportation.

Do not use makeshift jacks to adjust track sag. Follow

instructions given in the Repair Manual.

Rough terrain may cause the machine to sway and

roll to such an extent that boom/arm could get to
contact electric lines or other obstacles. Cross
obstacles at a right angle at low speed. Pay attention
to machine shaking when the centre of gravity
overcomes the obstacle.

Handle all parts carefully. Keep hands and fingers

away from gaps, gears, and similar. Always use and
wear certified safety clothes such as safety glasses,
gloves and footwear.
The attachment is kept constantly in position by an oil
column trapped into the high pressure circuit. Lower
the attachment to the ground and relieve pressure
from all circuits prior to carrying out any type of
maintenance or repair work.

Keep the bucket down at all times during transfers.

Drive with the lights on and use appropriate signals
and flags.
Get to know and respect local and national
regulations.

Do not service or repair the machine if it is parked

downhill. If this is unavoidable, in case of emergency,
block the carriages to prevent unexpected
movement, particularly if the work is to be carried out
on the final reduction units or travel motors.

Consider boom/arm and upperstructure dimensions

while turning.
Use a ramp to load the machine on a trailer. If a ramp
is not available, fabricate one using blocks. The ramp
should be sufficiently strong to support machine
weight. Always load and unload on level surface.

Consult the Operation and Maintenance Instruction

Manual for correct maintenance procedure.
Areas near articulated cutting edges where
mechanical parts are in motion are where personal
S1 - 7

E175B-E195B

GENERALITIES
Before any maintenance or repair, make sure that
there are no fuel or electrolyte leaks from the
batteries. If any, correct prior to proceeding with
further work. Do not recharge batteries in confined
spaces. Ensure proper ventilation is provided to
avoid accidental explosions due to build-up of
explosive gas released during charging.

Tow the machine following the instructions contained

in the Operation and Maintenance Instruction
Manual.

ENGINE

Disconnect batteries before working on the electrical

system or carrying out any other type of work.

Do not run the engine in closed buildings without

proper ventilation capable to remove harmful exhaust
fumes.
Do not place head, body, limbs, feet, hands or fingers
near rotating fans or belts. Be especially careful near
blower fans.

HYDRAULIC SYSTEM

Loosen the radiator cap very slowly to relieve system

pressure before removing it. Always top-up coolant
level with the engine off or idling if hot. See the
Operation and Maintenance Instruction Manual.

Pressure fluid escaping from a very small hole can be

almost invisible and still have sufficient force to
penetrate the skin. Always check any suspected
pressure leaks using a piece of cardboard or wood.

Keep the exhaust manifold and tube free from

combustible matters. Fit the machine with shields
and guards when working in the presence of
combustible matter free in the air.

Do not use hands. If injured by escaping fluid, obtain

medical attention immediately or serious infection or
reaction may develop.
Stop the engine and ensure pressure is relieved from
all systems before removing side panels, housings,
guards and covers. See the Operation and
Maintenance Instruction Manual.

Do not refuel with the engine running, especially if

hot, as this increases fire hazard in case of fuel
spillage.

Always use gauges of adequate capacity for

pressure testing. Refer to the Operation and
Maintenance Instruction Manual or Repair Manual.

Never attempt to check or adjust fan belt tensions

when the engine is running.
Do not adjust the fuel injection pump when the
machine is operating.
Do not lubricate the machine with the engine running.
Do not run the engine with the air intakes open and
not protected. If this cannot be avoided for service
reasons, place protection meshes on all intakes
before servicing the engine.

TOOLS
Always keep head, body, limbs, feet, hands, and
fingers away from the bucket and attachments, when
in the raised position.

ELECTRICAL SYSTEM

Prior to any maintenance or repair work, install all

supports necessary to this aim according to local and
national safety regulations.

Pay attention to connect connecting cables to correct

poles (+ to +) and (- to -) at both ends. Do not shortcircuit terminals. Thoroughly follow instructions given
in Operation and Maintenance Instruction Manual.

In case the attachment is to be operated for

maintenance or repair purposes, do so exclusively
while sitting in the drivers seat. Sound the horn
before starting the machine or moving the
attachment. Require that nobody remain near the
machine. Raise the attachment slowly.

Always move the key-start switch in the lock position

before servicing or repairing the machine.
Batteries contain SULPHURIC ACID. Protect the
eyes when working near the batteries against
possible sprays of the acid solution. Should acid
contact skin, eyes, or clothes, RINSE IMMEDIATELY
IN WATER
FOR AT LEAST 15 MINUTES.
Immediately seek medical attention.

Do not use the machine to transport loose objects,

unless proper securing devices are provided.
Never use gases other than nitrogen to charge the
accumulators.

Battery released gas is highly flammable. Leave

the battery compartment cover open during
recharging to improve ventilation. Never check
battery charge by placing metal objects across the
posts. Keep sparks or open flames away from
batteries. Do not smoke near the battery to prevent
explosion hazard.
S1 - 8

SAFETY PRECAUTIONS

E175B-E195B

RECOGNISE SAFETY INFORMATION

This is your SAFETY ALERT SYMBOL
- When you see this symbol on your machine or
in this Manual, be alert of the potential for
personal injury.
- Follow recommended precautions and safe
operating practices.

UNDERSTAND SIGNAL WORDS

In this Manual you will find the following words
referring to different hazard risks:
- DANGER;
- WARNING;
- CAUTION.

DANGER

These words are always accompanied by the safety

alert symbol.
DANGER: indicates an imminent hazardous
situation which, if not avoided, will result in death or
serious injury.

WARNING

WARNING: indicated a potential hazardous

situation which, if not avoided, could result in death
or serious injury.

CAUTION
IMPORTANT

CAUTION: indicates a potential hazardous situation

which, if not avoided, may result in minor or
moderate injury.

NOTE

IMPORTANT: indicates a situation which, if not

avoided, may cause damage to the machine.
NOTE: indicates an additional explanation for
information purposes.

ENVIRONMENTAL PROTECTION
This Manual also contains this symbol
accompanying instructions for correct behaviour
as regards environmental protection.

S2 - 1

E175B-E195B

SAFETY PRECAUTIONS

FOLLOW SAFETY PRECAUTIONS

Carefully read and observe all safety signs on the
machine and read all safety precautions in this
Manual.
Safety signs should be installed, maintained, and
replaced when necessary.
- If a safety sign or this Manual are damaged or
missing, obtain a replacement from your Dealer
in the same way you order a spare part (be sure
to detail machine model and serial number upon
ordering).
Learn how to operate the machine and its controls
correctly and safely.
Allow only trained, qualified, authorised personnel
to operate the machine.
Keep the machine in proper working conditions.
- Unauthorised changes to the machine may
impair function and/or safety and affect machine
life.
Safety messages in this Chapter SAFETY
PRECAUTIONS, are intended to illustrate basic
safety procedures of the machine. However, it is
impossible for these safety messages to cover
every hazardous situation you may encounter. If
you have any doubts, consult your direct
supervisor prior to operating or servicing the
machine.

PREPARE FOR EMERGENCIES

Be prepared if a fire starts or an accident occurs.
- Keep the first-aid kit and fire extinguisher on
hand.
- Thoroughly read and understand the label
attached to the fire extinguisher to use it
properly.
- Establish emergency priority procedures to
cope with fires and accidents.
- Keep emergency numbers for doctors,
ambulance service, hospitals and fire
department posted near the telephone.

S2 - 2

SAFETY PRECAUTIONS

WEAR PROTECTIVE CLOTHING

Wear close-fitting clothing and safety equipment
appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask;
Be sure to correctly wear equipment and clothing
for the job.
- Do not take any chances.
- Avoid wearing loose clothing, jewellery, or other
items that can catch on control levers or other
parts of the machine.
Operating equipment safely requires the full
attention of the operator. Do not wear radio or
music headphones while operating the machine.

PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause
impairment or loss of hearing.
- Wear a suitable hearing protection such as
earmuffs or earplugs to protect objectionable or
uncomfortably loud noise.

INSPECT THE MACHINE

Inspect the machine carefully every day or workshift by an attentive visual inspection of machine
outside prior to starting it to prevent damages and
personal injuries.

S2 - 3

E175B-E195B

E175B-E195B

SAFETY PRECAUTIONS

USE HAND HOLDS AND STEPS

Falling is one of the major causes of personal
injury.
- When you get on and off the machine, always
face the machine and maintain a three-point
contact with the steps and handrails.
- Prior to climbing or leaving the machine, check
that the fasteners of stepping points and the
handrails are tightened and are undamaged.
Repair them as required.
- Keep the access to the machine clear of foreign
objects and clean. Remove grease or mud from
stepping points and rails to minimise the danger
of slipping or stumbling.
- Do not use the controls or the safety lever as
hand holds when climbing on or off the machine.
- Do not climb or leave the machine running. Do
not jump on or off the machine.
- Do not climb or leave the machine while holding
tools or other objects in your hands.
- Do not climb or leave the machine while it is
moving.

ADJUST THE OPERATOR'S SEAT

A seat poorly adjusted for operator or work
requirements may quickly fatigue the operator
leading to improper operations.
- The seat should be adjusted whenever machine
operator changes.
- The operator should be able to fully press the
pedals and correctly move the control levers
with his back resting against the seat back.
- If not, move the seat fore and aft, and check
again.

S2 - 4

SAFETY PRECAUTIONS

FASTEN SEAT BELT

Should the machine overturn, the operator may
become injured and/or thrown from the cab. Not
only, the operator may be crushed by the
overturning machine resulting in serious injury or
even death.
- Prior to operating the machine, thoroughly
examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
- Be sure to remain seated with the seat belt
securely fastened at all times when the machine
is in operation to minimise injury hazard in case
of accident.
- After a significant accident, replace the seat
belts even though they do not look damaged.

MOVE AND OPERATE MACHINE SAFELY

Bystanders can be run over.
- Pay the utmost attention not to run over
bystanders.
- Be sure exposed personnel in the area of
operation are clear of the machine before
moving it or its attachments. Sound horn to
inform bystanders that the machine is going to
be operated.
- When operating, swinging, or moving the
machine in a congested area use a signal man.

S2 - 5

E175B-E195B

E175B-E195B

SAFETY PRECAUTIONS

OPERATE ONLY FROM THE DRIVER'S SEAT

Inappropriate engine starting procedures may
cause the machine unexpected movement,
possibly resulting in serious injury and even
death.
- Start the engine only from the operators seat.
- NEVER start the engine while standing on the
track or on the ground.
- Do not start the engine by shorting across
starter motor terminals.
- Before starting the engine, ensure that all
control levers are in the neutral position.

DO NOT CARRY PERSON ON THE MACHINE

Riders on the machine are exposed to serious
injuries.
- DO NOT carry riders on the machine. Besides
precluding a full vision by the operator, there is
the possibility of serious bodily harm or death
due to accidental falls from the machine.

CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN
Incorrect travel controls operation may result in
serious injury and even death.
- Before driving the machine, be aware of the
undercarriage position relative to the operators
position. If travel motors are located at the front of
the cab, the machine will move reverse when
travel controls are moved towards cab front.

S2 - 6

SAFETY PRECAUTIONS

AVOID INJURY FROM BACK-OVER AND

SWING ACCIDENTS
If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
To avoid back-over and swing accidents:
- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
- ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
- USE A SIGNAL PERSON WHEN BACKING
UP IF YOUR VIEW IS OBSTRUCTED.
ALWAYS KEEP THE SIGNAL PERSON IN
VIEW.
- Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
- No machine motions shall be made unless
signals are clearly understood by both
signalman and operator.
- Learn the meanings of all flags, signs, and
markings used on the job and confirm with the
person in charge of signalling.
- Always make sure that rear mirrors are clean
and correctly adjusted.
- Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.

S2 - 7

E175B-E195B

E175B-E195B

SAFETY PRECAUTIONS

DRIVE MACHINE SAFELY

Before moving the machine, confirm which way to
move travel pedals/levers for the corresponding
direction you wish to go.
- Pushing down on the front of the travel pedals or
pushing the levers forward moves the machine
towards the idlers.
Traveling on a grade may cause the machine to
slip or to overturn, possibly resulting in serious
injury or death.
- When traveling up or down a grade, keep the
bucket in the direction of travel, approximately
20 to 30 cm (A) above the ground.
- If machine starts to skid or becomes unstable,
lower the bucket immediately.
- Traveling across the face of a slope may cause
the machine to skid or to overturn. When
travelling (ascending/descending) on a slope,
be sure to point the tracks uphill/downhill.

- Turning on an incline may cause the machine to

tip over. If turning on an incline is absolutely
unavoidable, do so at a place where the slope is
gentle and the surface is firm.
- Do not travel on slopes with an angle exceeding
30. Do not travel across hill on slopes
exceeding an angle of 15.

S2 - 8

SAFETY PRECAUTIONS

AVOID OVERTURNING
When working on a slope or on unstable terrain,
the danger of tipping over is present with the
possibility of subsequent serious damages or fatal
injuries.
- Pay the utmost attention when working on a
slope. If possible, level first the work area.
- Avoid swing or steering the machine on a slope.
- Decrease the operating speed and actuate the
controls
carefully,
to
prevent
sudden
movements that could result in slipping or
tipping over.
- In case the engine is cut-off, lower the bucket to
the ground, move the controls in neutral and
restart the engine.
Pay the utmost attention when operating the
machine on frozen ground or in snowy conditions.
- Frozen ground, when the ambient temperature
increases, tends to be less firm jeopardising the
stability of the machine.
- Operate carefully when in snowy conditions.
The snow could hide invisible dangerous spots.
- Actuate the controls slowly and carefully to
prevent the machine from making unwanted
slippery manoeuvres or movements.
- Even on minor slopes, when snow is present
and on frozen ground, unwanted slippery
manoeuvres or movements of the machine
could occur.

PARK MACHINE SAFELY

To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Pull the safety lever (pilot-control shut-off lever)
to the LOCK position.
- Turn auto-idle switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Prior to leaving the machine, close the windows,
the cab door and all panels.

S2 - 9

E175B-E195B

E175B-E195B

SAFETY PRECAUTIONS

INVESTIGATE JOB SITE BEFORE

OPERATING THE MACHINE
Explore the working area to identify potential risks
before starting and operating the machine. Make
sure that the structure and the conditions of the
ground are safe before starting operations.
- Make sure that the digging area is sufficiently
stable and firm to support the weight of the
machine during the work operations.
- Working near edges and ditches presents a risk
for the stability of the machine. Check first that
edges and the walls of the digging are
sufficiently strong. If necessary, prop the edges
appropriately to prevent caving-ins.
- DO NOT dig too near the machine.
- Always position the tracks perpendicular to the
edge of the digging with the travel motors on the
rear side.
- When working on a slope or near the edge of the
road, have a flagman available.

PROTECTING AGAINST THE FALL OF

ROCKS AND LANDSLIDES
When operating in zones where the possibility of
falling rocks or landslides exists or when there is
the risk for front impacts with objects that could
penetrate the cab, make sure that protection
structures are installed: F.O.P.S. (Falling Object
Protection Structure) and FRONT GUARD.
- DO NOT install any cab lifting device to the
protection structures.
- DO NOT weld, drill or modify protective
structures. Any type of modification could
weaken the structural integrity of the safety
system, with serious consequences for the
operator, in case of collision, falling objects or
landslides.
- After an accident, DO NOT try to straighten or
repair protective structures. Contact a Dealer to
verify the functionality, to repair or to completely
or partially replace the protective structures.

S2 - 10

SAFETY PRECAUTIONS

DIG WITH CAUTION

Accidental severing of underground cables or gas
lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
- Before digging, check the location of cables, gas
lines, and water lines.
- Keep the minimum distance required by law
from cables, gas lines, and water lines. If a fiber
optic cable should be accidentally severed, do
not look into the end. Doing so may result in
serious eye injury.
- Contact local authorities and/or the utility
companies directly (electric power, gas,
telephone, water, sewers, telecommunications,
etc.) to obtain information about underground
utility lines.

OPERATE WITH CAUTION

If the front attachment or any other part of the
machine hits against an overhead obstacle, such
as a bridge, both the machine and the overhead
obstacle will be damaged, and personal injury
may results as well.
- Take care to avoid hitting overhead obstacles
with the boom or arm.

AVOID ELECTRIC LINES

Serious injury or death can result if the machine or
front attachments are not kept a safe distance from
electric lines.
- When operating near an electric line, NEVER
MOVE any part of the machine or load closer
than 5 m plus twice the line insulator length (L).
- Check and comply with any local regulations
that may apply.
- Wet ground will expand the area that could
cause any person on it to be affected by electric
shock.
- Keep all bystanders or co-workers away from
the site.

S2 - 11

E175B-E195B

E175B-E195B

SAFETY PRECAUTIONS

KEEP PERSONNEL CLEAR FROM

WORKING AREA
A person may be hit severely by the swinging front
attachment or counterweight and/or may be
crushed against an other object, resulting in
serious injury or death.
- Keep all persons clear from the area of
operation and machine movement.
- Before operating the machine, set up barriers to
the sides and rear area of the bucket swing
radius to prevent anyone from entering the work
area.

NEVER MOVE THE BUCKET OVER

ANY ONE
Never lift, move, or swing bucket above anyone or
a truck cab. Serious injury or machine damage
may result due to bucket load spill or due to
collision with the bucket.

SP0030

DO NOT OPERATE IN TUNNELS

DO NOT operate the machine in enclosed spaces
or, in any case, without appropriate ventilation.
Operations in tunnels or underground sites where
potential explosive conditions exist are not
allowed. There is a danger for explosions and
potentially deadly injuries. Please comply with the
ATEX regulation relative to devices to be used in
a potentially explosive environment.

S2 - 12

SAFETY PRECAUTIONS

NEVER UNDERCUT A HIGH BANK

The edges could collapse or a land slide could
occur causing serious injury or death.

SAFETY LOADS MOVING

The excavator is a machine designed specifically
to perform digging/loading works, thus it must not
be used to handle suspended loads. In the event,
under exceptional conditions, it becomes
necessary to handle materials, the following
indications must be strictly implemented:
- The machine must be equipped compulsorily
with the appropriate variant provided upon
request. Also, totally comply with the safety
precautions for the operation of the excavator as
a lifting equipment.
- Secure the loads to be raised using cables or
chains fastened with appropriate hooking
mechanisms.
- Never hook cables or chains to the bucket teeth.
- Nobody should be allowed to remain under the
raised load or within the excavator operating
range for any reason whatever.
- Never exceed specified loading capacity.
Incorrect fastening of slings or chains may
cause boom/arm failure or failure of the lifting
means with consequent bodily injuries and
even death.
- Always ensure that slings and chains used for
lifting are adequate to the load and in good
condition.
- All loading capacities are referred to the
machine on a level surface and should be
disregarded when working on a slope.
- In any case, comply with the current national or
local regulations on this matter.

S2 - 13

E175B-E195B

E175B-E195B

SAFETY PRECAUTIONS

AVOID EXCESSIVE DIGGING EFFORTS

Operate the machine complying with the load
limits in accordance with the "table of lifting loads"
located inside the cab.
- Do not exceed the prescribed load limits.
- Do not use the strength of the attachment to
travel or move the machine.
- Do not try digging exploiting the mass of the
machine.

PAY ATTENTION WHEN DIGGING DEEPLY

When digging deeply, pay special attention to
prevent contacts of the attachment and the
relevant hydraulic hoses with the ground.
DO NOT swing the turret or the undercarriage
when the attachment boom is fully lowered. Under
these conditions there is the danger that the boom
collides with the track chains.

DO NOT USE THE TRACTION FORCE OF

THE MACHINE FOR DIGGING
Do not travel the machine to dig. In doing this, an
excessive stress on the front attachment could
results in damages to the structure. Use the
undercarriage for travelling only.

DO NOT USE THE TURRET SWING FOR

DIGGING
Do not use the turret swing for digging or moving
rocks. An excessive stress on the front
attachment could results in damages to the
structure reducing the operating life of the swing
system. Also, this inappropriate use of the
machine could cause serious injuries or fatalities.

S2 - 14

SAFETY PRECAUTIONS

DO NOT USE THE BUCKET AS A HAMMER

The use of the bucket as a hammer or for piling
operations could cause serious damages to the
bucket itself and the components of the front
attachment. Also, this inappropriate use of the
machine could cause serious injuries or fatalities.

AVOID OPERATING THE CYLINDERS TO

FULL STROKE
Do not extend repeatedly the bucket and the arm
cylinders full stroke with the purpose of cleaning
the bucket from residual materials. This could
cause damages to the cylinders. To remove
residues from the bucket, use water under
pressure or remove them manually.
Tolerance A 50 mm

PROVIDE SIGNALS FOR JOBS INVOLVING

A NUMBER OF MACHINES
For jobs involving several machines, provide signals
commonly known by all personnel involved. Also,
appoint a signal person to co-ordinate the job site.
Make sure that all personnel obey the signal
persons directions.

TRANSPORTING THE MACHINE UNDER

SAFE CONDITIONS
During loading or unloading operations of the
machine on a truck or trailer the danger for tipping
over is always present.
- Use a truck or trailer appropriate for transporting
the machine.
- Secure safely the machine to the trailer with
appropriate chains or cables. Please refer to the
chapter "TRANSPORTATION" of this Manual
for the safe loading and unloading procedures.
- Make sure that you comply with National and
local regulations when transporting the machine
on open roads.

S2 - 15

E175B-E195B

E175B-E195B

SAFETY PRECAUTIONS

SAFE MAINTENANCE
To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Keep the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it
is in motion.
- Keep hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
4. Switch off the Auto-Idle.
5. Let the engine idle with no load for at least
five minutes until it has cooled down.
6. Move the key-start switch
position to stop the engine.

to the OFF

7. Remove the ignition key from the start

switch.
8. Apply the "Maintenance in progress" tag
(see SAFETY PLATE in this Chapter).
This tag can be applied o the left-hand
control lever, safety lever or cab door.
9. Let the engine cool down.
- Do not leave the machine unattended if
servicing requires the engine running.
- If the machine is to be raised, place boom and
arm at an angle 90 to 110. Lock machine
components which should be raised for
maintenance or repair using suitable supporting
means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or
replace as necessary. Refer to the Chapter
MAINTENANCE in this Manual.
- Keep all components in good condition and
properly install. Immediately repair any fault.
- Immediately repair any damage.Replace worn
or failed components. Remove grease, oil,
debris build-ups.
- Disconnect the negative cable (-) from the
battery before carry out any work on he
electrical sysem or arc-welding on he machine.

S2 - 16

SAFETY PRECAUTIONS

WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause
serious injury.
- Before performing any work on the machine,
attach a maintenance in progress tag (see also
SAFETY PLATES in this Chapter) . This tag can
be applied o the left-hand control lever, safety
lever or cab door.

SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without
securing the machine first.
- Always lower the attachment or tool to the
ground before working on the machine.
- If you must work on a lifted machine or
attachment, securely support the machine or
attachment.
- Do not support the machine on cinder blocks,
bollow tires, or props that may crumble under
continuous load.
- Do not work under a machine that is supported
solely by a jack.

STOP THE ENGINE PRIOR TO PERFORMING

DO NOT perform any maintenance operation with
the engine running. Trapping by moving parts
could cause serious injuries. Stop the engine and
wait that it cools-off prior to performing
maintenance operations.
In case it is indispensable to perform maintenance
operations with the engine running, have a person
co-operating with you sitting in the operator's seat,
to cut-off the engine immediately in case of
necessity.

S2 - 17

E175B-E195B

E175B-E195B

SAFETY PRECAUTIONS

DISPOSE OF WASTE IN THE APPROPRIATE

MANNER
Waste improperly disposed of represents a
danger for the envinronment. Potentially
dangerous waste used on the
excavators
includes lubricants, fuel, coolant, brake fluid,
filters and batteries.
- Used sealed containers when discharging
fluids. Do not use containers for food or
beverages which may induce drinking.
- Do not spill waste over the ground, into drains,
or water beds.
- Obtain information about the correct methods to
recycle or dispose of waste from local
Authorities, collection centres or your Dealer.

WORK IN A CLEAN AREA

- Before starting an operation, clean the working
area. Clear the area from all the objects that can
be dangerous for mechanics or people in the
working area.

PROPERLY LIGHT THE WORKING AREA

Properly and safely light the working area.
- Use safe portable lamps in order to work inside
and under the machine.
- Make sure that the lamp is shielded by a cage;
the incandescent filament of a lamp,
accidentally broken, can cause fuel or oil fire.

S2 - 18

SAFETY PRECAUTIONS

KEEP CLEAN THE MACHINE

Keep clean the engine compartment, radiator,
batteries, hydraulic pipes, fuel tank and operator's
position.
- The engine compartment temperature can
quickly rise, after stopping the engine. IN
THESE CASES, BE CAREFUL TO POSSIBLE
FIRES.
Open the access doors in order to quicken the
engine cooling process and clean the
compartment.
Remove all the traces of grease, oil and deposits,
in order to avoid people accidents or damages to
things.
- Do not spray water or steam in the cab.

PREVENT ACID SCALDS

The sulphuric acid, contained in the battery, is
poisonous. It is strong enough to scald the skin,
corrode clothes and cause blindness, if it is
sprayed into the eyes.
To avoid dangers:
- Fill the batteries in airy areas.
- Wear eye protections and rubber gloves.
- Avoid breathing the electrolyte vapours when
topping up.
- Avoid spilling or dripping the electrolyte.
- Use proper emergency starting techniques.
If you are touched with acid sprays:
- Rinse your skin well with water.
- Put on your skin sodium bicarbonate or clay to
help the acid neutralization.
- Rinse your eyes with water for 10-15 minutes.
- Immediately see a doctor.
If you have swallowed the acid:
- Immediately see a doctor.

S2 - 19

E175B-E195B

E175B-E195B

SAFETY PRECAUTIONS

STARTING THE ENGINE WITH BOOSTER

BATTERIES
If the engine is to be started using booster
batteries, ensure to comply with all procedures
detailed
in
the
chapter
OPERATING
INSTRUCTIONS.
- The operator should be sitting in the drivers
seat to keep the machine under control when
the engine starts. Starting the engine with
booster batteries is a two man operation.
- Do not use batteries that have been stored in
the cold for a long time.
- Mistakes in following procedures detailed for
starting the engine with slave batteries may
cause the batteries to explode or machine to
move unexpectedly

PREVENT BATTERY EXPLOSIONS

Battery gas can explode.
- Keep sparks, lighted matches, and flames away
from the top of battery.
- Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
- Do not charge a frozen battery; it may explode.
Warm battery to 16 C.
Battery electrolyte is poisonous. If the battery
should explode, battery electrolyte may be
splashed into eyes, possibly resulting in
blindness.
- Be sure to wear eye protection when checking
electrolyte specific gravity.

S2 - 20

SAFETY PRECAUTIONS

PREVENT BURNS
Hot spraying fluids:
After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines. Skin contact
with escaping hot water or steam can cause
severe burns.
- To prevent possible injury from hot spraying
water. Do not remove the radiator cap until the
engine is cool. When opening, turn the cap
slowly to the stop. Allow all pressure to be
released before removing the cap.
- The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.

Hot fluids and surfaces:

Engine oil, reduction gear oil and hydraulic oil also
become hot during operation. The engine, hoses,
lines and other parts become hot as well.
- Wait for the oil and components to cool down
before starting any maintenance or inspection
work.

STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic
breakers and blades can fall and cause serious
injury or death.
- Securely store attachments and implements to
prevent falling.
- Keep bystanders away from storage areas.

S2 - 21

E175B-E195B

E175B-E195B

SAFETY PRECAUTIONS

AVOID HIGH-PRESSURE FLUIDS

Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
- Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
- Tighten all
pressure.

connections

before

applying

- Search for leaks with a piece of cardboard; take

care to protect hands and body from highpressure fluids. Wear a face shield or goggles
for eye protection.
- In an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within
a few hours or gangrene may result.

PREVENT PARTS FROM FLYING OFF

Grease in the track adjuster is under high
pressure. Failure to follow the precautions below
may result in serious injury, blindness, or death.
- NEVER attempt to remove GREASE FITTING or
VALVE ASSEMBLY.
- As pieces may fly off, be sure to keep body and
face away from valve.

Travel reduction gears are under pressure.

- As pieces may fly off, be sure to keep body and
face away from air release plug to avoid injury.
Reduction gear oil is hot. Wait for gear oil to cool
down, then gradually loosen the air release plug
to release pressure.

S2 - 22

SP0047

SAFETY PRECAUTIONS

PROTECT AGAINST FLYING DEBRIS

If flying debris hit eyes or any other part of the
body, serious injury may result.
- Guard against injury from flying pieces of metal
or debris; wear goggles or safety glasses.
- Keep bystanderds away from the working area
before striking any object.

HANDLE FLUIDS SAFELY - AVOID FIRES

Handle fuel with care: it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur,
possibly resulting in serious injuty or death.
- Do not refuel the machine while smoking or
when near open flame or sparks.
- Always stop the engine before refuelling the
machine.
- Fill the tank outdoors.

All fuels, most lubrificants, and some antifreeze

fluids are flammable.
- Store flammable fluids well away from fire
hazards.
- Do not burn or puncture pressurized containers.
- Do not store oily rags; they can ignite and burn
spontaneously.

S2 - 23

E175B-E195B

E175B-E195B

SAFETY PRECAUTIONS

PREVENT FIRES
Check for Oil Leaks:
- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts
which may cause oil leaks.
- Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oilcooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts:
- Short circuits can cause fires.
- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10)
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
Check Key-start Switch:
- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF
position to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.
Check Heat Shields:
- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.

S2 - 24

SAFETY PRECAUTIONS

E175B-E195B

EVACUATING IN CASE OF FIRE

If a fire breaks out, evacuate the machine in the
following way:
- Stop the engine by turning the key-start switch
to the OFF position if there is time.
- Use a fire extinguisher if there is time.
- Exit the machine.

BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
- If you must operate in a building, be sure there
is adequate ventilation. Either use an exhaust
pipe extension to remove the exhaust fumes or
open doors and windows to bring enough
outside air into the area.

SP0062

USE APPROPRIATE TOOLS

Use tools appropriate for the job to be performed.
- Inappropriate tools, parts and procedures might
generate dangerous conditions.
- Use tools of correct size to tighten or loosening
securing elements, in order to avoid injuries
caused by a wrench getting out of control.
- Do not use U.S. Standard or British Standard
tools on metric fasteners and vice versa.
Use only genuine spare parts (please refer to the
Spare Parts Catalogue).

S2 - 25

E175B-E195B

SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED

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

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
- Do not weld or flame cut pipes or tubes that
contain flammable fluids.
- Clean them thoroughly with non-flammable
solvent before welding or flame cutting them.

REMOVE PAINT BEFORE WELDING OR

HEATING
Hazardous fumes can be generated when paints
is heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
- Avoid breathing potentially toxic fumes and
dust.
- Do all such work outside or in a well-ventilated
area.
- Dispose of paint and solvents properly.
- Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing
the dust. Wear an approved respirator.
2. If you use solvent or paint stripper, remove
stripper with soap and water before
welding. Remove solvent or paint stripper
containers and other flammable material
from area. Allow fumes to disperse at
least 15 minutes before welding or
heating.

S2 - 26

SAFETY PRECAUTIONS

WELDING REPAIR INTERVENTIONS

Welding repair interventions must be performed
only by a certified welder with sufficient
experience. Also, appropriate safety rules must be
implemented by all the personnel involved in the
operations. The duration through time of the
welding depends upon the quality and the
accuracy with which the operation is performed.
- Identify first all the fracture points and the zones
in which welding is required.
- Clean accurately the zones involved.
- Remove all paint and inspect the parts with
penetrating liquid or a magnetic particle tester.
- Move the starter switch into position "OFF" and
wait for 4 seconds to cut-off electricity from the
system.
- Disconnect the negative terminal (-) from the
battery.
- Connect the ground cable of the welder at least
1 m from the component to be welded.
- Make sure that the ground cable is NOT
connected to a seal or bearing and that there
are noo seals or bearings between the ground
cable and the part to be welded.
- Avoid welding pieces at low temperature i. e.
below 16 C. If necessary, warm-up the part
involved prior to welding it.
- Remove paints from all surfaces prior to
warming-up or welding. Painted surfaces, when
warmed-up or when welded, can generate toxic
fumes.
- Use appropriate masks or protective glasses.
- Wear gloves and adequate clothing to protect
the skin.

S2 - 27

E175B-E195B

E175B-E195B

SAFETY PRECAUTIONS

NOTE:

S2 - 28

SAFETY PLATES

E175B-E195B

SAFETY PLATES
Triple articulation version

SP0090

Triple articulation version

SP0091

1. Attachment operating range safety plate.

2. Track adjuster plate.
S3 - 1

E175B-E195B

SAFETY PLATES

14

12

11
13

8
10

SP0089

9. Controls lock/unlock plate (safety lever).

3. Counterweight operating range safety plate.

4. Read-your-manual plate.

10. Hydraulic oil pressurised tank warning plate.

5. Boom and arm movement warning plate

(Triple articulation version).

11. Burns warning plate.

12. Safety distance plate.

6. Open windscreen warning plate

(inside the cab).

13. No-stepping warning plate.

14. Special equipment movement warning plate

7. Tag indicating maintenance in progress.

8. Engine hood warning plate.
S3 - 2

SAFETY PLATES
1 - Attachment operating range safety plate
Ensure that any person near the working site is
outside the machine operating range before
starting the machine or operating the
attachments. Sound the horn.
Background: yellow
Border and icons: black

2 - Track adjuster plate

It shows that obligation is made to consult the
Operation and Maintenance Instruction Manual
prior to acting on the track adjust valve.
Danger of severe injuries.
Background: yellow
Border and icons: black

3 - Counterweight operating range safety plate

Ensure that any person near the working site is
outside the machine operating range before
starting the machine or operating the
attachments. Sound the horn.
Background: yellow
Border and icons: black

S3 - 3

E175B-E195B

E175B-E195B

SAFETY PLATES

4 - Read-your-manual plate
It is positioned in the cab to recommend to
carefully read the Operation and Maintenance
Instruction Manual prior to starting, operating,
servicing, refuelling or carrying out any other
work on the machine.
Background: yellow
Border and icons: black

5 - Boom and arm movement warning plate

(triple articulation version)
It shows the danger represented by the bucket
hitting the cab.
Pay special attention as no stops are provided to
prevent this problem.
Background: yellow
Border and icons: black

SP0073

6 - Open windscreen warning plate

It indicates the risk of injuries deriving from the
windscreen not being locked or being
improperly locked in the open position.
Background: yellow
Border and icons: black

S3 - 4

SAFETY PLATES
7 - Tag indicating maintenance in progress
Maintenance staff is obliged to apply the tag that
indicates that the machine is not fully efficient
and warns about maintenance staff being
located in not visible positions. This tag should
be applied to the left-hand control lever, safety
lever or cab door.
Background: yellow
Border and icons: black

8 - Engine hood warning plate

It highlights the obligation to stop the engine
before opening engine hood.
Danger of severe injuries following the presence
of rotating parts such as fan, pulleys, and belts.
Background: yellow
Border and icons: black

9 - Controls lock/unlock plate

It shows the position that the safety lever can
assume when the engine is running.
When the operator is about to leave the cab with
the engine running, even if for a short time, he
must move the safety lever to the LOCK
position. Controls are disabled and therefore no
accidental machine or attachment movement is
possible.
Background: white
Border and icons: black

S3 - 5

E175B-E195B

E175B-E195B

SAFETY PLATES

10 - Hydraulic oil pressurised tank

warning plate
It indicates that the hydraulic oil is pressurised.
Consult the Operation and Maintenance
Instruction Manual. Prior to intervening on the
hydraulic oil tank, bleed the pressure by
actuating the appropriate bleeding button
located on the cap. The hydraulic oil, at
operating temperature, can cause burns in
case of contact with the skin.
Background: yellow
Border and icons: black

11 - Burns danger plate

It indicates that a burns danger exists, since
the zone is characterised by high temperature.
Background: yellow
Border and icons: black

12 - Safety distance plate

It instructs to keep at a safe distance from a
zone dangerous for personal safety.
Background: yellow
Border and icons: black

S3 - 6

SAFETY PLATES
13 - No-stepping warning plate
It instructs not to step on the zone where this
decal is attached.
Background: yellow
Cross: red
Border and icons: black

14 - Special equipment movement warning plate

It shows the danger represented by the special
equipment hitting the cab.
Pay special attention as no stops are provided
to prevent this problem.
Background: yellow
Border and icons: black

S3 - 7

E175B-E195B

E175B-E195B

SAFETY PLATES

NOTE:

S3 - 8

OPERATIONAL PRINCIPLE

M0103

OPERATIONAL PRINCIPLE

E175B-E195B

SECTION AND GROUP CONTENTS

Section 1

GENERAL

Group 1

Specifications

Section 2

SYSTEM

Group 1
Group 2
Group 3

Mechatro Control System

Hydraulic System
Electrical System

Section 3

COMPONENT OPERATION

Group 1
Group 2
Group 3
Group 4
Group 5
Group 6
Group 7
Group 8

Hydraulic Pump Assy

Pilot Valve
Control Valve
Swing Device
Travel Device
Swing Joint
Cylinders
Air Conditioner

SECTION 1

GENERAL

CONTENTS
Group 1 - Specifications
Main components .............................. T1-1-1
Hydraulic components E175B ........... T1-1-5
Hydraulic components E195B ........... T1-1-8
Excavator performance...................... T1-1-11
Digging data E175B
(Monoblock Version) .......................... T1-1-12
Digging data E175B
(Triple Articulation Version) ............... T1-1-13
Transporting dimensions E175B
(Monoblock Version) .......................... T1-1-14
Transporting dimensions E175B
(Triple Articulation Version) ............... T1-1-15
Bucket applications as a function
of the arms E175B ............................. T1-1-16
Digging data E195B
(Monoblock Version) .......................... T1-1-17
Digging data E195B
(Triple Articulation Version) ............... T1-1-18
Transporting dimensions E195B
(Monoblock Version) .......................... T1-1-19
Transporting dimensions E195B
(Triple Articulation Version) ............... T1-1-20
Bucket applications as a function
of the arms E195B ............................. T1-1-21

E175B-E195B

SPECIFICATIONS

E175B-E195B

MAIN COMPONENTS

12345678910 -

Bucket
Bucket link
Idler link
Bucket cylinder
Arm
Arm cylinder
Boom
Boom cylinder
Cab
Swivel joint

11 12 13 14 15 16 17 18 19 20 -

Swing motor
Fuel tank
Hydraulic oil tank
Control valve
Engine muffler
Hydraulic pump
Engine
Counterweight
Engine radiator
Travel motor

T1-1-1

21 22 23 24 25 26 27 28 29 -

Track link
Batteries
Upper roller
Track guide
Lower roller
Air cleaner
Crawler adjuster
Front idler
Shoe plate

E175B-E195B

SPECIFICATIONS

Main Components Upper Structure

SM1051

1-

Control Cab

5-

Hydraulic Pump

2-

Proportional Solenoid Valve Block

6-

Control Valve

3-

Radiators

7-

Swing Motor Unit

4-

Engine

8-

Center Joint

T1-1-2

SPECIFICATIONS

E175B-E195B

Main Components Under Carriage

section A - A
SM0013

1-

Right Travel Motor Unit

4-

Swing Gear

2-

Left Travel Motor Unit

5-

Front Idler Assy

3-

Center joint

T1-1-3

E175B-E195B

SPECIFICATIONS

Main Components Front Attachment

1
3

SM0014

1-

Boom cylinder

5-

Monoblock Boom

2-

Arm cylinder

6-

Boom (Triple Articulation Version)

3-

Bucket Cylinder

7-

Arm

4-

Positioning Cylinder (Triple Articulation

Version)

8-

Positioner (Triple Articulation Version)

T1-1-4

SPECIFICATIONS

E175B

HYDRAULIC COMPONENTS E175B

HYDRAULIC PUMP
Item

Main pump

Gear pump for pilot

Pump

K7V630TP112R-OE13-V

ZX10LPRZ2-07G

Type

Variable displacement plunger

pump: regulator attached type

Fixed displacement type gear

pump

Max. displacement capacity

cm3

65 x 2

10

Revolution

rpm
(Clockwise
seen from
shaft end)

2200

Pressure

Rated
Rated
ATT boost

34.3

MPa

Max. flow

L/min

Max. input Power

(at 2000 rpm)
Max. input torque
(at 1200 rpm)

143 x 2 at 7.8 MPa

22

kW

78.3

3.4

Nm

340

14.7

Model
Regulator

Mass

5.0

37.8

KR76-OE13-V

Control
function

Electric flow control, positive flow control, total power control at

emergency mode and power shift control

Others

With solenoid proportional reducing valve (KDRDE5K-31/

30C50)

kg

88

NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump.
CONTROL VALVE
Item

STD VALVE

Model

KMX13YD / B44061

Max. flow rate

Main relief valve set pressure

L/min

143 x 2

MPa

34.3 at 60 x 2 L/min

When power boost pressure

Over load relief valve set pressure

37.8 at 55 x 2 L/min
MPa

Boom H, Bucket H, Arm R

39.7 at 30 L/min

Boom R, Bucket R, Arm H

37.8 at 30 L/min

Mass

kg
Item

OPT VALVE

Model
Over load relief valve set pressure

155

KADV22Y / 501103A
MPa

Positioner R

39.7 at 30 L/min

Positioner H

37.8 at 30 L/min

Mass

kg

T1-1-5

11

E175B

SPECIFICATIONS

PILOT VALVE
ATTACHMENT

TRAVEL

PV48K2004

6TH6NRZ

5.0 MPa

4.9 MPa

0.6 ~ 3.2 MPa

0.54 ~ 2.35 MPa

Model
Primary pressure
Secondary pressure
Rated flow
Mass

20 L/min

25 L/min

Approx. 2 kg

Approx. 8 kg

Hydraylic motor

SWING MOTOR UNIT

Antireaction
valve block

Model

M5X130CHB10A59B/285-122

Type

Swash-plate type, fixed-displacement plunger

motor

Displacement

cm3

121.6

Working pressure

MPa

34.3

Max. flow

L/min

148

Braking torque

Nm

583

Release pressure

MPa

2.3~5.0

Relief set pressure

MPa

28

Mass

kg

49

Type
Mass

Hydraulic motor assy mass

2KAR6P72/240-712
kg

2.5

kg

51.5

Speed reduction type

Planetary 2-stage

Reduction unit

Reduction ratio

Total mass

15.38

Lubicate oil
Lubicate oil volume

Gear oil SAE90 (API class GL4 grade)

L

Grease

3.0
Extreme pressure lithium base # 2 grease

Grease volume

kg

Approx. 1.0

Mass

kg

144.2

kg

Approx. 196

T1-1-6

SPECIFICATIONS

E175B

TRAVEL DEVICE
Reduction gear unit

Epicycloidal, three-stage planetary type

Model

709 C3 K

Gearbox ratio

1 : 63.1

Travel motor

Two speed, axial piston swash plate type

Model

MAG 85 VP-17

Displacement

high speed

50.4 cm3/rev

low speed

87.3 cm3/rev

Max. flow
Max. gearbox
torque

130.4 L/min
output

Parking brake torque

high speed

17378 Nm

low speed

30087 Nm

static

234 Nm

dynamic

194 Nm

Min. pressure parking brake release

Relief valve set pressure

14 bar

cracking

311 bar at 1.5 L/min

total flow

353 bar at 37 L/min

Mass

245 kg

CYLINDERS
Cylinder bore /
Rod Dia.

Stroke

(mm)

(mm)

Center distance
of pins
Full extend B /
Full retract A
(mm)

Boom

110 / 80

1150

2815 / 1665

Arm

125 / 90

1290

3060 / 1770

Bucket

105 / 75

1025

2565 / 1540

Positioning

135 / 85

1012

2555 / 1543

Use

T1-1-7

Cushion

Mass
(kg)

With cushion
on rod side
With cushion
on both sides
With cushion
on rod side
Without cushion

149
194
128
196

E195B

SPECIFICATIONS

HYDRAULIC COMPONENTS E195B

HYDRAULIC PUMP
Item

Main pump

Gear pump for pilot

Pump

K5V80DTP1KBR-OE02-V

ZX10LPRZ2-07G

Type

Variable displacement plunger

pump: regulator attached type

Fixed displacement type gear

pump

Max. displacement capacity

cm3

80 x 2

10

Revolution

rpm
(Clockwise
seen from
shaft end)

2200

Pressure

Rated
Rated
ATT boost

34.3

MPa

Max. flow

L/min

Max. input Power

(at 2000 rpm)
Max. input torque
(at 1200 rpm)

176 x 2 at 7.8 MPa

22

kW

91.9

3.2

Nm

399

15

Model
Regulator

Mass

5.0

37.8

KR38-OE02-V

Control
function

Electric flow control, positive flow control, total power control at

emergency mode and power shift control

Others

With solenoid proportional reducing valve (KDRDE5K-31/

30C50)

kg

89.5

NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump.
CONTROL VALVE
Item

STD VALVE

Model

KMX13YD / B44071

Max. flow rate

Main relief valve set pressure

L/min

176 x 2

MPa

34.3 at 70 x 2 L/min

When power boost pressure

Over load relief valve set pressure

37.8 at 60 x 2 L/min
MPa

Boom H, Bucket H, Arm R

39.7 at 30 L/min

Boom R, Bucket R, Arm H

37.8 at 30 L/min

Mass

kg
Item

OPT VALVE

Model
Over load relief valve set pressure

155

KADV22Y / 501103A
MPa

Positioner R

39.7 at 30 L/min

Positioner H

37.8 at 30 L/min

Mass

kg

T1-1-8

11

SPECIFICATIONS

E195B

PILOT VALVE
ATTACHMENT

TRAVEL

PV48K2004

6TH6NRZ

5.0 MPa

4.9 MPa

0.6 ~ 3.2 MPa

0.54 ~ 2.35 MPa

Model
Primary pressure
Secondary pressure
Rated flow
Mass

20 L/min

25 L/min

Approx. 2 kg

Approx. 8 kg

Hydraylic motor

SWING MOTOR UNIT

Antireaction
valve block

Model

M5X130CHB10A58B/305-99

Type

Swash-plate type, fixed-displacement plunger

motor

Displacement

cm3

99.1

Working pressure

MPa

34.3

Max. flow

L/min

176

Braking torque

Nm

588

Release pressure

MPa

2.3~5.0

Relief set pressure

MPa

30

Mass

kg

49

Type
Mass

Hydraulic motor assy mass

2KAR6P72/250-712
kg

2.5

kg

51.5

Speed reduction type

Planetary 2-stage

Reduction unit

Reduction ratio

Total mass

15.38

Lubicate oil
Lubicate oil volume

Gear oil SAE90 (API class GL4 grade)

L

Grease

3.0
Extreme pressure lithium base # 2 grease

Grease volume

kg

Approx. 1.0

Mass

kg

144.4

kg

Approx. 196

T1-1-9

E195B

SPECIFICATIONS

TRAVEL DEVICE
Reduction gear unit

Epicycloidal, three-stage planetary type

Model

710 C3 K

Gearbox ratio

1 : 55.2

Travel motor

Two speed, axial piston swash plate type

Model

MAG 170 VP

Displacement

high speed

81.2 cm3/rev

low speed

129.3 cm3/rev

Max. flow
Max. gearbox
torque

220 L/min
output

Parking brake torque

high speed

24469 Nm

low speed

38949 Nm

static

581 Nm

dynamic

484 Nm

Min. pressure parking brake release

Relief valve set pressure

11 bar

cracking

311 bar at 1.2 L/min

total flow

353 bar at 40 L/min

Mass

235 kg

CYLINDERS
Cylinder bore /
Rod Dia.

Stroke

(mm)

(mm)

Center distance
of pins
Full extend B /
Full retract A
(mm)

Boom

110 / 80

1150

2815 / 1665

Arm

130 / 95

1290

3083 / 1793

Bucket

110 / 80

1105

2730 / 1625

Positioning

135 / 85

1012

2555 / 1543

Use

T1-1-10

Cushion

Mass
(kg)

With cushion
on rod side
With cushion
on both sides
With cushion
on rod side

220

Without cushion

196

149

149

SPECIFICATIONS

E175B-E195B

EXCAVATOR PERFORMANCE
GRADEABILITY......................................................................................................................................... 70%
TRAVEL SPEED
Excavator
Speed

E175B

E195B

First speed

3.0 km/h

3.0 km/h

Second speed

5.4 km/h

5.0 km/h

ENGINE DATA E175B-E195B

MAIN SPECIFICATIONS
-

Manufacturer..................................................................................................................................CNH U.K.

Model ..........................................................................................................................................445TA/MLF

Type ..................................................................................... Diesel, 4 stroke, direct injection, turbocharged

Number of cylinder............................................................................................................................4 in-line

Bore ................................................................................................................................................. 104 mm

Stroke .............................................................................................................................................. 132 mm

Total displacement......................................................................................................................... 4485 cm3

Compression ratio............................................................................................................................... 17.5:1

Net power at flywheel (at 2000 rpm) (ISO 14396) .............................................................................. 93 kW

Torque (at 1200 rpm) ........................................................................................................................525 Nm

Engine idle at no-load ...................................................................................................................... 800 rpm

INJECTION PUMP
-

Type ...............................................................................................................................VI4/12 F 1000 L935

Injection order ....................................................................................................................................1-3-4-2

BATTERY
-

Voltage - Capacity..............................................................................................................2 x 12 V - 100 Ah

STARTER MOTOR
-

Manufacturer.....................................................................................................................................BOSCH

Voltage - Output...........................................................................................................................24V - 4 kW

ALTERNATOR
-

Manufacturer.....................................................................................................................................BOSCH

Type .................................................................................................................................NCB1 28V 35-70A

Voltage - Output............................................................................................................................ 24V - 70A

T1-1-11

E175B

SPECIFICATIONS

DIGGING DATA E175B

(Monoblock Version)

G
E

C
D
F

B'

A'

NH0350

Arm

2200

2600

3100

8488

8844

9349

8676

9024

9520

5649

6049

6549

5401

5820

6363

9155

9325

9685

6478

6669

7010

2991

2835

2895

3820

3471

2984

4339

4731

5060

(Dimensions in mm)

T1-1-12

SPECIFICATIONS

E175B

DIGGING DATA E175B

(Triple Articulation Version)

C
D
F

B'

A
A'

NH0351

Arm

2200

2600

3100

8345

8704

9385

8536

8888

9212

5271

5655

6162

5146

5538

6054

9804

10066

10497

7056

7317

7749

2350

2110

2174

4091

3645

3155

2423

2760

2988

(Dimensions in mm)

T1-1-13

E175B

SPECIFICATIONS

TRANSPORTING DIMENSIONS E175B

(Monoblock Version)
E
D

L
M

A
N

B
NH0352

VERSIONS

E175BL

E175BLC

3280

3280

4087

4087

1021

1021

2520

2520

(1) 8723

(1) 2973

(2) 8672

(2) 2846

(3) 8678

(3) 2928

(1) 8723

(1) 2973

(2) 8672

(2) 2846

(3) 8678

(3) 2928

2490

3008

950

490

2490

3008

950

490

Arm:
(1) 2200 mm
(2) 2600 mm
(3) 3100 mm

(dimensions in mm)

E175BL

E175BLC

M Track shoe width

(mm)

500

600

700

800

500

600

700

800

900

N Gauge

(mm)

2490

2590

2690

2790

2690

2790

2890

2990

3090

(kg) 17250

17500

17750

18000

17550

17800

18050

18300

18550

0.39

0.34

0.30

0.47

0.39

0.34

0.30

0.27

(*) Working weight

Spec. ground pres.

(bar)

0.46

(*) With arm 3100 mm and bucket 0.51 m

T1-1-14

SPECIFICATIONS

E175B

TRANSPORTING DIMENSIONS E175B

(Triple Articulation Version)
E
D

L
M

A
N

B
NH0353

VERSIONS

E175BL

E175BLC

3280

3280

4087

4087

1021

1021

2520

2520

(1) 8574

(1) 3008

(2) 8520

(2) 2878

(3) 8525

(3) 2993

(1) 8574

(1) 3008

(2) 8520

(2) 2878

(3) 8525

(3) 2993

2490

3008

950

490

2490

3008

950

490

Arm:
(1) 2200 mm
(2) 2600 mm
(3) 3100 mm

(dimensions in mm)

E175BL

E175BLC

M Track shoe width

(mm)

500

600

700

800

500

600

700

800

900

N Gauge

(mm)

2490

2590

2690

2790

2690

2790

2890

2990

3090

(kg) 17650

17900

18150

18400

17950

18200

18450

18700

18950

0.45

0.39

0.34

0.54

0.45

0.39

0.35

0.31

(*) Working weight

Spec. ground pres.

(bar)

(*) With arm 3100 mm and bucket 0.51 m

0.53

T1-1-15

E175B

SPECIFICATIONS

BUCKET APPLICATIONS AS A FUNCTION OF THE ARMS E175B

E175B Monoblock
BUCKETS
Width
(mm)

Capacity
(dm3)
SAE J296
(ISO 7451)

Mass
(kg)

500

236

375

780

430

472

880

510

509

1030

633

561

1230

793

610

1330

878

664

2200

E175BL

E175BLC

Arm (mm)

Arm (mm)

2600

3100

2200

2600

3100

E175B Triple Articulation

BUCKETS
Width
(mm)

Capacity
(dm3)
SAE J296
(ISO 7451)

Mass
(kg)

500

236

375

780

430

472

880

510

509

1030

633

561

1230

793

610

1330

878

664

2200

E175BL

E175BLC

Arm (mm)

Arm (mm)

2600

3100

2200

General digging work (specific weight of material < 1.8 t/m3)

Slightly heavy digging work (specific weight of material < 1.5 t/m3)
Loading work (specific weight of material < 1.2 t/m3)

T1-1-16

2600

3100

SPECIFICATIONS

E195B

DIGGING DATA E195B

(Monoblock Version)

G
E

C
D
F

B'

A'

NH0350

Arm

2200

2600

3100

8489

8902

9442

8681

9085

9614

5720

6120

6620

5449

5889

6441

8789

9119

9592

6509

6719

7095

3058

2851

2888

3956

3590

3112

5054

5286

5534

(Dimensions in mm)

T1-1-17

E195B

SPECIFICATIONS

DIGGING DATA E195B

(Triple Articulation Version)

C
D
F

B'

A
A'

NH0351

Arm

2200

2600

3100

8352

8765

9305

8547

8951

9480

5305

5711

6232

5181

5596

6125

9634

10012

10533

6964

7267

7732

2426

2216

2262

4177

3731

3246

3202

3343

3463

(Dimensions in mm)

T1-1-18

SPECIFICATIONS

E195B

TRANSPORTING DIMENSIONS E195B

(Monoblock Version)
E
D

L
M

A
N

B
NH0352

VERSIONS

E195BEL

E195BLC

3656

3656

4451

4451

1035

1035

2620

2620

(1) 8877

(1) 3031

(2) 8794

(2) 2930

(3) 8785

(3) 3007

(1) 8877

(1) 3031

(2) 8794

(2) 2930

(3) 8785

(3) 3007

2503

3027

948

471

2503

3027

948

471

Arm:
(1) 2200 mm
(2) 2600 mm
(3) 3100 mm

(dimensions in mm)

E195BEL

E195BLC

Track shoe width

(mm)

500

600

700

600

700

800

900

Gauge

(mm)

2490

2590

2690

2800

2900

3000

3100

(kg)

18600

18850

19100

19150

19400

19650

19900

(bar)

0.50

0.42

0.37

0.42

0.37

0.32

0.29

(**) Working weight

Spec. ground pres.
(*) With arm 3100 mm and bucket 1.3

m3

T1-1-19

E195B

SPECIFICATIONS

TRANSPORTING DIMENSIONS E195B

(Triple Articulation Version)
E
D

L
M

A
N

B
NH0353

VERSIONS

E195BEL

E195BLC

3656

3656

4451

4451

1035

1035

2620

2620

(1) 8726

(1) 3069

(2) 8639

(2) 2973

(3) 8626

(3) 3078

(1) 8726

(1) 3069

(2) 8639

(2) 2973

(3) 8626

(3) 3078

2503

3027

948

471

2503

3027

948

471

Arm:
(1) 2200 mm
(2) 2600 mm
(3) 3100 mm

(dimensions in mm)

E195BEL

E195BLC

Track shoe width

(mm)

500

600

700

600

700

800

900

Gauge

(mm)

2490

2590

2690

2800

2900

3000

3100

(kg)

19300

19550

19800

19850

20100

20350

20600

(bar)

0.52

0.44

0.38

0.44

0.38

0.34

0.30

(**) Working weight

Spec. ground pres.
(*) With arm 3100 mm and bucket 1.3

m3

T1-1-20

SPECIFICATIONS

E195B

BUCKET APPLICATIONS AS A FUNCTION OF THE ARMS E195B

E195B Monoblock

Width
(mm)

BUCKETS

E195BEL

E195BLC

Capacity
(dm3)
Mass (kg)
SAE J296
(ISO 7451)

Arm (mm)

Arm (mm)

750

525

503

850

625

537

1000

789

634

1200

1000

651

1300

1105

698

2200

2600

3100

2200

2600

3100

E195B Triple Articolation

BUCKETS
Width
(mm)

Capacity
(dm3)
SAE J296
(ISO 7451)

Mass
(kg)

750

525

503

850

625

537

1000

789

634

1200

1000

651

1300

1105

698

2200

E195BEL

E195BLC

Arm (mm)

Arm (mm)

2600

3100

2200

General digging work (specific weight of material < 1.8 t/m3)

Slightly heavy digging work (specific weight of material < 1.5 t/m3)
Loading work (specific weight of material < 1.2 t/m3)

T1-1-21

2600

3100

E175B-E195B

SPECIFICATIONS

NOTE:

T1-1-22

SECTION 2

E175B-E195B

SYSTEM

CONTENTS
Group 1 - Mechatro Control System
1 Preface .............................................. T2-1-1
2 Summary of Mechatro control system T2-1-2
2.1

Mechatro control system in

general ..................................... T2-1-2

2.2

Unload valve control ................. T2-1-4

2.3

Positive control & P-Q control... T2-1-5

2.4

Boom up conflux control ........... T2-1-7

2.5

Arm in recirculation & conflux

control....................................... T2-1-8

2.6

Arm-in anti-cavitation control .... T2-1-10

2.7

Arm-out conflux control............. T2-1-11

2.8

Bucket digging (dump) conflux

control....................................... T2-1-12

2.9

Bucket digging anti-cavitation

control....................................... T2-1-13

5 Positioning circuit (triple articulation

version) .............................................. T2-2-8
6 Color coding standard for hydraulic
circuits................................................ T2-2-10
7 Neutral circuit .................................... T2-2-10
8 Travel circuit ...................................... T2-2-12
9 Bucket circuit ..................................... T2-2-14
10 Boom circuit ...................................... T2-2-16
11 Swing circuit ...................................... T2-2-20
12 Arm circuit ......................................... T2-2-22
13 Combined circuit ............................... T2-2-28
14 Pressure draining (releasing) circuit . T2-2-32

Group 3 - electrical system

Electrical system main components........ T2-3-1
Electrical system (Overall system) ..... T2-3-1

2.10 Swing priority control ................ T2-1-15

Electrical system diagram ...................... T2-3-13

2.11 Travel straight control ............... T2-1-16

Electrical system diagram (No. 1) ...... T2-3-15

2.12 Pressure release control........... T2-1-18

Electrical system diagram (No. 2) ...... T2-3-17

2.13 N&B switch control (option) ...... T2-1-19

Electrical system diagram (No. 3) ...... T2-3-19

2.14 Option conflux control (option).. T2-1-20

Electrical system diagram (No. 4) ...... T2-3-21

3 Mechatro controller ............................ T2-1-21

3.1

Summary of multi display ......... T2-1-21

3.2

Self diagnosis display ............... T2-1-27

3.3

Service diagnosis display

function ..................................... T2-1-29

3.4

Trouble history diagnosis.......... T2-1-39

3.5

Trouble diagnosis mode ........... T2-1-40

3.6

Set procedure of maintenance

schedule ................................... T2-1-41

3.7

Adjusting procedure of display . T2-1-42

3.8

Mechatro control equipment ..... T2-1-48

Group 2 - Hydraulic circuits

1 Summary ........................................... T2-2-1
2 Hydraulic circuits and components .... T2-2-2
3 N&B hydraulic circuit (option) ............ T2-2-4
4 Holding valve for boom & arm (option)T2-2-6

Electrical system diagram (No. 5) ...... T2-3-23

Wiring harness ........................................ T2-3-24
Cluster gauge wiring harness
assembly................................... T2-3-25
Platform wiring harness assembly .... T2-3-27
Upper frame wiring harness assembly . T2-3-29
Engine wiring harness (KSB & STOP) . T2-3-30

MECHATRO CONTROL SYSTEM

E175B-E195B

1. PREFACE
This chapter explains only those related to the electro hydraulic conversion as mechatro control. This chapter
summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding
the conditions before and after each conversion, refer to the hydraulic system and the electric system.

T2-1-1

E175B-E195B
2

MECHATRO CONTROL SYSTEM

SUMMARY OF MECHATRO CONTROL SYSTEM

2.1

MECHATRO CONTROL SYSTEM IN GENERAL

ELECTRIC
CONTROLLER INPUT SIGNAL
HYDRAULIC
PILOT SECONDARY PRESSURE

VOLTAGE OUTPUT L1

SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE

SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT

LH

RH

LH

RH

OPTION PILOT VALVE

PILOT VALVE
FOR TRAVEL

PILOT VALVE
FOR ATT

SE-9
SE-10

SE-11
LOW PRESSURE SENSOR

SE-4

(4)

GAUGE CLUSTER
LCD DISPLAY
FOR SELECTION
FUEL GAUGE
COOLANT TEMP. GAUGE
SWITCH

SENSOR BLOCK

SE-3

SE-7

SCREEN CHANGE
BUZZER STOP

(1)

(8)
(7)

L4

(6)

WASHER

SE-5

WIPER

ACCEL DIAL
SE-16

SERIAL COMMUNICATION

TRAVEL
AUTO-IDLE

(5)

OUTPUT VOLTAGE

MODE

SERIAL COMMUNICATION

(2)

SE-1
SE-8

L2
L3

(3)

SE-2

PSV-R
SHORT-CIRCUIT
VALVE

PROPORTIONAL
VALVE

SE-23
HIGH PRESSURE SENSOR

C-1

SE-22

MECHATRO CONTROLLER

ENGINE
GOVERNOR
MOTOR

M-2

A1

L5
A2

A3

SPEED SENSOR

SE-13

PSV -P1
P1 PUMP PROPORTIONAL VALVE

: HIGH PRESSURE SENSOR

(FOR P1,P2 : 2pcs)

PSV -P2
P2 PUMP PROPORTIONAL VALVE

: GOVERNOR MOTOR
: E/G SPEED SENSOR

L6

: LOW PRESSURE SENSOR

(ATT : 7pcs, TRAVEL : 2pcs)

L7
VOLTAGE 24V

PROPORTIONAL COMMAND CURRENT

SM0116

T2-1-2

MECHATRO CONTROL SYSTEM

L1

E175B-E195B

MAIN CONTROL VALVE

SE-29

(3)

UP

REVERSE

REVERSE

L2
L3

LEFT ARM OUT

(5)

(7)

SV-13
N&B
SELECTOR VALVE

(8)

OPTION

(6)

BOOM UP
CONFLUX
P2 UNLOAD

TRAVEL LEFT

PL1
ATTACHMENT BOOST
P1 P2

(3)

ARM 1 SPEED

DIGGING

FORWARD

(4)

SWING

(1)

DOWN FORWARD

TRAVEL
P1 UNLOAD
STRAIGHT

BUCKET

ARM 2 SPEED

(2)

TRAVEL RIGHT

DUMP

(8)

BOOM LOW SPEED

ARM OUT

SOL

RIGHT ARM IN

SOLENOID VALVE

L4
SWING MOTOR PARKING RELEASE

PSV
-A

PSV PSV PSV

-D
-C
-B

SV
-2

SV
-3

SV
-1

BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX

SAFETY LOCK LEVER

SWING PARKING BRAKE

TRAVEL 1,2 SPEED

ATTACHMENT BOOST

P2 UNLOAD

TRAVEL STRAIGHT

P1 UNLOAD

L5

ARM IN 2 SPEED

TRAVEL MOTOR 1,2 SPEED SELECT

SV
-4

ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX

(7)

ARM IN

L6

BUCKET CYLINDER
DIGGING / DUMP CONFLUX

L7
PROPORTIONAL VALVE
SOLENOID VALVE

) BLOCK
SM0117

T2-1-3

E175B-E195B

P2

(LEFT)

(RIGHT)

OPTIONAL
PILOT VALVE

PILOT
VALVE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX
P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

UNLOAD VALVE CONTROL

OPTION

2.2

MECHATRO CONTROL SYSTEM

P1

PILOT
VALVE

PILOT VALVE
FOR TRAVEL

SE-11
SE-10

SE-9

LOW
LOW
PRESSURE PRESSURE
SENSOR
SENSOR
SE-1~4

SE-5,7,8

pi

PILOT SIGNAL
PROCESS

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS

P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0118

1. On starting any one of operations, the control pilot secondary pressure switches spools and enters in
respective low pressure sensors.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3. Each unload pressure proportional valves output pilot secondary pressure according to the command
output by mechatro controller and switches each unload spools.
4. With this operation, the bleed opening according to lever manipulated movement is obtained, consequently
the pump pressure which is used to actuate each actuators are delivered and makes each actuator start
operating.
T2-1-4

MECHATRO CONTROL SYSTEM

P2

SE-23

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

OPTIONAL
PILOT VALVE

P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

POSITIVE CONTROL & P-Q CONTROL

OPTION

2.3

E175B-E195B

P1

SE-22

SE-11

(LEFT)

(RIGHT)

PILOT
VALVE

PILOT
VALVE

PILOT VALVE
FOR TRAVEL

SE-10

SE-9

LOW
LOW
PRESSURE PRESSURE
SENSOR
SENSOR
SE-1~4

SE-5,7,8

pi

PILOT SIGNAL
PROCESS

P2 PUMP
PROPORTIONAL
VALVE COMMAND

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

PILOT SECONDARY PRESSURE

pi

pi

PILOT SIGNAL
PROCESS
PILOT SECONDARY PRESSURE

P1 PUMP
PROPORTIONAL
VALVE COMMAND

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE

SECONDARY PRESSURE
SM0119

T2-1-5

E175B-E195B

MECHATRO CONTROL SYSTEM

1. Positive control
1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each
low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator,
and consequently the working speed according to the lever manipulated movement will be obtained.
2. P-Q control
1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller
and the mechatro controller processes pilot signal and operates the command according to the input
voltage (load pressure).
2) The lower value between command values calculated by positive control and operated value found by
P-Q control {operated value found in item 1)} is selected and is output to each pump proportional valve
as command value.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator and
consequently working speed will be obtained according to lever movement.

P-Q CONTROL

PILOT SIGNAL PROCESS

PUMP PROPORTIONAL
SECONDARY PRESSURE

PUMP PROPORTIONAL
SECONDARY PRESSURE

POSITIVE CONTROL

PILOT PRESSURE

PILOT SIGNAL PROCESS

PUMP DELIVERY PRESSURE

SM0120

T2-1-6

MECHATRO CONTROL SYSTEM

P2

PILOT
VALVE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX
P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

BOOM UP CONFLUX CONTROL

OPTION

2.4

E175B-E195B

P1

LOW
PRESSURE
SENSOR
SE-3

pi

PILOT SIGNAL
PROCESS

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS
MECHATRO
CONTROLLER
BOOM UP PILOT SECONDARY PRESSURE

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

P2 UNLOAD
PROPORTIONAL
VALVE PSV-D

pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

SM0121

1. On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux
spool and is input to low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control
valve.
4. With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and
also with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are
switched and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during
boom up operation.

T2-1-7

E175B-E195B

P2

LOW
PRESSURE
SENSOR
SE-1~6

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

PILOT
VALVE

P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

ARM IN RECIRCULATION & CONFLUX CONTROL

OPTION

2.5

MECHATRO CONTROL SYSTEM

P1

LOW
PRESSURE
SENSOR
SE-7

CONTROL PROCESS
FOR 2 SPEED

pi

PILOT SIGNAL
PROCESS

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

ARM IN PILOT SECONDARY PRESSURE

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SECONDARY PRESSURE

PILOT SIGNAL
PROCESS

P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM IN PILOT SECONDARY PRESSURE

P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

pi
PILOT SECONDARY PRESSURE

pi

ARM PILOT SECONDARY

PRESSURE

P2 PUMP PRESSURE

REVERSE PROPORTIONAL
VALVE CONTROL
PROCESS FOR ARM
2 SPOOL

MECHATRO
CONTROLLER

REVERSE PROPORTIONAL
VALVE FOR ARM
2 SPOOL PSV-A

pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0122

T2-1-8

MECHATRO CONTROL SYSTEM

E175B-E195B

1. Recirculation and conflux (Low loading)

1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2
spool and low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional
valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool.
In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure
sensor and the output voltage is input to mechatro controller. And the mechatro controller processes
pilot signal according to the combined operation and outputs command, which is different from the armin independent operation, to P1 pump proportional valve, P1 unload proportional valve and reverse
proportional valve for arm-in 2 spool.
3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure
and it switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool
controls recirculation rate and conflux rate.)
The other proportional valves output proportional secondary pressure according to command from
mechatro controller. These proportional valves change the delivery rate of P1, P2 pump, and switch
P1, P2 unload valve.
4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2
unload spools and arm 2 spool are switched according to the command output by mechatro controller,
and consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps
delivery oil during arm operation.
2. Recirculation cut
The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load
is raised during arm operation the mechatro controller processes pilot signal processing according to the
pressure detected by high pressure sensor and outputs command to cut recirculation into reverse
proportional valve for arm-in 2 spool.
The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the
command output by mechatro controller and switches arm 2 spool to recirculation cut position, and
consequently recirculation passage is blocked.

T2-1-9

E175B-E195B

P2

LOW
PRESSURE
SENSOR
SE-7

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

TRAVEL LEFT

TRAVEL
STRAIGHT

PILOT
VALVE

P2 UNLOAD

SWING

SOLENOID

ARM 1 SPEED

N&B
SELECTOR
VALVE

BOOM UP CONFLUX

ARM-IN ANTI-CAVITATION CONTROL

OPTION

2.6

MECHATRO CONTROL SYSTEM

P1

ACCEL
POTENTIO

pi

PILOT SIGNAL
PROCESS

ARM IN PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL
PROCESS

pi
P2 PUMP
PROPORTIONAL
VALVE PSV-P2

REVERSE PROPORTIONAL
VALVE CONTROL PROCESS
FOR ARM 2 SPOOL PSV-Bpi

ARM IN PILOT SECONDARY PRESSURE

pi
REVERSE PROPORTIONAL
VALVE FOR ARM
2 SPOOL COMMAND

ENGINE SPEED (COMMAND VALUE)

MECHATRO
CONTROLLER

REVERSE PROPORTIONAL
VALVE FOR ARM 2 SPOOL
PSV-A

pi

pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0123

1. On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input
to low pressure sensor.
2. The engine speed command output by accel potentiometer is input to mechatro controller.
3. Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes
pilot signal processing and outputs command according to the input voltage to P2 pump proportional valve
and P2 unload proportional valve.
4. And also outputs command according to input pressure output by potentiometer to reverse proportional
valve for arm 2 spool.
5. Each proportional valve outputs pilot secondary pressure according to each command output by mechatro
controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke
according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if
pump delivery rate is low due to low engine speed.

T2-1-10

MECHATRO CONTROL SYSTEM

PILOT
VALVE

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX
P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

ARM-OUT CONFLUX CONTROL

OPTION

2.7

E175B-E195B

P1

LOW
PRESSURE
SENSOR
SE-8

pi

PILOT SIGNAL
PROCESS

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

ARM OUT PILOT SECONDARY PRESSURE

pi
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

ARM OUT PILOT SECONDARY PRESSURE

pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM OUT PILOT SECONDARY PRESSURE

pi

MECHATRO
CONTROLLER
ARM OUT PILOT SECONDARY PRESSURE

P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

SM0124

1. On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and
is input to low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control
valves.
4. With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the
command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and
consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out
operation.
T2-1-11

E175B-E195B

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

BOOM UP CONFLUX

TRAVEL LEFT

TRAVEL
STRAIGHT

PILOT
VALVE

P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

BUCKET DIGGING (DUMP) CONFLUX CONTROL

OPTION

2.8

MECHATRO CONTROL SYSTEM

P1

LOW
PRESSURE
SENSOR
SE-1(2)
pi

PILOT SIGNAL
PROCESS

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL
PROCESS

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL
PROCESS

P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL
PROCESS

P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL
PROCESS

TRAVELSTRAIGHT
PROPORTIONAL
VALVE PSV-C

MECHATRO

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE

SECONDARY PRESSURE

SM0125

1. On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches
bucket spool and is input to low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload proportional valves and travel straight proportional valve.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel
straight valve of the control valve.
4. The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump
delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
T2-1-12

MECHATRO CONTROL SYSTEM

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

PILOT
VALVE

P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

BUCKET DIGGING ANTI-CAVITATION CONTROL

OPTION

2.9

E175B-E195B

P1

LOW
PRESSURE
SENSOR
SE-1 (2)

pi

PILOT SIGNAL
PROCESS

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS
ACCEL
POTENTIO

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS

P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL
PROCESS

BUCKET
ANTI-CAVITATION
PROCESS

ATT BOOST
SOLENOID VALVE
SV-2

ENGINE SPEED (COMMAND VALUE)

MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

P1 PUMP PRESSURE

T2-1-13

SM0126

E175B-E195B

MECHATRO CONTROL SYSTEM

1. On starting bucket digging operation, bucket digging operating pilot pressure switches bucket spool and is
input to low pressure sensor.
2. The engine speed command output by accel potentiometer is input to mechatro controller.
3. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload proportional valves and travel straight proportional valve.
4. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel
straight valve of control valve.
5. The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump
delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
6. ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary
pressure, and actuate stroke limiter and then controls the stroke of bucket spool.
The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and
pump delivery rate is low.
7. When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to
the pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control
the stroke limit of bucket spool.

T2-1-14

MECHATRO CONTROL SYSTEM

E175B-E195B

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX
P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

PILOT
VALVE

OPTION

2.10 SWING PRIORITY CONTROL

P1

LOW
PRESSURE
SENSOR
SE-5

SE-7

pi

ARM IN PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL
PROCESS

PILOT SIGNAL
PROCESS

pi

pi

SWING PILOT SECONDARY PRESSURE

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

ARM IN PILOT SECONDARY PRESSURE

SWING PILOT SECONDARY PRESSURE

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

TRAVEL STRAIGHT
PROPORTIONAL
VALVE COMMAND

TRAVEL STRAIGHT
COMMAND
PROPORTIONAL
VALVE PSV-C

REVERSE PROPORTIONAL
VALVE CONTROL
PROCESS FOR ARM
2 SPOOL

REVERSE PROPORTIONAL
VALVE FOR ARM
2 SPOOL PSV-A

MECHATRO
CONTROLLER

pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

SM0127

1. During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low
pressure sensor on starting swing operation (or arm-in operation during swing operation), and swing
operation pilot secondary pressure switches swing spool and is input to low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve
for arm 2 spool.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel straight
spool, arm 2 spool.
4. With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the
command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are
switched enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently
the return oil on arm cylinder rod side is recirculated into arm cylinder head side.
5. Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery
rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with
minimum speed drop possible.
T2-1-15

E175B-E195B

MECHATRO CONTROL SYSTEM

(RIGHT)

PILOT
VALVE

P2

PILOT VALVE
FOR TRAVEL

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

TRAVEL LEFT

BOOM UP CONFLUX

PILOT
VALVE

TRAVEL
STRAIGHT

(LEFT)

P2 UNLOAD

SOLENOID

SWING

N&B
SELECTOR
VALVE

ARM 1 SPEED

OPTIONAL
PILOT VALVE

OPTION

2.11 TRAVEL STRAIGHT CONTROL

P1

SOLENOID SHORT CIRCUIT

VALVE

SE-10

SE-9

SE-11

LOW
PRESSURE
SENSOR

VALVE SIGNAL
TRAVEL STRAIGHT SIGNAL

pi

PILOT SIGNAL
PROCESS

PROPORTIONAL
VALVE PSV-R
IN SHORT-CIRCUIT
VALVE

PILOT
SECONDARY PRESSURE

pi

PILOT SIGNAL
PROCESS

TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C

PILOT
SECONDARY PRESSURE

pi

PILOT SIGNAL
PROCESS

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

PILOT
SECONDARY PRESSURE
pi

PILOT SIGNAL
PROCESS

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT
SECONDARY PRESSURE
pi

PILOT SIGNAL
PROCESS

P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL
PROCESS

PILOT
SECONDARY PRESSURE

T2-1-16

P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

SM0128

MECHATRO CONTROL SYSTEM

E175B-E195B

1. Judgment travel straight

1) During travel operation (right and left), pilot pressure switches each travel spool and is input to low
pressure sensor on carrying out attachment system operation.
2) Mechatro controller decides as travel straight on receiving the input according to the combination
shown in the table from the low pressure sensor and turns travel straight signal on.
3) On turning travel straight signal on, the following commands are output to each proportional valve.
2. Operation of each proportional valve
(Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump in
travel straight condition.)
1) Travel straight proportional valve outputs switching pressure according to the high priority select
pressure in the attachment system operating (Boom, arm, bucket, swing, option) pilot pressure during
operation.
2) Short-circuit proportional valve outputs pressure according to the high priority select pressure in the
both attachment and travel system operating pilot pressure during operation.
3) P1 unload proportional valve outputs switching pressure according to the high priority select pressure
in the attachment system operating pilot pressure during operation.
4) P2 unload proportional valve outputs switching pressure according to the high priority select in the
travel operating pilot pressure during operation.
5) P1 pump proportional valve outputs switching pressure according to the high priority select pressure in
the attachment system operating pilot pressure during operation.
6) P2 pump proportional valve outputs switching pressure according to the high priority select in the travel
operating pilot pressure during operation.
ATT operation

Boom

Arm

Right travel operation (P1)

Left travel operation (P2)

T2-1-17

Bucket

Swing

Option

E175B-E195B

MECHATRO CONTROL SYSTEM

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

PILOT
VALVE

P2 UNLOAD

GAUGE CLUSTER

SWING

SOLENOID

ARM 1 SPEED

N&B
SELECTOR
VALVE

OPTION

2.12 PRESSURE RELEASE CONTROL

P1

SE-23

SE-22

ENGINE
(M-2)

PRESSURE
RELEASE
CONTROL

ENGINE SPEED
CONTROL

pi

pi

pi

pi

PILOT SIGNAL
PROCESS

PILOT SIGNAL
PROCESS

PILOT SIGNAL
PROCESS

PILOT SIGNAL
PROCESS
MECHATRO
CONTROLLER

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

SM0130

1. Change mechatro controller to PRESSURE DRAING MODE by operating switch on gauge cluster.
For detail of changing mode method, refer to Pressure draining (releasing) circuit on GROUP 2 HYDRAULIC CIRCUIT.
2. Once mechatro controller decides it as pressure release control, regardless of each input signal (operating
pilot, accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to
minimum tilt angle.
2) Outputs command of pressure release to control step-by step motor (M2) and fixes engine speed to
pressure release control speed.
3) Outputs maximum command to P1 and P2 unload proportional valves and each pilot secondary
pressure fixes P1 and P2 unload valves to the maximum opening.
3. Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump
pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
4. Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure)
to be released by operating each control lever and switching spool with the unload valve opened.

T2-1-18

MECHATRO CONTROL SYSTEM

E175B-E195B

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX
P2 UNLOAD

SWING

SOLENOID

OPTION

PRESSURE SENSOR N&B

FOR BREAKER
SELECTOR
SE-29
VALVE

ARM 1 SPEED

2.13 N&B SWITCH CONTROL (OPTION)

P1

A MODE

B MODE
GAUGE CLUSTER

pi

B MODE SWITCH

MECHATRO
CONTROLLER

pi : OUTPUT OF N&B SELECTOR SOLENOID

SM0131

1. Nibbler circuit
1) Select A mode through gauge cluster.
2) Nibbler display appears on gauge cluster.
3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of
main control valve.
4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output.
It is in normal when there is no output from sensor in A mode, and in cases of other than above, error
display is output to gauge cluster.
2. Breaker circuit
1) Select B mode through gauge cluster.
2) Breaker display appears on gauge cluster.
3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in B mode, and in cases of other than above, error
display is output to gauge cluster.

T2-1-19

E175B-E195B

MECHATRO CONTROL SYSTEM

P2

LOW
PRESSURE
SENSOR

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD
TRAVEL
STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX
P2 UNLOAD

SOLENOID

SWING

PILOT VALVE

ARM 1 SPEED

N&B
SELECTOR
VALVE

OPTION

2.14 OPTION CONFLUX CONTROL (OPTION)

P1

SINGLE / CONFLUX
SWITCH

SE-11

pi

PILOT SIGNAL
PROCESS

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS

P2 PUMP
PROPORTIONAL
VALVE PSV-P2

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

OPTION PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL
PROCESS

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS

OPTION PILOT SECONDARY PRESSURE

P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C

MECHATRO
pi : PROPORTIONAL VALVE
CONTROLLER
SECONDARY PRESSURE

SM0132

1. Select the Conflux with the aid of Conflux/Single switch.

2. On starting option operation, option operating pilot pressure switches option spool and is input to low
pressure sensor.
3. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload pressure proportional valves and travel straight proportional valve.
4. Each proportional valves output pilot proportional valve secondary pressure according to the command
output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload
valves and travel straight valve of the control valve.
5. The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and
P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.

T2-1-20

MECHATRO CONTROL SYSTEM

3.

E175B-E195B

MECHATRO CONTROLLER

3.1

SUMMARY OF MULTI DISPLAY

Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
1. Controls

SWING PARKING
BRAKE RELEASE
SWITCH

GAUGE
CLUSTER
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.

FUSE &
RELAY BOX

STARTER SWITCH
ACCEL DIAL

DETAIL A

SM0133

2. Gauge cluster

11

22:00
H
1

2
3
10
4

No.

Name

Engine coolant temperature gauge

Fuel level gauge

Screen change switch

Buzzer stop switch

Work mode select switch

Washer switch

Wiper switch

Travel high speed, low speed select switch

Auto accel switch

10

Select switch

11

Multi display (LCD)

SM0134

T2-1-21

E175B-E195B

MECHATRO CONTROL SYSTEM

3. Screen selection by work mode select switch

After starting engine, "S" mode is usually set.
The work modes "S","H","B" and "A" are selected in order every time (
) is pressed.
Select efficient work mode according to the working condition and the purpose from the following table.
The selected mode is displayed on the left lower corner on multi display.

S mode: For standard digging work

H mode: For heavy duty digging work
B mode: For works with breaker
A mode: For works with crusher (nibbler)

10:25
H

SM0135

Work mode

Display

S mode

10:25

Contents
"S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.

10:25

H mode

"H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.

B mode

10:25

For the work with breaker, select "B mode" without fail.

10:25

For the work with crusher (nibbler), select "A mode".

A mode

T2-1-22

MECHATRO CONTROL SYSTEM

1) Pump flow rate adjustment (A mode /B mode)

No. Switches
1

Screen change switch

Buzzer stop switch

KPSS work mode select switch

Washer switch

Wiper switch

Travel speed select switch

Auto accel switch

Select switch

E175B-E195B

SM0140

According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow
rate in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 210L/min. The adjustment (increase
or decrease) of flow rate is changeable by 10L/min step.
Main screen

Attachment mode (A mode)

10:25

Flow
rate

130 L/m

Flow
rate

Enter

(a)

Flow
rate

100 L/m

(b)

(d)

100 L/m

Increase/Decrease

In Breaker mode (B mode)

Flow
rate

130 L/m

Flow
rate

Enter

B
Screen in Attachment/Breaker mode
A mode
Flow
rate

(c)

(d)

Flow
rate

100 L/m

Increase/Decrease
When the conflux switch is tuned
on, the double flow rate is displayed.

B mode
130 L/m

Flow
rate

100 L/m

130 L/m

B
(b)

(c)

SM0141

1) Turn starter key switch on and display main screen (a).

2) The display on the left lower corner of screen is changed in order of "S" "H" "B" "A" each time the
"MODE" switch (3) is pressed under the condition where main screen (a) is displayed.
3) Select "A" and A mode screen is displayed, and select "B" and B mode screen is displayed.
4) Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and
the screen (d) is displayed. In this condition, press FEED (4)/ (5) and the flow rate value increases or
decreases.
5) Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.

T2-1-23

E175B-E195B

MECHATRO CONTROL SYSTEM

4. MAINTENANCE SCREEN DISPLAYS

This screen displays the remaining time to the end of recommended replacement/change interval specified
for filter/oil.
For the initial set value of recommenced replacement/change time, see the following table.
Replacement interval
Item

Default

Engine oil

500 Hr

Fuel filter

500 Hr

Hydraulic oil filter

1,000 Hr

Hydraulic oil

5,000 Hr

This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.

1) Remaining time display to the engine oil change

This display shows the remaining time to the coming engine oil change.

492Hr

ENGINE OIL

2) Remaining time display to the coming fuel filter replacement

This display shows the remaining time to the coming engine fuel filter
replacement.

492Hr

FUEL FILTER

3) Remaining time display to the coming hydraulic oil filter replacement

This display shows the remaining time to the coming hydraulic oil filter
replacement.

992Hr

HYD. FILTER

4) Remaining time display to the coming hydraulic oil change

This display shows the remaining time to the coming hydraulic oil
change.

4992Hr
HYD. OIL

NOTE:
The display automatically changes to the main screen, if switch is not operated for 30 seconds.
For the setting procedure of maintenance time to be performed to the coming oil change in each type and
filter replacement, see the paragraph 3.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.

T2-1-24

MECHATRO CONTROL SYSTEM

E175B-E195B

5. Gauge cluster display

After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen.
The display functions of multi display are explained below.

CLOCK DISPLAY
SELF DIAGNOSIS / WARNING
MACHINE CONDITION

H
MULTI DISPLAY INDICATIONS

SM0146

1) Display function for operator .........................Screen usually displayed during operation

1.1 Clock display function ............................Current time is displayed.
1.2 Self-diagnosis display ............................When abnormality is detected on mechatro system like
sensor, proportional valve, etc., this displays error code.
1.3 Warning display .....................................When machine was thrown into dangerous state, or was
failed, displays warning symbol. (For warning contents, see items shown on the next page.)
1.4 Machine condition display ......................Displays machine operating condition.
2) Display function for maintenance...................Displays remaining time up to replacement/change of
following items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil
3) Failure history display function.......................Stores abnormality occurred on mechatro system in the past
and displays in order of recent occurrence.
4) Mechatro adjustment display .........................Displays procedure for adjustment of mechatro system like
output adjustment and unload adjustment, etc.
5) Service diagnosis display...............................Displays information like pressure sensor sensed value,
proportional valve command, etc. output by mechatro controller
6) Failure diagnosis mode display function .......Specifies failed section automatically for failures which are not
detected by self diagnosis and displays the results.

T2-1-25

E175B-E195B

MECHATRO CONTROL SYSTEM

Warning table
These descriptions indicate error codes stored as trouble history code

W009

CAUTION ATTACHMENT

W005

LOW ENG OIL PRESS.

W011

PREHEAT

W006

POWER BOOST ON

HIGH ENG WATER TEMP.

CPU

CHARGE ERROR

W004

DATA COMMUNICATION
ERROR

LOW ENG WATER LEVEL

W001

W010

SWING BRAKE
DISENGAGED

DRAIN WATER
SEPARATOR

LOW FUEL LEVEL

AUTO WARMING UP

W008

ENG LOW PRESSURE

(ENGINE STOP)

CLOGGED AIR FILTER

CHANGE ENG OIL

NOTE: Error codes were stored as trouble history, and displayed on the monitor by the
trouble history display function.

T2-1-26

MECHATRO CONTROL SYSTEM

E175B-E195B
Warning Condition

Level
Priority
(*)

Screen

DATA COMMUCATION ERROR

SWING BRAKE DISENGAGED

ENGINE STOP

FAIL DRAIN HYD. PRESSURE

DRAINING HYD. PRESS.

Condition

Engine
Only
Key ON
Run

Data from Mechatro controller

is not received
The swing parking brake
switch is turned ON
Engine is stopped after engine
oil pressare low warning
Impossible to drain hyd.
Pressure

Auto
Stop

Possible to drain hyd. Pressure

CAUTION ATTACHMENT

The selector valve (OPT) is

malfunction

POWER BOOST ON

The power boost switchis turn ON

FINISH WARM-UP

After finishing warming up

control

Low engine oil pressure

W005

LOW ENG OIL PRESS.

W006

W010

W008

O
O

W001

W009

The engine water is more than

105 C
Water in water separator filter
is increased

HIGH ENG. WATER TEMP.

DRAIN WATER SEPA

CLOGGED AIR FLTR

(SELF DIAGNOSIS SCREENS)

PREHEAT

CHARGE ERROR

No signal from the alternator

LOW FUEL LEVEL

The fuel level is less than 10 %

LOW ENG WATER LEVEL

AUTO WARMING UP

CHANGE ENG OIL

The air filter is clogged

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

The warter engine coolant

reservoir is low
The auto warming up control is
activated
The remaining time is reached
zero Huors

(*) 1: these extremely influence safety and the machine

performance
2: these warn the machine control mode is switched
3: fatal failure
4: normal priority warning
5: low priority message

3.2

Type
(**)

Disconnection

Trouble
History
Manual Code
Stop

Buzzer sounds

W011

W004

(**) 1: Continuation
2: Beep ON 0.2 sec. OFF 0.3 sec.
3: Beep ON 0.5 sec. OFF 0.5 sec.
4: Beep ON 0.5 sec. OFF 1.0 sec.

SELF DIAGNOSIS DISPLAY

CONTROL

1. Outline
This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during
machine operation through self diagnosis. The failed items are displayed on multi display of gauge
cluster. For connector No. and pin No., refer to the section "Mechatro Control Equipment" explained later.
Electric circuit diagram or harness is available to identify wire No. and wire color.
2. I/O configuration
Pressure sensor, Governor motor
INPUT Proportional valve, Battery relay
Selector valve (SOL)

SERIAL COMMUNICATION
Gauge cluster
(Buzzer sound)
SM0147

T2-1-27

E175B-E195B

MECHATRO CONTROL SYSTEM

3. Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure
type with the aid of error code.
Alphabet: Decide system failure occurred.

10:25

B 01 3

B013

Last 2nd and 3rd digits: Specifies failed section.

Last 1 digit: Specifies failure type.

This failure symbol is displayed simultaneously with error code during failure diagnosis.

ERROR CODE

SM0148

ALPHABET
A
Controller
memory

Low pressure
sensor

High pressure
sensor

D
Proportional
valve for

Proportional
valve for

nd

Solenoid valve

G
Speed sensor

Throttle

Boom up

P1 pump

P1 unload

P1 pump

ATT boost

Step motor

02

Torque adjust
data

Boom down

P2 pump

P2 unload

P2 pump

Swing parking
brake

Step motor

03

Unload
adjust data

Arm out

Boom head

Travel straight

05

Bucket
digging

06

Bucket dump

07

Swing

09

Travel right

10

Travel left

11

Selector
position

Communication

Battery relay

Relay output

Battery relay

Wiper ark
prevention

AND 3 DIGIT

01

Arm in

rd

Engine
adjust data

04

H
Potentiometer
etc.

Wiper ark
forward

Travel 1,2
speed

Wiper ark
reverse

Option
selector

Washer motor

Arm 2 spool for

arm in

Fuel sensor

13
14
PSV-R Short
Cricuit valve

15
16

P1 side option

AIS relay2

17

P2 side option

Engine stop
relay
Safety lock
lever relay

18
21

Adjustment
data sector 1

22

Adjustment
data sector 2

23

Hourmeter
sector 1

24

Hourmeter
sector 2

25

Proportional
valve adjust

Safety relay

Cluster
communication

31

LAST DIGIT
Larger than
normal range

0
1

Larger than
normal range
Transistor
OFF failure/

Wrong output

Wrong output

Disconnection

Disconnection

Power source
short circuit

Power source
short circuit

Transistor ON
failure
Disconnection

Transistor ON
failure
Disconnection

Over run
Transistor ON
failure /

Disconnection

Disconnection
Power source
short circuit

Obnormal
data

T2-1-28

Time is over
Contact point
is melted and
adhered

Power source
short circuit

MECHATRO CONTROL SYSTEM

3.3

E175B-E195B

SERVICE DIAGNOSIS DISPLAY FUNCTION

The current service diagnosis is displayed on multi display based on the data received from mechatro
controller. This section explains the operating procedure and examples of each screen. The values in display
changes according to the conditions like engine speed, attachment position, etc.
1. Service diagnosis display screen operating procedure
1)

Turn starter switch ON keeping buzzer stop switch pressed.

2) After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in
"Screen No.1".
The screen number each mode can display differs. The screen number displayed by each mode is as
follows.
Mode No.1: Screen No.1~No.30
Mode No.2: Screen No.1, Screen No.31~No.40
Mode No.3: Screen No.1, Screen No.41~No.50
3) The screen changes each time each switch is pressed from now on.
Washer switch: Screen gains by 1 in order. (No.2No.3No.4...)
Wiper switch: Screen loses by 1 in order. (No.24No.23No.22...)
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns
to No.1. (No.1No.2No.3No.1...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then
returns to No.3. (No.3No.2No.1No.3...)
4) Turn key switch OFF and the display of service diagnosis mode is closed.

T2-1-29

E175B-E195B

MECHATRO CONTROL SYSTEM

2. Service diagnosis display screen (Example)

The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low
speed and lever to neutral position.)
1) Service diagnosis Mode No.1

No.
1

Displays

Contents

NO.1
MAIN CONT. P/N
YN22E00207F1
PROGRAM VERSION
1-VER 2.00
2-VER 0.00

P/No. indication

NO.2 ENG
G-3 SPEED SET
MEAS
G-5 ENG PRS.
WATER TEMP

Service diagnosis mode

MODE
H-1 ACCEL VOLT.
POS.
G-1 MOTOR STEP
POS.
COIL A
COIL B
G-2 LIMIT SW.

NO.3 SOL.VALVE
F-1 POWER BOOST
COMP.
MEAS.
SWITCH
F-2 SWING-BRAKE
COMP.
MEAS.
RELEASE SW
F-3 1/2-TRAVEL
COMP.
MEAS.
SWITCH

5
1000
1000
LIVE
20 C OFF
H
0.3 V
0%
30
0%
1.5 A
1.5 A
OFF

No load setting rpm

Actual rpm
Engine oil pressure
Coolant temperature sensor / Coolant tempreature switch

Work mode
Potentiometer voltage
Voltage % indication
Number of step
Step % indication
A phase current
B phase current
Limit switch

6
OFF
OFF
OFF

Set value in computer

Measured value
Switch

ON
ON
OFF

Set value in computer

Measured value
Switch

OFF
OFF
OFF

Set value in computer

Measured value
Switch

Displays

Contents

NO.4 RELAY
K-1 AIS RELAY 2
K-2 SAFETY RLY
K-3 ENG STOP
KEY SWITCH
START SWITCH
CHARGE
K-4 LOCK LEVER
SWITCH

Program version indication

SERVICE DIAG 1

No.
4

NO.5 PRESS.SENSOR
B-1 BOOM RAISE
0.4 V
0.0 M
B-2 BOOM LOWER
0.4 V
0.0 M
B-3 ARM OUT
0.4 V
0.0 M
B-4 ARM IN
0.4 V
0.0 M
B-5 BUCKET DIG
0.4 V
0.0 M
B-6 BUCKET DUMP
0.4 V
0.0 M

NO.6 PRESS.SENSOR
B-7 SWING
0.4 V
0.0 M
B-9 TRAVEL (R)
0.4 V
0.0 M
B-10 TRAVEL (L)
0.4 V
0.0 M
B-16 P1 OPT.
0.4 V
0.0 M
B-17 P2 OPT.
0.5 V
0.0 M
B-18 DOZER 1
0.0 V
0.0 M
B-19 DOZER 2
0.0 V
0.0 M

ON
ON
OFF
ON
OFF
LIVE
OFF
ON

Indicated value
Indicated value
Indicated value
Key switch
Starter switch
Alternator
Indicated value
Switch

Sensor voltage / Pressure converted value

Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value

Sensor voltage / Pressure converted value

Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value

SM0149

T2-1-30

MECHATRO CONTROL SYSTEM

No.
7

10

11

Displays

Contents

NO.7 P.SENSOR PROPO-V

C-1 PUMP P1
0.4 V 0.3 M
C-2 PUMP P2
0.4 V 0.0 M
C-3 BOOM-HEAD
0.5 V 0.9 M
C-4 BOOM-ROD
0.0 V 0.0 M
PROPO-VALVE
E-3 OPT RELIEF 1
COMP. 0 mA
2.0 M
MEAS. 0 mA
2.0 M
E-4 OPT RELIEF 2
COMP. 0 mA
2.0 M
MEAS. 0 mA
2.0 M

Sensor voltage / Pressure converted value

Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value
Set value in computer / Converted value from pressure
Measured value / Converted value from pressure
Set value in computer / Converted value from pressure
Measured value / Converted value from pressure

NO.8 PROPO-VALVE
D-1 P1 UN-LOAD(BP-CUT)
COMP. 750 mA
3.0 M
MEAS. 750 mA
3.0 M
D-2 P2 UN-LOAD(BP-CUT)
COMP. 750 mA
3.0 M
MEAS. 750 mA
3.0 M
D-3 S-TRAVEL
COMP. 350 mA
0.6 M
MEAS. 350 mA
0.6 M
D-6 ARM IN-2-SPEED
COMP. 750 mA
0.0 M
MEAS. 750 mA
0.0 M

NO.9 PROPO-VALVE
E-1 P1 PUMP
COMP. 417 mA
MEAS. 417 mA
POWER SHIFT
FLOW RATE
E-2 P2 PUMP
COMP. 417 mA
MEAS. 417 mA
POWER SHIFT
FLOW RATE

Set value in computer / Converted value from pressure

Measured value / Converted value from pressure
Set value in computer / Converted value from pressure
Measured value / Converted value from pressure
Set value in computer / Converted value from pressure
Measured value / Converted value from pressure
Set value in computer / Converted value from pressure
Measured value / Converted value from pressure

1.0 M
1.0 M
0 mA
30 L

Set value in computer / Converted value from pressure

Measured value / Converted value from pressure

1.0 M
1.0 M
0 mA
30 L

Set value in computer / Converted value from pressure

Measured value / Converted value from pressure

Power shift
Flow rate of pump P1

Power shift
Flow rate of pump P2

20
Fuel level
Hydraulic oil temperature
Glow switch
Air filter clogging
Water separator clogging
Engine oil filter clogging
Front window open/close switch
Conflux/Single flow select switch
Command from grid heater
Engine oil level
Coolant level

21
OFF
OFF

SPOOL POS.
NIB
SELECT SWITCH NIB
F-5 FAN PUMP
COMP.
--MEAS.
--F-6
COMP.
--MEAS.
---

15

18

19

NO.10 SENSOR,SWITCH
H-9 FUEL LEVEL
1.2 V 77%
H-10 HYD.OIL TEMP
0.0 V 0
GLOW
--AIR FILTER
LIVE
WATER SEPA.
LIVE
ENG OIL FILTER
--FRONT WINDOW
OFF
DOUBLE FLOW
ON
KPSS SW
--HEATER
OFF
ENG OIL LEVEL
OK
COOLANT LEVEL
OK
NO.11 SOL.VALVE
F-4 OPT SELECT
COMP.
MEAS.

No.
16

NO.15 PROPO-VALVE
D-11 P1 I-TRAVEL
COMP.
0 mA
MEAS.
0 Ma
D-12 P2 I-TRAVEL
COMP.
0 mA
MEAS.
0 mA
D-15 P1 BY PASS VALVE
COMP.
347 mA
MEAS.
347 mA
D-16 P2 BY PASS VALVE
COMP.
0 mA
MEAS.
0 mA

Set value in computer

Measured value (Feed back value)
Spool position
Mode of selector valve
Set value in computer
Measured value
Set value in computer
Measured value

22
0.0 M
0.0 M

Set value in computer / Converted value from pressure

Measured value / Converted value from pressure

0.0 M
0.0 M

Set value in computer / Converted value from pressure

Measured value / Converted value from pressure

0.6 M
0.6M

Set value in computer / Converted value from pressure

Measured value / Converted value from pressure

0.0 M
0.0 M

Set value in computer / Converted value from pressure

Measured value / Converted value from pressure

Displays
NO.16 PRESS.SENSOR
B-11
0.4 V 0.0 M
B-12
0.0 V 0.0 M
B-13
0.0 V 0.0 M
B-14
0.0 V 0.0 M
B-15
0.0 V 0.0 M
B-20
0.0 V 0.0 M

E175B-E195B

Contents

Sensor voltage / Pressure converted value

Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value

NO.18 DIGITAL INPUT

DI1
OFF
DI2
ON
DI3
OFF
DI4
OFF
DI5
OFF
DI6
OFF
DI7
--DI8
OFF
DI9
OFF
DI10 OFF
DI11 --DI12 --DI13 ON
DI14 ---

ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication

NO.19 DIGITAL INPUT

DI15 --DI16 ON
DI17 ON
DI18 OFF
DI19 --DI20 OFF
DI21 --DI22 --DI23 ON
DI24 OFF
DI25 ON
DI26 --DI27 OFF
DI28 ---

ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication

NO.20 DIGITAL INPUT

DI29 OFF
DI30 --DI31 --DI32 --DI33 ON
DI34 --DI35 --DI36 OFF
DI37 --DI38 OFF
DI39 --DI40 OFF
DI41 --DI42 ---

ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication

NO.21 DIGITAL OUTPUT

DO1 COMP. OFF
MEAS. OFF
DO2 COMP. OFF
MEAS. OFF
DO3 COMP. OFF
MEAS. OFF
DO4 COMP. OFF
MEAS. OFF
DO5 COMP. --MEAS. --DO6 COMP. --MEAS. --DO7 COMP. OFF
MEAS. OFF

Set value in computer

Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value

NO.22 DIGITAL OUTPUT

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

Set value in computer

Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value

See
Mechatro
controller
connector

SM0150

T2-1-31

E175B-E195B

No.
23

24

25

MECHATRO CONTROL SYSTEM

Displays

Contents

NO.23 DIGITAL OUTPUT

DO15 COMP. --MEAS. --DO16 COMP. ON
MEAS. ON
DO17 COMP. OFF
MEAS. OFF
DO18 COMP. OFF
MEAS. OFF
DO19 COMP. OFF
MEAS. OFF
DO20 COMP. --MEAS. --DO21 COMP. ON
MEAS. ON

Set value in computer

Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value

NO.24 DIGITAL OUTPUT

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

Set value in computer

Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value
Set value in computer
Measured value

NO.25 WIPER SYSTEM

WIPER SW
RISEUP SW
REVERSE SW
PREVENT ARC
CW MOTOR RLY
CCW MOTOR RLY
WASHER SW
MOTOR RELAY

OFF
ON
ON
OFF
OFF
OFF
OFF
OFF

Wiper switch
Wiper rise-up switch
Wiper reverse rotation switch
Wiper motor ark prevention
relay
Wiper normal rotation relay
Wiper reverse rotation relay
Washer switch
Washer motor relay

SM0151

T2-1-32

MECHATRO CONTROL SYSTEM

E175B-E195B

2) Service diagnosis Mode No.2

No.
1

Displays

Contents

NO.1
MAIN CONT. P/N
YN22E00207F1
PROGRAM VERSION
1-VER 2.00
2-VER 0.00

P/No. indication
Program version indication
MERIT controller program version

SERVICE DIAG 2

31

32

No.
33

Service diagnosis mode 2

34

NO.31 BOOM
C-1 P1 PUMP
C-2 P2 PUMP
E-1 P1-PSV
E-2 P2-PSV
D-1 P1-UL(BPC)
D-2 P2-UL(BPC)
B-1 BOOM RAISE
B-2 BOOM LOWER
G-3 ENG SPEED
POWER SHIFT

0.2 M
0.0 M
417 mA
417 mA
750 mA
750 mA
0.0 M
0.0M
1000
0 mA

Pump pressure sensor

Pump pressure sensor
Command current
Command current
Command current
Command current
Boom up pressure sensor
Boom down pressure sensor
Engine actual speed
Power shift current

NO.32 ARM,SWING
C-1 P1 PUMP
C-2 P2 PUMP
E-1 P1-PSV
E-2 P2-PSV
D-1 P1-UL(BPC)
D-2 P2-UL(BPC)
D-3 S-TRAVEL
D-6 ARM-IN-2
B-3 ARM OUT
B-4 ARM IN
B-1 BOOM RAISE
B-7 SWING
G-3 ENG SPEED
POWER SHIFT

0.2 M
0.0 M
417 mA
417 mA
750 mA
750 mA
350 mA
750 mA
0.0 M
0.0 M
0.0 M
0.0 M
1000
0 mA

Pump pressure sensor

Pump pressure sensor
Command current
Command current
Command current
Command current
Command current
Command current
Arm out pressure sensor
Arm in pressure sensor
Boom up pressure sensor
Swing pressure sensor
Engine actual speed
Power shift current

35

Displays

Contents

NO.33 BUCKET
C-1 P1 PUMP
C-2 P2 PUMP
E-1 P1-PSV
E-2 P2-PSV
D-1 P1-UL(BPC)
D-2 P2-UL(BPC)
D-3 S-TRAVEL
B-5 BUCKET DIG
B-6 BUCKET DUMP
G-3 ENG SPEED
POWER SHIFT

0.2 M
0.0 M
417 mA
417 mA
750 mA
750 mA
350 mA
0.0 M
0.0 M
1000
0 mA

Pump pressure sensor

Pump pressure sensor
Command current
Command current
Command current
Command current
Command current
Bucket digging pressure sensor
Bucket dump pressure sensor
Engine actual speed
Power shift current

NO.34 TRAVEL
C-1 P1 PUMP
C-2 P2 PUMP
E-1 P1-PSV
E-2 P2-PSV
D-1 P1-UL(BPC)
D-2 P2-UL(BPC)
D-3 S-TRAVEL
B-9 TRAVEL(R)
B-10 TRAVEL(L)
Pi-P1
Pi-P2
G-3 ENG SPEED
POWER SHIFT

0.2 M
0.0 M
417 mA
417 mA
750 mA
750 mA
350 mA
0.0 M
0.0 M
0.0 M
0.0 M
1000
0 mA

Pump pressure sensor

Pump pressure sensor
Command current
Command current
Command current
Command current
Command current
Travel right pressure sensor
Travel left pressure sensor
Pilot pressure at travel straight (P1 side)
Pilot pressure at travel straight (P2 side)
Engine actual rpm
Power shift current

NO.35 OPT
C-1 P1 PUMP
0.2 M
C-2 P2 PUMP
0.0 M
E-1 P1-PSV
417 mA
E-2 P2-PSV
417 mA
D-1 P1-UL(BPC)
750 mA
D-2 P2-UL(BPC)
750 mA
D-3 S-TRAVEL
350 mA
E-3 OPT RELIEF
110 mA
B-16 P1 OPT
0.0 M
B-17 P2 OPT
0.0 M
F-4 OPT SELECT
NIB
DOUBLE FLOW SW OFF
G-3 ENG SPEED
1000
POWER SHIFT
0 mA

Pump pressure sensor

Pump pressure sensor
Command current
Command current
Command current
Command current
Command current
Command current
P1 side option pressure sensor
P2 side option pressure sensor
Optional selector SOL (Nibbler line)
Conflux/ Single selector switch
Engine actual rpm
Power shift current
SM0152

3) Service diagnosis Mode No.3

No.
1

Displays
NO.1
MAIN CONT. P/N
YN22E00207F1
PROGRAM VERSION
1-VER 2.00
2-VER 0.00
SERVICE DIAG 3

41

NO.41 ADJUSTMENT 1
ENG
HI-IDLE
2230
PUMP
ACT I
515 mA
7 mA
PUMP P
35.0 M
ESS N
930
UN-LOAD
P1
565 mA
P2
565 mA
BOOM
0
0
ARM
0
0
OFFSET
0
0
INTER-B
0
0

Contents

No.
43

P/No. indication
Program version indication
MERIT controller program version
Service diagnosis mode 3

44
Engine speed high idle
Current at pump adjustment
Current correction at pump adjustment
Pressure at pump adjustment
Engine speed sensor rpm
P1 unload corrective current
P2 unload corrective current
Angle adjustment
Angle adjustment
Angle adjustment
Angle adjustment

Displays
NO.43 MACHINE-INFORM.
HOUR METER
3550
TRIP METER
3500
OPERATION
3300
TRAVEL
300
SWING
3000
HAMMER
100
CRANE
100
STARTER
1200

Contents
Hour meter of controller
Trip meter of controller
All accumulated operating time
All accumulated traveling time
All accumulated swing time
All accumulated breaker operating time
All accumulated high-reach crane operating time

All accumulated starter operating time

NO.44 MACHINE-INFORM.
PUMP PRESS.
TOTAL 10Hr
LEVEL1 24% 22%
LEVEL2 50% 50%
LEVEL3 25% 25%
LEVEL4 1 %
3%

Pump pressure distribution (%)

Total / In the last 10 hours
Total / In the last 10 hours
Total / In the last 10 hours
Total / In the last 10 hours

WATER TEMP.
TOTAL 10Hr
LEVEL1 24% 22%
LEVEL2 50% 50%
LEVEL3 25% 25%
LEVEL4 1 %
3%

Coolant temperature distribution (%)

Total / In the last 10 hours
Total / In the last 10 hours
Total / In the last 10 hours
Total / In the last 10 hours
SM0153

T2-1-33

E175B-E195B

MECHATRO CONTROL SYSTEM

3. Service diagnosis data list

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use these
data to decide normal/abnormal status.
The values in following display are reference values with standard attachment attached machine.
The value of pressure sensor is calculated taking variation into accounts. When compared to performance
check reference criteria, measure it with the aid of calibrated measuring instrument.
The current of proportional valve is not the measured value, but command value. The measured value
should be confirmed by the value in the displayed value for each proportional valve.
The current value of pump proportional valve is reference value because it varies according to pump
pressure and adjusted torque value.
The value in display during operation shows the value in steady state, rather than, at start of operation.
Check on machine after sufficiently warming up machine.
The value in display may differ according to software version. Contact our dealer/distributor.

Operation No.1 : No operation

H mode Hi idle

Operation No.2 : No operation

S mode Hi idle

No.32 ARM, SWING

No.32 ARM, SWING

C-1 P1-PRES

0.2~1.5 M

C-1 P1-PRES

0.2~1.5 M

C-2 P2-PRES

0.2~1.5 M

C-2 P2-PRES

0.2~1.5 M

E-1 P1-PSV

350 mA

E-1 P1-PSV

350 mA

E-2 P2-PSV

350 mA

E-2 P2-PSV

350 mA

D-1 P1-UL(BPC)

750 mA

D-1 P1-UL(BPC)

750 mA

D-2 P2-UL(BPC)

750 mA

D-2 P2-UL(BPC)

750 mA

D-3 S-TRAVEL

350 mA

D-3 S-TRAVEL

350 mA

D-6 ARM-IN-2

750 mA

D-6 ARM-IN-2

750 mA

B-3 ARM OUT

0.0 M

B-3 ARM OUT

0.0 M

B-4 ARM IN

0.0 M

B-4 ARM IN

0.0 M

B-1 BOOM RAISE

0.0 M

B-1 BOOM RAISE

0.0 M

B-7 SWING

0.0 M

B-7 SWING

0.0 M

G-3 ENG SPEED

POWER SHIFT

1970~2030

G-3 ENG SPEED

0 mA

POWER SHIFT

1770~1830
0 mA

Operation No.3 : Boom up in full lever operation & relief

H mode Hi idle

Operation No.4 : Boom up in full lever operation & in operation

H mode Hi idle

No.31 BOOM

No.31 BOOM

C-1 P1-PRES

33.0~35.8 M

C-1 P1-PRES

11.0~16.0 M

C-2 P2-PRES

33.0~35.8 M

C-2 P2-PRES

11.0~16.0 M

E-1 P1-PSV

415~525 mA

E-1 P1-PSV

560~750 mA

E-2 P2-PSV

415~525 mA

E-2 P2-PSV

560~750 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

B-1 BOOM RAISE

3.0 M

B-1 BOOM RAISE

3.0 M

B-2 BOOM LOWER

0.0 M

B-2 BOOM LOWER

0.0 M

G-3 ENG SPEED

POWER SHIFT

1970~2060

G-3 ENG SPEED

0 mA

POWER SHIFT
T2-1-34

1970~2060
0 mA

MECHATRO CONTROL SYSTEM

E175B-E195B

Operation No.5 : Boom down in full lever operation & in

operation
H mode Hi idle

No.31 BOOM
C-1 P1-PRES

12.5~16.0 M

C-2 P2-PRES

0.2~1.5 M

E-1 P1-PSV

600~617 mA

E-2 P2-PSV

350 mA

D-1 P1-UL(BPC)

427~477 mA

D-2 P2-UL(BPC)

750 mA

B-1 BOOM RAISE

0.0 M

B-2 BOOM LOWER

3.0 M

G-3 ENG SPEED

POWER SHIFT

1970~2060
0 mA

Operation No.6 : Arm-in in full lever operation & relief

H mode Hi idle

Operation No.7 : Arm-in in full lever operation & in operation

No.32 ARM, SWING

No.32 ARM, SWING

H mode Hi idle

C-1 P1-PRES

33.0~35.8 M

C-1 P1-PRES

12.5~16.5 M

C-2 P2-PRES

33.0~35.8 M

C-2 P2-PRES

12.5~16.5 M

E-1 P1-PSV

415~525 mA

E-1 P1-PSV

550~750 mA

E-2 P2-PSV

415~525 mA

E-2 P2-PSV

550~750 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

350 mA

D-3 S-TRAVEL

350 mA

D-6 ARM-IN-2

200 mA

D-6 ARM-IN-2

400 mA

B-3 ARM OUT

0.0 M

B-3 ARM OUT

0.0 M

B-4 ARM IN

3.0 M

B-4 ARM IN

3.0 M

B-1 BOOM RAISE

0.0 M

B-1 BOOM RAISE

0.0 M

B-7 SWING

0.0 M

B-7 SWING

0.0 M

G-3 ENG SPEED

POWER SHIFT

1970~2060

G-3 ENG SPEED

0 mA

POWER SHIFT

T2-1-35

1970~2060
0 mA

E175B-E195B

MECHATRO CONTROL SYSTEM

Operation No.8 :
Arm-out in full lever operation & relief
H mode Hi idle

Operation No.9 :
Arm-out in full lever operation & in operation
H mode Hi idle

No.32 ARM, SWING

No.32 ARM, SWING

C-1 P1-PRES

33.0~35.8 M

C-1 P1-PRES

15.0~22.0 M

C-2 P2-PRES

33.0~35.8 M

C-2 P2-PRES

15.0~22.0 M

E-1 P1-PSV

415~525 mA

E-1 P1-PSV

488~677 mA

E-2 P2-PSV

415~525 mA

E-2 P2-PSV

488~677 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

350 mA

D-3 S-TRAVEL

350 mA

D-6 ARM-IN-2

750 mA

D-6 ARM-IN-2

750 mA

B-3 ARM OUT

3.0 M

B-3 ARM OUT

3.0 M

B-4 ARM IN

0.0 M

B-4 ARM IN

0.0 M

B-1 BOOM RAISE

0.0 M

B-1 BOOM RAISE

0.0 M

B-7 SWING

0.0 M

B-7 SWING

0.0 M

G-3 ENG SPEED

1970~2060

POWER SHIFT

G-3 ENG SPEED

0 mA

1970~2060

POWER SHIFT

0 mA

* Measure the values after a lapse of 5 minutes or

after release of low temperature mode

* Measure the values after a lapse of 5 minutes or

after release of low temperature mode

Operation No.10 :
Swing in full lever operation & relief
H mode Hi idle

Operation No.11 :
Swing in full lever operation & in operation
H mode Hi idle

No.32 ARM, SWING

No.32 ARM, SWING

C-1 P1-PRES

0.2~1.5 M

C-1 P1-PRES

0.2~1.5 M

C-2 P2-PRES

28.0~35.8 M

C-2 P2-PRES

10.0~15.0 M

E-1 P1-PSV

350 mA

E-1 P1-PSV

350 mA

E-2 P2-PSV

528~750 mA

E-2 P2-PSV

750 mA

D-1 P1-UL(BPC)

750 mA

D-1 P1-UL(BPC)

750 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

350 mA

D-3 S-TRAVEL

350 mA

D-6 ARM-IN-2

750 mA

D-6 ARM-IN-2

750 mA

B-3 ARM OUT

0.0 M

B-3 ARM OUT

0.0 M

B-4 ARM IN

0.0 M

B-4 ARM IN

0.0 M

B-1 BOOM RAISE

0.0 M

B-1 BOOM RAISE

0.0 M

B-7 SWING

3.0 M

B-7 SWING

3.0 M

G-3 ENG SPEED

POWER SHIFT

1970~2060

G-3 ENG SPEED

0 mA

POWER SHIFT

T2-1-36

1970~2060
0 mA

MECHATRO CONTROL SYSTEM

E175B-E195B

Operation No.12 :
Bucket digging in full lever operation & relief
H mode Hi idle

Operation No.13 :
Bucket digging in full lever operation & in operation
H mode Hi idle

No.33 BUCKET

No.33 BUCKET

C-1 P1-PRES

33.0~35.8 M

C-1 P1-PRES

4.0~8.0 M

C-2 P2-PRES

33.0~35.8 M

C-2 P2-PRES

4.0~8.0 M

E-1 P1-PSV

415~525 mA

E-2 P2-PSV

415~525 mA

E-1 P1-PSV

650~750 mA

E-2 P2-PSV

540~563 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

720 mA

D-3 S-TRAVEL

720 mA

B-5 BUCKET DIG

3.0 M

B-5 BUCKET DIG

3.0 M

B-6 BUCKET DUMP

0.0 M

B-6 BUCKET DUMP

0.0 M

G-3 ENG SPEED

1970~2060

POWER SHIFT

G-3 ENG SPEED

0 mA

POWER SHIFT

1970~2060
0 mA

Operation No.14 :
Bucket dump in full lever operation & relief
H mode Hi idle

Operation No.15 :
Bucket dump in full lever operation & in operation
H mode Hi idle

No.33 BUCKET

No.33 BUCKET

C-1 P1-PRES

33.0~35.8 M

C-1 P1-PRES

C-2 P2-PRES

33.0~35.8 M

6.0~15.0 M

C-2 P2-PRES

6.0~15.0 M

E-1 P1-PSV

415~525 mA

E-1 P1-PSV

577~750 mA

E-2 P2-PSV

415~435 mA

E-2 P2-PSV

415~435 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

720 mA

D-3 S-TRAVEL

720 mA

B-5 BUCKET DIG

0.0 M

B-5 BUCKET DIG

0.0 M

B-6 BUCKET DUMP

3.0 M

B-6 BUCKET DUMP

3.0 M

G-3 ENG SPEED

POWER SHIFT

1970~2060

G-3 ENG SPEED

0 mA

POWER SHIFT

T2-1-37

1970~2060
0 mA

E175B-E195B

MECHATRO CONTROL SYSTEM

Operation No.16 :
P2 side option in full lever operation & relief
A mode Hi idle

Operation No.17 :
P2 side option in full lever operation & relief
B mode Hi idle

No.35 OPT

No.35 OPT

C-1 P1-PRES

22.5~26.0 M

C-1 P1-PRES

0.2~1.5 M

C-2 P2-PRES

22.5~26.0 M

C-2 P2-PRES

22.5~26.0 M

E-1 P1-PSV

459~584 mA

E-1 P1-PSV

500 mA

E-2 P2-PSV

459~584 mA

E-2 P2-PSV

665~750 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

750 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

720 mA

D-3 S-TRAVEL

350 mA

E-3 OPT RELIEF

0 mA

E-3 OPT RELIEF

0 mA

B-16 P1 OPT

0.0 M

B-16 P1 OPT

0.0 M

B-17 P2 OPT

2.0~2.6 M

B-17 P2 OPT

2.0~2.6 M

F-4 OPT SELECT

DOUBLE FLOW SW.
G-3 ENG SPEED
POWER SHIFT

NIB

F-4 OPT SELECT

ON

DOUBLE FLOW SW.

1970~2060

G-3 ENG SPEED

0 mA

POWER SHIFT

BRK
OFF
1970~2060
0 mA

* Conflux switch is ON. Relief set pressure is value

of shipping.

* Conflux switch is OFF. Relief set pressure is value

of shipping.

Operation No.18 :
Travel right in full lever operation & travel idling
H mode Hi idle

Operation No.19 :
Travel left in full lever operation & travel idling
H mode Hi idle

No.34 TRAVEL

No.34 TRAVEL

C-1 P1-PRES

5.0~12.0 M

C-1 P1-PRES

0.2~1.5 M

C-2 P2-PRES

0.2~1.5 M

C-2 P2-PRES

5.0~12.0 M

E-1 P1-PSV

750 mA

E-1 P1-PSV

350 mA

E-2 P2-PSV

350 mA

E-2 P2-PSV

750 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

750 mA

D-2 P2-UL(BPC)

750 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

350 mA

D-3 S-TRAVEL

350 mA

B-9 TRAVEL (R)

2.0~2.5 M

B-9 TRAVEL (R)

0.0 M

B-10 TRAVEL (L)

0.0 M

B-10 TRAVEL (L)

2.0~2.5 M

Pi-P1

0.0 M

Pi-P1

0.0 M

Pi-P2

0.0 M

Pi-P2

0.0 M

G-3 ENG SPEED

POWER SHIFT

1970~2060

G-3 ENG SPEED

0 mA

POWER SHIFT

T2-1-38

1970~2060
0 mA

MECHATRO CONTROL SYSTEM

3.4

E175B-E195B

TROUBLE HISTORY DIAGNOSIS

The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as
one of history. And the errors are able to be indicated on the multi display.

A part of warning contents is stored (the stored items are listed in warning table).
The error code for self diagnosis is stored.

1. How to display
1) Turn starter switch on.
2) Press buzzer stop switch continuously 5 times and the trouble history screen is displayed.

(Example)
No errors

NO ERROR

Error detected in the past

SM0154

3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
Hour meter and 4 failure data are displayed on screen.
In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
Press washer switch ( ) A, and the item moves upward.
Press wiper switch ( ), and the item moves downward.
5) Turn starter switch off, and the display is disappeared.
2. How to delete contents of trouble history
1)
2)
3)
4)

Display trouble history screen.

Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
When "NO ERROR" is displayed, the deletion is completed.
Turn starter switch off.

NOTE: all the stored items are erased. It is impossible to erase data partially.

T2-1-39

E175B-E195B
3.5

MECHATRO CONTROL SYSTEM

TROUBLE DIAGNOSIS MODE

The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be
detected through the use of self diagnosis function (the failure can be specified through the use of error code)
like disconnection and abnormal output. This is useful to save the time for troubleshooting.
1. Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are
automatically actuated, the sensor detects the machine status and the mechatro controller identifies
the normal condition or failed condition of the system.
For details of how to use, refer to Chapter: TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".

T2-1-40

MECHATRO CONTROL SYSTEM

3.6

E175B-E195B

SET PROCEDURE OF MAINTENANCE SCHEDULE

This machine is equipped with multi-display which allows confirmation of remaining time to the coming
replacement/change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the
remaining time reaches to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc.
and perform the initial setting by the following order.
NOTE: interval of replacement of parts is mentioned
below.

Screen change
switch

Buzzer stop
switch

KPSS work mode

select switch
Washer
switch

Engine oil : 500 Hr

Fuel filter : 500 Hr
Hydraulic filter : 1,000 Hr
Hydraulic oil : 5,000 Hr

Select
switch

Auto accel
switch

Travel speed
select switch

Wiper
switch
SM0155

Procedure

Operating Procedure

Display on Multidisplay
NEW HOLLAND

Turn starter key switch on.

KOBELCO

Press "
" switch press once display
change switch on the switch panel once. And
the clock display changes to the display of
remaining time for coming engine oil change.
Press "
" switch press once select
switch once and the display for the engine
oil change reverses.
When required to adjust the interval to the coming
change time by 10 hours, press "
" switch
and the time to the coming engine oil change is
added. Press "
" switch and the time to the
coming engine oil change is reduced.
When desired to return to the initial set time,
press "
" buzzer stop switch once.
Press "
" select switch once and the set
time is stored.

10:25
H

250 Hr
ENGINE OIL

250 Hr
ENGINE OIL

500 Hr
ENGINE OIL

After several seconds,

display is changed to
clock autmatically.

Press screen change

switch
once more.

Press select switch

once more.

Replacing interval is
changed with each
pressing of switch.

To set the desired interval,

press the select switch

10:25
H

250 Hr
ENGINE OIL

250 Hr
ENGINE OIL

500 Hr
ENGINE OIL

500 Hr
ENGINE OIL

H
SM0156

NOTE:
1. After displaying the display for setting by pressing the display change switch, set the respective
maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does
not sound.

T2-1-41

E175B-E195B
3.7

MECHATRO CONTROL SYSTEM

ADJUSTING PROCEDURE OF DISPLAY

1. For operator
1) Clock Adjustment Switches
No.

Switches

Screen Change Switch

Buzzer Stop Switch

Work Mode Select Switch

Washer Switch

Wiper Switch

Travel Speed Select Switch

Auto Accel Switch

Select Switch
Main screen

10:25

SM0140

(a)
SWITCH STATUS
CLOCK/CONTRAST

13:15

H
(a)

H
(b)

(c)
SWITCH STATUS
CLOCK/CONTRAST

(d)

(e)

ADJUST CLOCK
ADJ CONTRAST

Y M D H M
06 04 01 13 15

Select Year/Month/Day/Hour/Minute

Enter

Increase/Decrese
SM0157

1) Turn starter key switch on and display main screen (a) for operator, and then press select switch (8)
and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2) In operations of FEED
(4) and FEED
(5), move cursor to "CLOCK/CONTRAST" screen (c) and
then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4) Select any of "YMDHM" in operation of FEED
operations of FEED (6) and FEED (7).

(4) and FEED

(5) and vary the values in

5) After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting
is completed, and then the screen returns to main screen (a).

T2-1-42

MECHATRO CONTROL SYSTEM

2) Contrast Adjustment Switches

No.

E175B-E195B

Switches

Screen Change Switch

Buzzer Stop Switch

Work Mode Select Switch

Washer Switch

Wiper Switch

Travel Speed Select Switch

Auto Accel Switch

Select Switch
Main screen

10:25

SM0140

SWITCH STATUS
CLOCK/CONTRAST

H
(a)

(b)

(c)
SWITCH STATUS
CLOCK/CONTRAST

(d)

(a)

ADJUST CLOCK
ADJ CONTRAST

10:25
H

(e)
ADJUST CLOCK
ADJ CONTRAST

(f)
Enter

ADJ CONTRAST
55555

Adjustable range
11111~99999
(Default 55555)

Increase/Decrease
SM0158

1) Turn starter key switch on and display main screen (a), and press select switch (8) and display
"SWITCH STATUS CLOCK CONTRAST" select screen (b).
2) In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.
3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and
then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4) Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5) Vary the values by pressing the desired figure in operations of FEED (4) and FEED
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) 99999 (clear) * The initial set value is 55555.

(5).

6) Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).

T2-1-43

E175B-E195B

MECHATRO CONTROL SYSTEM

2. Function for service

Following items are provided for adjustment of service function.

LANGUAGE/LOGO
Function

Explanation

Range

All language data is stored in 15

one gauge cluster
languages

LANGUAGE

To change language

LOGO

To change Company Logo

Note

5 Logos

Default
ISO
NHK

ADJUSTING MODE 1
Function

Explanation

RISE-UP WIPER

Note

To change wiper control, when special

CAB is installed on demolition OFF is for special CAB
machine

Range
ON/OFF

Default
ON

P1 OPT SENSOR To activate the self-diagnosis when P1 Switch to ON when 2PB is

ON/OFF
ACTIVE
OPT pressure sensor is failed
installed

OFF (*)

P2 OPT SENSOR To activate the self-diagnosis when P2 Switch to ON when N&B

ON/OFF
ACTIVE
OPT pressure sensor is failed
option is installed

OFF (*)

PRIORITY MODE

Only for EU, to activate the priority

valve

ON/OFF

OFF

LEFT
ACTIVE

To use P1 option pedal for P4-rotation

circuit, releasing auto accel. And not
activating unload valve

ON/OFF

OFF

PEDAL

SELECT
SYSTEM

OPT

1:No selector valve

Switch to ON when N&B
2:Selector Valve + Mechanical relief
1 or 3
option is installed
3:Selector Valve + Electrical relief

1 or 3 (*)

ADJ
OVERLOAD To change the pressure for overload
PRESS
alarm in EU

10 - 27

18

ENG
DISPLAY

ON/OFF

OFF

SPEED To activate the engine

information for customer

speed

AUTO ACCEL

To change auto accel control type

START MODE

To change
(S,H,B,A)

the

starting

6, 8, 10, 12,
18
14, 16, 18

MODE X: return to default MODE

S, H, B, A, X S
when key sw is ON

To cancel the low temp. mode to

CANCEL
LOW
OFF = Low Temp. Mode
prevent hydraulic hunching at low
ON/OFF
TEMP MODE
ACTIVE
temp.

OFF

DRAIN
PRESS

OFF

HYD. To activate the

pressure function

drain

hydraulic When switch is ON, this

ON/OFF
function starts.

To adjust Pressure and Flow for

ADJ OPT HAMMER
Follow setting procedure
Hammer (9set)

20
35
15 Mpa (at
Pressure
220 L/min)
30 - 220
220 L/min
Flow rate

To adjust Pressure and Flow for

Follow setting procedure
Nibbler (9set)

20
35
15 Mpa (at
Pressure
220 L/min)
30 - 220
220 L/min
Flow rate

ADJ OPT NIBBLER

(*) Autodetect

T2-1-44

MECHATRO CONTROL SYSTEM

E175B-E195B

2.1 Setting the language

To modify the language, proceed as follows:
1. Keep BUZZER CUT-OFF button (1) pressed
and, at the same time, move the STARTER
SWITCH onto ON; the screen shows display
(A).

10:25

2. Keep BUZZER CUT-OFF button (1) pressed,

then press SELECT button (2) three times; the
screen shows display (B).
3. Press SELECT button (2); the screen shows
display (C) indicating the symbol of the language
previously set, for example: ENG (English).
4. Press WIPER button (3) or WINDSHIELD
WASHER button (4), once or more until the
symbol of the desired language is displayed, for
example FRA (French); the screen shows
display (D).

1
4
5
3

5. Press SELECT button (2) to memorize the

language selected, the screen shows display
(E). At this stage, the language is selected and
after about three seconds returns automatically
to display (B).
To exit the program, move the STARTER
SWITCH onto OFF.

SM0069

NO. 1

(A)
List of the languages available:

MAIN CONT. P/N

YN 22E 00207 F1
PROGRAM VERSION
1 VER 2.00
2 VER 0.00
SERVICE DIAG 1

EU (ISO icons only)

ITA

(B)

USA

LANGUAGE/LOGO
ADJUSTING MODE 1
PRESET BY FACTORY

CHN
IDN
THA

SELECT LANGUAGE

ESP

(C)

FRA

ENG
FEED

DEU
VNM

MYS

MMR
TAM

SELECT LANGUAGE

POR

(D)

ENG

FRA
FEED

JPN

SELECT LANGUAGE

(E)

FRA
FEED
SM0070

T2-1-45

E175B-E195B

MECHATRO CONTROL SYSTEM

2.2 Setting Adjusting Mode 1

NO. 1

To enter the displays Adjusting Mode 1 proceed as

follows:
1. Keep BUZZER CUT-OFF button (1) pressed
and, at the same time, move the STARTER
SWITCH onto ON; the screen shows display
(A)
2. Keep BUZZER CUT-OFF button (1) pressed,
then press SELECT button (2) three times; the
screen shows display (B).
3. Press WINDSHIELD WASHER button (3) to get
ADJUSTING MODE 1, the screen shows display
(C).

(A)

MAIN CONT. P/N

YN 22E 00207 F1
PROGRAM VERSION
1 VER 1.00
2 VER 0.00
SERVICE DIAG 1

x3

1
(B)

LANGUAGE/LOGO
ADJUSTING MODE 1
PRESET BY FACTORY

(C)

4. By pressing SELECT button (2) you enter the

Adjusting Mode 1 functions; the first function is
shown on the screen, display (D).
To enter the other functions, actuate WIPER
button (3), to move forward or WINDSHIELD
WASHER button (4), to return back.

LANGUAGE/LOGO
ADJUSTING MODE 1
PRESET BY FACTORY

11
RISE-UP WIPER
ON

(D)

FEED

2.3Adj. Overload Press (tip-over momentum

device)

SM0071

To modify the value of the pressure at which the

pressure sensor goes ON to operate the tip-over
momentum device, proceed as follows:
1. In function Adjusting Mode 1, display (C), press
SELECT button (2) to enter the functions and
use WIPER button (3), to select function 63 ADJ OVERLOAD PRESS on display (E).

(C)
2

2. Press SELECT button (2) to choose the number

relative to the setting pressure, display (F).
18 = 180 bar

63

(E)

3. Press WINDSHIELD WASHER button (4), to

increase the pressure, or WIPER button (3), to
decrease it.
4. Set the desired pressure value (for example: 11),
display (G), press SELECT button (2) to
memorise it.
By pressing SCREEN CHANGE button (5) you
return to display (C).
To exit the program, move the STARTER
SWITCH onto OFF.

LANGUAGE/LOGO
ADJUSTING MODE 1
PRESET BY FACTORY

ADJ OVERLOAD PRESS

18

FEED

63

(F)

ADJ OVERLOAD PRESS

18

FEED

4
63

(G)

ADJ OVERLOAD PRESS

11

FEED

63
ADJ OVERLOAD PRESS
11

FEED

5
SM0073

T2-1-46

MECHATRO CONTROL SYSTEM

E175B-E195B

2.4 Drain Hyd. Press

To drain the hydraulic pressure from the system,
proceed as follows:
1. In function Adjusting Mode 1, display (C), press
SELECT button (2) to enter the functions and
using WIPER button (3), select on the display
function DRAIN HYD. PRESS, display (H).

(C)

LANGUAGE/LOGO
ADJUSTING MODE 1
PRESET BY FACTORY

2. Press SELECT button (2) to show the writing

OFF, display (I).

(H)

3. Press WINDSHIELD WASHER button (4) to

activate function ON, display (L).

DRAIN HYD PRESS

OFF

FEED

4. Press SELECT button (2) and start the engine.

The screen shows display (M). At this point, with
the engine in operation, actuate the pilot valves
performing all the movements so that the
pressure is drained from all the actuators.
The function is automatically deactivated by
returning the STARTER SWITCH onto OFF.

(I)

DRAIN HYD PRESS

OFF

FEED

4
NOTE: if the monitor displays FAIL DRAIN HYD
PRES. this means that the pressure draining
operation has not been performed correctly. In this
case, repeat the operation.

(L)

DRAIN HYD PRESS

ON

FEED

10:25

(M)

PR

S
SM0072

T2-1-47

E175B-E195B
3.8

MECHATRO CONTROL SYSTEM

MECHATRO CONTROL EQUIPMENT

1. C-1 Mechatro controller

1) Outside view
2 1

10

2 1

22

18

4 2 1 8

16
26
34
27
CN101
CN105

CN102

16 12
CN103

28

22

CN104

CN106
CN107
CN108
CN109
21 7
2 16
21 9
21 7
21

21

10

31

22

16

24

17

12

17

28
10 22
13 19
20
15 16

SM0159

2) List of connectors
Connector No.

Pin No.

Port name

CN101

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

GA
A1
+5VA
+5VA
A2
GA
GA
A3
+5VA
+5VA
A4
GA
GA
A5
+5VA
+5VA
A6
GA
TXD1
RXD1
GP
SHG1
TXD3
RXD3
DL
GP
CANH1
CANL1
DO 20
DO 21
DO 22
DO 23
DO 24
DI 36

Function

Input/putput

Boom up

Input

Boom down

Input

Arm in

Input

Arm out

Input

Bucket digging

Input

Bucket dump

Input

Gauge cluster

Transmission

Down load

Transmission

Reception

Reception

Spare
Spare
Safety relay
Spare
Extra pressure release
Spare
Heavy lift

Output
Output
Output
Output
Output
Input

Signal level
0V
0.5~4.5V
Power output 5V
Power output 5V
0.5~4.5V
0V
0V
0.5~4.5V
Power output 5V
Power output 5V
0.5~4.5V
0V
0V
0.5~4.5V
Power output 5V
Power output 5V
0.5~4.5V
0V
RS232C communication
RS232C communication
0V
Shield GND
RS232C communication
RS232C communication
EARTH / OPEN(5V
0V
CAN communication
CAN communication
EARTH/OPEN
EARTH/OPEN
EARTH/OPEN
EARTH/OPEN
EARTH/OPEN
EARTH/OPEN
SM0160

T2-1-48

MECHATRO CONTROL SYSTEM

Connector No.
CN102

Connector No.
CN103

Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Port name
GA
A8
+5VA
+5VA
A9
GA
GA
A10
+5VA
+5VA
A13
GA
GA
A14
+5VA
+5VA
A27
GA
GA
A28
+5VA
D1 37

Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Port name
GA
A
+5VA
+5VA
A11
GA
GA
A12
+5VA
+5VA
A15
GA
GA
A16
+5VA

Function

E175B-E195B

Input/putput

Travel right

Input

Travel left

Input

Accelation

Input

P1 option

Input

P2 option

Input

Spare

Input

Spare

Input

Spare

Input
Function

Input/putput

Swing

Input

P1 pump

Input

P2 pump

Input

Boom angle

Input

Arm angle

Input

Reserved

Signal level
0V
0.5~4.5V
Power output 5V
Power output 5V
0.5~4.5V
0V
0V
0.5~4.5V
Power output 5V
Power output 5V
0.5~4.5V
0V
0V
0.5~4.5V
Power output 5V
Power output 5V
0.5~4.5V
0V
0V
0.5~4.5V
Power output 5V

GND / OPEN

Signal level
0V
0.5~4.5V
Power output 5V
Power output 5V
0.5~4.5V
0V
0V
0.5~4.5V
Power output 5V
Power output 5V
0.5~4.5V
0V
0V
0.5~4.5V
Power output 5V
SM0161

T2-1-49

E175B-E195B

Connector No.
CN104

Connector No.
CN105

MECHATRO CONTROL SYSTEM

Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

Port name
GA
A17
+5VA
+5VA
A18
GA
GA
A19
+5VA
+5VA
A20
GA
A21
GA
A22
GP
A23
GA
GA
A24
+5VA
+5VA
A25
GA
GA
A26
+5VA
DI 1

Pin No.
1
2

Port name
+24V
+24V

3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

+24V
DO 7
DO 8
DO 9
DO 11
GND
GND
D10+
D1+
D1D2+
D2D3+
D3D4+
D4D5+
D5GND
D10D6+
D6D7+
D7D8+
D8D9+
D9+24V

Function

Input/putput

Signal level
0V
0.5~4.5V
Power output 5V
Power output 5V
0.54.5V
0V
0V
0.5~4.5V
Power output 5V
Power output 5V
0.5~4.5V
0V

Boom head (Over load)

Input

Spare

Input

Extra pressure source

Input

Spare

Input

Engine coolant
temperature

Input

Resistor

Fuel level

Input

Resistor

Spare

Input

Resistor

Selector detection

Input

Extra pressure source

Input

Spare

Input

Starting point of accel motor

Input

Function

Input/putput

Battery relay output side

Battery relay output side

Output
Swing P/B select valve
Output
Travel 1,2 speed select valve Output
Attachment boost select valve Output
Battery (-)
Battery (-)
OPT changeable relief 1
Output
P1 unload
Output
Travel 1,2 speed select valve

P2 unload

Output

Travel straight

Output

Arm in

Output

P1 pump

Output

Battery (-)
OPT changeable relief 1
P2 pump

Output
Output

Spare

Output

Spare

Output

Spare

Output

Battery direct connection

0V
0.5~4.5V
Power output 5V
Power output 5V
0.5~4.5V
0V
0V
0.5~4.5V
Power output 5V
GND / OPEN
Signal level
20~32V
20~32V
20~32V
24V/OPEN
24V/OPEN
24V/OPEN
24V/OPEN
0V
0V
+0~800mA
+0~800mA
-0~800mA
+0~800mA
-0~800mA
+0~800mA
-0~800mA
+0~800mA
-0~800mA
+0~800mA
-0~800mA
0V
-0~800mA
+0~800mA
-0~800mA
+0~800mA
-0~800mA
+0~800mA
-0~800mA
-0~800mA
+0~800mA
20~32V
SM0162

T2-1-50

MECHATRO CONTROL SYSTEM

Connector No.
CN106

Connector No.
CN107

Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Port name
+24V
SHGF
F1+
F1F2+
F2OIL
OILG
D11+
D11D12+
D12D13+
D13D14+
D14GND
D12+
D12E1+
E1SHG3
CANH2
CANL2

Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Port name
DI 3
DI 8
DI 9
DI 10
DI 11
DI 12
DI 13
DI 14
DI 15
DI 20
DI 28
DI 32
DI 38
DI 39
DI 40
DI 41

Function
Battery relay secondary side

E175B-E195B

Input/putput

Oil level (spare)

Output
Output
Output
Output
0

OPT changeable relief 2

Output

Spare

Output

Bypass valve

Output

Spare

Output

Battery (-)
Spare

Output

Accel motor A phase

Accel motor A phase
Accel motor B phase
Accel motor B phase

E/G speed sensor

Input

Proportional vlave expand unit

Input/putput
Function
Grid heater feedback
Input
Engine coolant temperature
Input
Input
E/G oil pressure
Air filter
Input
Spare
Input
Spare
Input
E/G coolant level
Input
Spare
Input
Spare
Input
Heater temperature of fuel filter
Input
Spare
Input
Hand control nibbler
Input
Quick coupler
Input
Spare
Input
Heater temperature
Input
Spare
Input
Reserved

Signal level
20~32V
Shield GND
1.5A
1.5A
1.5A
1.5A

+0~800mA
-0~800mA
+0~800mA
-0~800mA
+0~800mA
-0~800mA
+0~800mA
-0~800mA
0V
+0~800mA
-0~800mA
XX~XXVp-p
0V
Shiled GND
CAN communication
CAN communication
Signal level
+24V/OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
EARTH / OPEN
SM0163

T2-1-51

E175B-E195B

Connector No.
CN108

MECHATRO CONTROL SYSTEM

Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

Connector No.
CN109

Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Port name

DI 2
DI 4
DI 5
DI 6
DI 7
DI 16
DI 17
DI 18
DI 19
DI 21
DI 22
DI 23
DI 24

DI
DI
DI
DI
DI

25
26
27
29
30

GP
DI 33
DI 34
DI 35
H1+
H2H2+
H2Port name

DO 1
DO 2
DO 3
DO 4
DO 5
DO 6
DO 12
DO 13
DO 14
DO 15
DO 16
DO 17
DO 18
DO 19
GP
TXD2
RXD2
RTS
CTS
SHG2
DO 10

Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input

Signal level
+24V / OPEN
+24V / OPEN
GND / OPEN
+24V / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
+24V / OPEN
+24V / OPEN
+24V / OPEN
GND / OPEN

Front window open or close

Spare
Conflux/single select
Overload select
Spare
Reserved

Input
Input
Input
Input
Input

GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN

Charge
Spare
Spare
Reserved
Spare

Input
Input
Input

~12V / 12V~
+24V / OPEN
+24V / OPEN

Function
Key switch (ON)
Water separator
Swing P/B release
E/G start
Spare
Wiper rise up
Wiper reverse
ATT boost
Spare
Spare
Spare
Lever lock
Hand control rotation

Input/putput

0~5V
0V
0~5V
0V

Spare
Function
Wiper arc prevention
Wiper normal moving
Wiper reserve moving
Washer motor
Spare
Reserved
Spare
Swing flasher (RH)
Swing flasher (LH)
Travel alarm
Auto idle stop relay
Engine stop
Lever lock
Grid heater
Reserved

Input/putput

Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output

Signal level
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
GND / OPEN
0V

Tranmission RS232C communication

Spare

Spare

Reception RS232C communication

RS232C communication
RS232C communication
Shiled GND
24V/OPEN
SV
SM0164

T2-1-52

MECHATRO CONTROL SYSTEM

E175B-E195B

2. Gauge cluster (symbol C-2)

1) General view

4. BUZZER
1. MULTI
DISPLAY LCD

2. COOLANT

TEMPERATURE

GAUGE
FUEL LEVEL
GAUGE

MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2

5. SCREEN
CHANGE
SWITCH ETC.
6. BUZZER STOP SWITCH

7. WORK MODE SWIHCH

SM0165

2) Connector CN-600 (Harness side)

No.

Item name

Wire color

No.

Item name

Wire color

Gauge cluster Mechatro

controller
(RS232C
communication)

White

GND source (+24V Battery

direct connection)

Yellow /
Black

Mechatro controller Gauge

cluster
(RS232C
communication)

Red

GND

Black

Source (+24V starter switch

ON)

White

GND
communication)

Black

(RS232C

3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller,
displays them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
4) Summary of display and drive item
No.

Item

Remarks

Monitor display

LCD dot 120168

Gauge display (Coolant temp., Fuel level)

Stepping motor

Buzzer

Screen change switch

Buzzer stop switch

Work mode select switch

Piezo-electricity type

T2-1-53

E175B-E195B

MECHATRO CONTROL SYSTEM

3. Relay & fuse box (symbol E-1)

1) General view

(Overhead view of box)

LABEL

INSIDE
Note) These circles indicate the parts
which are used in standard specification

14

CN2-1

20

14

12

CN2-2

20

CN4-1

17

11

22

10

CN5

15

26

13

13

CN3-2

12

16

24

12
CN8

17

CN3-1

26

13

1
CN9

20

12

1
CN2-3
3

CN15

3 CN12

CN1

CN14

CN4-2

1
CN17

CN16

CN13
6

2
1

6
2

CN10

LOCATION OF CONNECTORS (Seen from backside)

LOCATION OF RELAY & FUSE

LABEL OF RELAY & FUSE BOX

No. CODE IN CIRCUIT

PARTS NAME

SM0166

T2-1-54

MECHATRO CONTROL SYSTEM

E175B-E195B

2) Circuit diagram

SM0167

T2-1-55

E175B-E195B

MECHATRO CONTROL SYSTEM

SM0168

T2-1-56

MECHATRO CONTROL SYSTEM

E175B-E195B

SM0169

T2-1-57

E175B-E195B

MECHATRO CONTROL SYSTEM

4) High pressure sensor : YN52S00048P1

SPECIFICATION :

ECONOSEAL SERIES MARK(+)>

3POLES CAP
MATING HOUSING174357-2

PRESSURE RANGE : 0

50 MPa

POWER SOURCE VOLTAGE : 5.0+0.5V DC

OUTPUT : 1/10Vs-9/10Vs

COMMON

(Vs=5V DC 0.5

OUTPUT (+)

INSURANCE RESISTANCE : 100M

POWER SOURCE (+)

PLASTIC POTTING

(BETWEEN CASING AND ALL IN/OUT

TERMINAL

TERMINALS AT 50V DC MEGGER)

CONDENSER

DIE

ELECTRIC CONNECTING DIAGRAM

CASING

FLEXIBLE BOARD
CIRCUIT

OR MORE

HOUSING

COVER

(Ex. Construction of internal controller)

DIAPHRAGM

O-RING P14
JIS B2401 CLASS1B
PF 3/8
Tightening torgue
73.5N.m (54.2lbf.ft)

4.5V DC)

PIPE
THREAD

STRUCTURE

SM0170

5) Low pressure sensor : YX52S00013P1

Tightening torgue

Vout

29.434.3N.m (21.725.3lbf.ft)
PF1/4

Vcc

GND

ELECTRIC CONNECTING DIAGRAM

(Ex. Construction of internal controller)

SPECIFICATION :
PRESSURE RANGE : 0

3.0 MPa

RATED VOLTAGE : 5.0+0.5V DC

OUTPUT CHARACTERISTIC

INSURANCE RESISTANCE : 50M

OR MORE

(BETWEEN BODY AND EACH TERMINAL AT

50V DC MEGGER)

SM0171

T2-1-58

HYDRAULIC SYSTEM

E175B-E195B

1. SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety, mass
volume handling and low fuel consumption.

1-2 travel speed change and low speed / high

torque at heavy duty

Auto parking brake

Automatic braking when parking

Motor overrun protection

Prevents overrunning of travel motor on the

Travel pilot operation

Prevents hunting by the built in travel

Reverse rotation protective function

Easy positioning to protect it from swinging

back when stops swinging.

Swing priority circuit

(simultaneous operation of arm in and swing
motions)

Easy operation of stable swing speed, arm

slanted leveling, swing press digging

Automatic swing parking brake

Swing parking brake when operating at on a

slope

Hydraulic pilot control system

Light action with operating lever

Pilot safety lock system

Cut out of pilot circuit by safety lock lever.

Lock valve (boom / arm)

Protect boom and arm from unexpected drop

(Natural fall).

Holding valve for boom (Option)

Prevention of boom falling when boom head

side piping breaks

manual

valve

for

lowering

Pump

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

speed return

Device

Attachment

Travel straight at combined operation

Mass handling capability

Performance

Micro
computer

Swing
Attachment

Features

Travel straight

Emergency
attachment

Others

Easy operability and safety

Function

Low fuel
consumption

Device

Travel

Performance

Function

Features

Electric flow controlled variable displacement

pump

Pump delivery rate control by a current

command to the solenoid proportional valve
of the variable displacement pump

Positive flow rate control

Flow control by positive pilot control pressure

Hydraulics backup control

Backup control by hydraulic when the electric

flow controlled variable displacement pump
fails.

Boom up conflux circuit

Speed up of boom up operation

Arm conflux circuit

Speed up of arm operation

Bucket conflux circuit

For speed-up of bucket operation (digging &

dump)

Optimum operation by work mode select

(H,S,A,B)

Efficient operation in all work modes

Auto accel

Reduce fuel consumption and noise by

lowering engine speed when control lever is
in neutral position.

For safety, this valve lowers risen attachment

to the ground, if the machine stops with
engine trouble, and the pressure in the
cylinder of attachment can be released.

Pressurized hydraulic oil tank

To prevent hydraulic oil from entering dust

and to promote self suction ability of pump

Suction strainer

Remove dust on suction side.

Line filter; pilot circuit

To prevent pilot
malfunctioning

Return circuit oil filter

To prevent hydraulic oil from contamination

Cooling hydraulic oil by oil cooler

To prevent hydraulic oil from being deteriorated.

Pressure draining circuit

To release the main circuit pressure for piping

repair work.

Main control valve with optional valve

Optional piping and additional work are easy

Switching of return line for N&B machine in

the cab (Option)

Switching of return line for N&B machine is

able to change with a switch in the cab

operating

circuit

from

T2-2-1

E175B-E195B

HYDRAULIC SYSTEM

2. HYDRAULIC CIRCUITS AND COMPONENTS (E175B)

HYDRAULIC DIAGRAM READING KEY
Item

T2-2-2

Component name

Hyd. pump assy

Control valve (main)

Swing motor unit

Travel motor unit

Boom cylinder (RH & LH)

Arm cylider

Bucket cylinder

Swivel joint

Pilot valve (ATT)

10

Pilot valve (travel)

11

Inline filter

12

Suction strainer

13

Solenoid valve assy

14

Return filter

15

Air breather

16

Restrictor

17

Shuttle valve

18

Short-circuit valve

19

Low pressure sensor block

HYDRAULIC SYSTEM

E175B-E195B

HYDRAULIC CIRCUIT (MONOBLOCK VERSION) (E175B)

4

18
3

11
15

14
19

12
9
17

7
6

10

16
16
13

SM1262

T2-2-3

E175B-E195B

HYDRAULIC SYSTEM

2. HYDRAULIC CIRCUITS AND COMPONENTS (E195B)

HYDRAULIC DIAGRAM READING KEY
Item

T2-2-4

Component name

Hyd. pump assy

Control valve (main)

Swing motor unit

Travel motor unit

Boom cylinder (RH & LH)

Arm cylider

Bucket cylinder

Swivel joint

Pilot valve (ATT)

10

Pilot valve (travel)

11

Inline filter

12

Suction strainer

13

Solenoid valve assy

14

Return filter

15

Air breather

16

Restrictor

17

Shuttle valve

18

Short-circuit valve

19

Low pressure sensor block

HYDRAULIC SYSTEM

E175B-E195B

HYDRAULIC CIRCUIT (MONOBLOCK VERSION) (E195B)

4

18

11
15

14
19

12
9
17

7
6

10

16
16
13

SM1263

T2-2-5

E175B-E195B

HYDRAULIC SYSTEM

3. N&B HYDRAULIC CIRCUIT (OPTION)

N&B HYDRAULIC CIRCUIT READING KEY

Item

Component name

50

Selector valve

51

Stop valve

52

Pilot valve

53

Overload relief valve

The hydraulic circuit for N&B is used to add to

standard circuit
Selection condition and proportional valve
command when any of nibbler single & conflux flow
or breaker in service.
SELECTION

Conflux/single flow
changeover switch

Electromagnetic
command signal of
selector valve (50)
(W:O, W/O: -)

Conflux flow of
nibbler

Conflux ON

Single flow of
nibbler
Breaker

P1
Pump

P2
Pump

Travel
Straight

P1
Unload

P2
Unload

Conflux OFF

Conflux OFF

When using nibbler, according to specification of

nibbler installed.
Adjust overload relief valve (53) of optional port to
customize specification ordinary set pressure.

T2-2-6

Command signal of solenoid proportional valve

(W:O, W/O: -)

HYDRAULIC SYSTEM

E175B-E195B

N&B HYDRAULIC CIRCUIT

51

53
52

53

50

SM1264

T2-2-7

E175B-E195B

HYDRAULIC SYSTEM

4. HOLDING VALVE FOR BOOM & ARM

(OPTION)
HOLDING VALVE FOR BOOM
The holding valve for boom prevents the boom
falling in case of head side cylinder piping breaks.
HOLDING VALVE FOR ARM
The holding valve for arm prevents the arm falling in
case of rod side cylinder piping breaks.

HYDRAULIC CIRCUIT READING KEY

Item

T2-2-8

Component name

54

Holding valve for boom cylinders

55

Holding valve for arm cylinder

HYDRAULIC SYSTEM

E175B-E195B

HOLDING VALVE FOR BOOM & ARM HYDRAULIC CIRCUIT

54

54

55

SM1265

T2-2-9

E175B-E195B

HYDRAULIC SYSTEM

5. POSITIONING CIRCUIT
(TRIPLE ARTICULATION VERSION)
HYDRAULIC POSITIONING CIRCUIT READING
KEY
Item

Component name

56

P1 OPT valve

57

Holding valve for positioner cylinder

58

Positioner cylinder

59

Positioning pilot valve

OPERATION
When the operation for positioning is performed, the
pilot proportional secondary pressure is delivered
through port A of the positioning pilot valve (59) and
flows to PAo1 port of the P1 OPT valve (56) then,
the spool of P1 OPT valve (56) is switched. The
pressure oil by P1 pump is supplied to (R) side of
positioner cylinder (58) through Ao1 port of P1 OPT
valve (56). On the other hand, the return oil from (H)
side of positioner cylinder returns to the tank circuit
thorough Bo1 port of P1 OPT valve (56).
The holding valve (57) prevents the positioning
falling in case of rod side cylinder piping breaks.

T2-2-10

HYDRAULIC SYSTEM

E175B-E195B

POSITIONING CIRCUIT (TRIPLE ARTICULATION VERSION)

57

R
POSITIONING
CYLINDER

58

59

56

SM1266

T2-2-11

E175B-E195B

6. COLOR CODING STANDARD FOR

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

HYDRAULIC SYSTEM

7. NEUTRAL CIRCUIT

7.3 PUMP POSITIVE FLOW CONTROL

This section describes the following.

7.1 Bypass cut valve and unload valve control
7.2 Safety lock lever and pilot circuit
7.3 Pump positive flow control
7.4 Pump P-Q (Pressure-Quantity) curve control

(1) Type:
Electric flow controlled variable displacement
pump.

7.1 OPERATION OF BY-PASS CUT VALVE AND

UNLOADING VALVE HOUSED IN CONTROL
VALVE

(3) Operation:

(1) By-pass cut valve

On starting engine, P1 and P2 unloading
proportional valves (PSV-D, PSV-B) output
secondary pressure according to the command
output by mechatro controller, and this pressure
exerts on PBp1 and PBp2 ports, and
consequently the by-pass cut spool is switched
to CLOSE side.
The by-pass cut spool is usually held on CLOSE
side after the engine started. And it is switched
to OPEN side only when failure occurred on
pump proportional valve and mechatro
controller.
(2) Unloading valve
On starting engine, like by-pass cut valve, the
secondary pressures output by P1 and P2
unloading proportional valves (PSV-D, PSV-B)
exert on PCb and PCa ports, consequently the
P1 and P2 unloading valves are switched to
OPEN side.
7.2 SAFETY LOCK LEVER AND PILOT CIRCUIT
(1) Purpose:
To protect attachment
movement for safety.

from

unexpected

(2) Principle:
Cut pressure source of pilot valve for operation.
(3) Operation:
If the safety lock lever (red) is pushed forward
after the engine starts, the limit switch (SW-11)
is turned on. The timer relay is actuated one
second later which causes the solenoid (SV-4)
of the solenoid valve block (13) to be energized
and makes the pilot operating circuit to stand by.

T2-2-12

(2) Principle:
The current command I to the pumps solenoid
proportional valve controls the delivery rate of
the pump.
1) Flow rate rise operation (Eg. P1 pump)
By operating any of control levers, the
operating secondary pressure of pilot valve
rises, and the rising pressure is transformed
to the rise of output voltage corresponding
to the pressure input by the low pressure
sensor.
Mechatro
controller
signalprocesses this change of voltage, resulting
in rise of command current value I to the
pump proportional solenoid valve and
consequently the pump flow rate rises. This
is called "Positive Control System".
As the pump command current value rises,
the secondary pressure of proportional
solenoid valve also rises. On the regulator
attached on the pump, the spool (652)
through piston (643) is pushed rightward,
and stops at the position where being in
proportion to the force of pilot spring (646).
The tank port connected to the large bore of
servo piston (532) opens, and the piston
moves leftward by delivery pressure P1 of
the small bore resulting in the increase of tilt
angle ( ).
The servo piston (532) and spool (652) are
connected to feedback lever (611).
Therefore when servo piston moves
leftward, the spool (652) also moves
rightward by means of feedback lever. With
this movement, the opening of spool sleeve
closes gradually, and the servo piston stops
at the position the opening closed
completely.
2) Flow rate reduction operation
As the current value I of mechtro controller
reduces, the secondary pressure of
solenoid proportional valve reduces, and
spool (652) is moved leftward by the force of
pilot spring (646). With the movement of
spool, the delivery pressure P1 usually flows
into the large bore of piston through the
spool.
The delivery pressure P1 flows in the small
bore of servo piston, but the servo piston
moves rightward due to the difference of
area, resulting in the reduction of tilt angle.
Similarly, when the servo piston moves
rightward, the spool (652) is moved leftward
by the feedback lever.

The operation is maintained until the

opening of spool sleeve is closed.

7.4 PUMP P-Q CURVE CONTROL OPERATION

(1) Type:
Electrical flow control type variable pump
(2) Principle:
Perform an operation of the value from pump
high pressure sensor to P-Q curve control value,
and send a command to the pump solenoid
proportional valve.
(3) Operation:
The pump high pressure sensor converts the
pressure to the output voltage corresponding to
the pump delivery pressure.
The mechatro controller converts the voltage
output by the high pressure sensor to the P-Q
curve control value. On the other hand, select
the pump positive control command current
value from the low pressure sensor in lower
order, and the values are output to respective
pump proportional valve as a command current.
With this operation, the pump power is
controlled so as not to be exceed the engine
power, therefore engine dose not stall.

HYDRAULIC SYSTEM

E175B-E195B

NEUTRAL CIRCUIT: Positive control function at safety lock lever down (unloked position)
4

18

652

651

646

643

611
532

11
15

14

19
12
9

17

7
6

10

16
16
13

SM1267

T2-2-13

E175B-E195B

HYDRAULIC SYSTEM

8. TRAVEL CIRCUIT
This section describes the following.
8.1 Travel forward pilot simultaneous operation
circuit
8.2 2 speed travel solenoid command circuit and
auto 1-speed return function
8.3 Travel main circuit
8.4 Travel motor function
8.1 TRAVEL FORWARD PILOT
SIMULTANEOUS OPERATION CIRCUIT
(1) Purpose:
Light operating force and shockless operation
(2) Mechatronics :
1) If the travel lever with damping mechanism
is operated for travel right, left and forward
motions, the secondary pilot proportional
pressure comes out of the 3, 1 ports of P/V
(10). The higher of the pressures is
selected, comes out of the 6, 5 ports and
acts upon the low pressure sensors (SE-9)
(SE-10).
2) The pilot secondary pressure flows to PAr
and PAL ports of the control valve (2),
moves the travel spool, and switches the
main circuit.
3) The low pressure sensor output voltage is
input into mechatro controller. The mechatro
controller performs signal processing and
outputs current corresponding to the
increase of flow rate to P1 pump
proportional valve (PSV-P1) and P2 pump
proportional valve (PSV-P2), and at the
same time the command current is output to
P1 unloading valve (PSV-D) and P2
unloading valve (PSV-B).
4) The secondary pressures output by P1
pump proportional valve (PSV-P1) and P2
pump proportional valve (PSV-P2) exert on
pump regulator, actuating the pump on the
delivery flow rate increase side.
5) The secondary pressure delivered in P1
unloading valve (PSV-D) and P2 unloading
valve (PSV-B) is fed to PBp1, PCb, PBp2
and PCa ports provided in control valve (2).
The secondary pressure from proportional
valve which has exerted on PBp1 and PBp2
ports holds the by-pass cut spool on CLOSE
side, like the operation in the lever neutral
position.
The secondary pressure from proportional
valve which has exerted on PCb and PCa
ports switches the unloading spool in
CLOSE side.

T2-2-14

8.2 2-SPEED TRAVEL SOLENOID COMMAND

CIRCUIT AND AUTO 1st SPEED RETURN
FUNCTION
1) Purpose:
Change travel motor speed with switch.
(2) Principle:
If the switch is turned, an electric signal is
issued. It excites the 2-speed travel solenoid
which in turn converts the primary pilot pressure
and the self pressure to a tilting angle of the
variable displacement motor.
(3) Operation:
If the rabbit marked switch on the gauge cluster
is pressed, the solenoid (SV-3) of the
proportional valve block (13) is excited and
changes the proportional valve. Then the
solenoid command pressure is issued from port
A3, enters the Ps port of the travel motor (4),
opens the oil passage to the 2nd speed select
piston, and causes the motor to run in the 2nd
speed tilting mode by its self pressure.
However, when the main circuit pressure rises
above 27.3 MPa (3960 psi) (E175B) and 28 MPa
(4060 psi) (E195B), the motors self pressure
pushes the 2nd speed select piston back to the
1st speed.
8.3 TRAVEL MAIN CIRCUIT
(1) Operation:
The delivery oil from Pump A1 and A2 ports by
changing the travel spool with the operation of
travel pilot flows into P1 port on the left side
motor (4) and P2 port on the right side motor (4)
through C,D ports of swivel joint (8) from AL, AR
ports of C/V, and rotates the travel motor.
8.4 TRAVEL MOTOR FUNCTION
(1) Function:
1) Prevents the motor from over running on a
slope.
2) Check valve that prevents cavitation of the
hydraulic motor.
3) Shockless relief valve and anti cavitation
valve when inertia force stops.
4) High/Low 2 step speed change mechanism
and auto 1st speed return at high load.
5) Travel parking brake.

HYDRAULIC SYSTEM

E175B-E195B

TRAVEL CIRCUIT: Travel 2nd speed, RH & LH simultaneous operation.

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SM1268

T2-2-15

E175B-E195B

HYDRAULIC SYSTEM

9. BUCKET CIRCUIT
This section describes the following.
9.1
9.2
9.3
9.4
9.5

Bucket digging pilot circuit

Auto accel operation
Flow control in the work mode
Bucket digging travel priority main circuit
Bucket spool stroke limiter

9.1 PILOT CIRCUIT FOR BUCKET DIGGING

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

T2-2-16

5) The secondary pressure delivered in travel

priority proportional valve (PSV-C) is led to
PTb port provided in control valve (2) and
shifts the travel priority valve one stage.
9.2 AUTO ACCELERATION OPERATION
(1) Principle:
Auto acceleration actuates according to signals
from low pressure sensor.
(2) Operation:
<When lever is set to neutral position>
In the event where the sensor does not receive
signal for 4 seconds or more even though the
acceleration dial is set to MAX position, the
engine speed should be raised to 1050 rpm.
<When lever is operated>
When the pressure 0.6MPa (87psi) is input to
low pressure sensor in STD specification (travel,
bucket, swing, arm), proportional voltage from
low pressure sensor inputs in mechatro
controller, and then the engine speed returns to
the dial set position corresponding to the lever
operation.
9.3 FLOW CONTROL IN THE WORK MODE
(1) Principle:
When the engine speed is intermediate speed
or lower, command current value to have the
pump delivery rate constant is output.
(2) Operation:
Even if the engine speed specified by
acceleration potentiometer is low speed, as the
delivery rate corresponds to the intermediate
speed, the actuator moves earlier than the
movement equivalent to the control lever angle
rate in light load operation.
9.4 BUCKET DIGGING AND TRAVEL PRIORITY
CONFLUENCE (CONFLUX) MAIN CIRCUIT
(1) Operation:
1) The oil delivered through A1 port of P1
pump goes into P1 port of C/V (2), opens
load check valve LCc through parallel circuit
and enters in bucket spool.
2) On the other hand, the oil delivered through
A2 port of P2 pump goes into P2 port of C/V
(2), confluences with oil from P1 pump
through travel priority valve, and goes into
bucket spool. (Confluence of oil from 2
pumps)
3) 3)With the function of pilot circuit, the oil flow
is switched from bucket spool, and is fed into
bucket cylinder head side through Ac port of
C/V (2). On the other hand, the return oil
from cylinder rod (R) side is throttled by

bucket spool and returns to tank circuit from

Bc port of C/V (2).
References:
In bucket dumping operation, the travel
priority valve also switches like digging
operation, resulting in confluence with travel
straight.
When the bucket operation and other
operation are simultaneously performed, the
travel priority valve does not actuate,
resulting in single flow of bucket circuit.
9.5 BUCKET SPOOL STROKE LIMITER
(1) Purpose:
To secure simultaneous operability of boom and
arm on boosting up attachment pressure (Pump
flow rate decreases.) and to prevent cavitations
at low engine speed
(2) Operation:
On boosting up attachment pressure, pilot
primary pressure exerts on PCc port of C/V(2)
through attachment booster solenoid valve,
operates stroke limiter of bucket spool, and
throttle oil path of spool. As a result, P1 pump
pressure increases, making the simultaneous
operation of boom up and bucket digging
possible.
Even though the engine speed is low, similarly
the cavitations can be prevented by actuating
the stroke limiter.

HYDRAULIC SYSTEM

E175B-E195B

BUCKET CIRCUIT: Bucket digging (Travel priority conflux), Auto-accelation and Standby flow rate constant control
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SM1269

T2-2-17

E175B-E195B

HYDRAULIC SYSTEM

10. BOOM CIRCUIT

This section describes the boom raise conflux
operation.
10.1 Boom up pilot circuit
10.2 Boom up 2 pumps conflux main circuit in C/V
10.1 BOOM RAISE PILOT CIRCUIT
(1) Operation:
1) If boom up operation is performed, the
secondary pilot proportional pressure from
the right pilot valve (9) gets out of port 4 and
acts upon the low pressure sensor (SE3). At
the same time, the pressure acts upon the
PAb and PB1 ports.
2) The secondary pressure which enters the
PAb port of C/V (2) shifts the boom spool.
The secondary pressure which enters the
PB1 port shifts the boom conflux spool.
10.2 BOOM UP 2 PUMPS CONFLUX MAIN
CIRCUIT IN C/V
(1) Purpose:
Boom up speed up
(2) Principle:
Confluxing oil from 2 pumps
(3) Operation:
1) The oil delivered through A1 port of P1
pump flows into C/V (2) P1 port, and
branches into bypass circuit and parallel
circuit. Since P1 unloading valve is closed,
the boom spool is moved and bypass circuit
is closed, the oil opens load check valve
LCb through parallel circuit and flows into
boom spool.
2) Then the oil passes through boom spool,
opens lock valve of boom lock valve CRb,
and is led into (H) side of boom cylinder
through C/V (2) Ab port.
3) Meanwhile, the oil delivered from the A2
port of the P2 pump enters the P2 port of C/
V (2) and due to shut off the P2 unloading
valve, the oil then passes through the
parallel circuit and via the restrictor on the
circumference of the boom conflux spool,
pushes the load check valve CCb open from
the boom conflux circuit, and combines the
oil delivered by the P1 pump internally.
4) The return oil from boom cylinder (R) side
flows into tank circuit through boom spool
from C/V (2) Bb port.

T2-2-18

HYDRAULIC SYSTEM

E175B-E195B

BOOM CIRCUIT : Boom up operation, Confluence function.

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SM1270

T2-2-19

E175B-E195B

HYDRAULIC SYSTEM
This section describes boom lower operation.
10.3 Boom down pilot circuit
10.4 Prevention of natural fall by lock valve and
actuation at lowering
10.5 Constant recirculation function of boom down
main circuit
10.3 BOOM DOWN PILOT CIRCUIT
(1) Operation:
1) If the boom down operation is performed,
the secondary pilot proportional pressure
comes out of port 2 of the right pilot valve (9)
and acts upon the low pressure sensor (SE4).
At the same time, the pressure acts upon
the PBb port of C/V (2).
2) The voltage output of the low pressure
sensor (SE-4) enters the mechatro
controller and processed in it.
3) Then, the proportionl secondary pressure
fed into C/V (2) PBb port and branches off in
two lines and switches boom spool and
releases boom lock valve.
10.4 PREVENTION OF NATURAL FALL BY LOCK
VALVE AND ACTUATION AT LOWERING
(1) Purpose:
Prevention of natural fall when the lever is
neutral
(2) Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation:
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line
on the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from
making a natural fall.

T2-2-20

10.5 CONSTANT RECIRCULATION FUNCTION

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

HYDRAULIC SYSTEM

E175B-E195B

BOOM CIRCUIT: Boom down operation & Prevention of natural boom falling.
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SM1271

T2-2-21

E175B-E195B

HYDRAULIC SYSTEM

11. SWING CIRCUIT

This section describes the following operations.
11.1 Swing left pilot circuit
11.2 Swing auto parking brake
11.3 Swing main circuit
11.4 Swing motor circuit
11.1 PILOT CIRCUIT FOR LEFT SWING
(1) Operation:
1) When the left swing operation is performed,
the pilot proportional secondary pressure is
delivered through port (1) of left pilot V (9),
and the secondary pressure acts on PBs
port of C/V (2), and simultaneously flows out
from Pss port of C/V and acts on low
pressure sensor (SE-5).
2) The voltage output by the low pressure
sensor is input in the mechatro controller,
and is signal-processed.
3) Then, the secondary pressure led into PBs
port of C/V (2) switches the swing spool.
11.2 SWING AUTO PARKING BRAKE
(1) Purpose:
Swing lock in neutral position and parking
(2) Principle:
Release mechanical brake only when required
to operate swing and arm in.
(3) Operation:
1) The swing parking system excites the swing
parking SOL (SV-1) usually if the key switch
is turned on and works by the action of the
mechanical brake.
2) The mechanical brake is released if the
swing parking solenoid is de-excited only
when the secondary operating pressure in
the swing and arm in actions acts upon any
of the low pressure sensors (SE-5, 7).
3) The swing parking solenoid (SV-1) is excited
five seconds after the pressure of the swing
low pressure sensors (SE-5) is reduced to
zero.
In the case of arm in operation, the swing
parking solenoid (SV-1) is excited the
moment the pressure of the arm in low
pressure sensor (SE-7) is reduced to zero.
This causes the mechanical brake to
operate.
11.3 SWING MAIN CIRCUIT
(1) Operation:
The oil delivered from the A2 port of the P2
pump enters the P2 port of C/V (2) and is
branched off into the bypass line and the parallel
circuit. However, since the bypass line is closed
T2-2-22

as the swing spool is shifted, the oil pushes the

load check valve LCs open through the parallel
circuit, enters the B port of the swing motor via
the Bs port of C/V (2), and rotates the swing
motor counterclockwise.
11.4 SWING MOTOR CIRCUIT
(1) Anti cavitation circuit at swing deceleration
(2) Shockless relief valve that prevents the swing
motor from being reversed.

HYDRAULIC SYSTEM

E175B-E195B

SWING CIRCUIT: Swing operation (LH)

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SM1272

T2-2-23

E175B-E195B

HYDRAULIC SYSTEM

12. ARM CIRCUIT

This section describes the following operations.
12.1 Arm in, light-load operating pilot circuit
12.2 Arm in, light-load variable normal recirculation
main circuit / internal conflux main circuit
12.1 ARM IN, LIGHT-LOAD OPERATING PILOT
CIRCUIT
(1) Purpose:
Speed-up and Anticavitation when the arm is at
light loaded.
(2) Principle:
The oil returning from the arm cylinder rod (R) is
recirculated variably to the head (H) at arm 2
spool in C/V.
(3) Operation:
1) When the arm in operation is performed, the
secondary pilot proportional pressure gets
out of port 4 of the left pilot valve (9) and acts
upon the low pressure sensor (SE-7).
At the same time, the pressure is branched
off in two flows, acts upon the PAa1 port and
the PLc2 port, changes over the arm spool
and the arm lock valve CRar releases.
2) The output voltage by the low pressure
sensor is input into mechatro controller, and
is pilot signal-processed, and is output to
P1, P2 pump proportional valve (PSV-P1),
(PSV-P2) and arm 2 inverse proportional
valve (PSV-A).
3) The secondary pressure from pilot
proportional valve, which is reduced by arm
2 inverse proportional valve (PSV-A)
switches arm 2 spool.
12.2 ARM-IN, LIGHT-LOAD VARIABLE NORMAL
RECIRCULATION, INTERNAL CONFLUX
MAIN CIRCUIT
(1) Operation:
1) The P2 pump delivery oil flows in travel left
section through P2 port of C/V (2) and is
branched off in by-pass circuit and parallel
circuit, but because arm 1 spool is switched,
the delivery oil which goes through parallel
circuit opens load check valve LCa and is
flowed into arm 1 spool.
2) On the other hand, P1 pump delivery oil
flows in P1 port of C/V (2), and the flows in
travel straight section and travel right
tandem path. Then because arm 2 spool
was switched, the delivery oil opens load
check valve LCAT2, goes through arm 2
spool, and confluences with P2 pump
delivery oil in the valve section, and then is
flowed into arm cylinder head (H) side
through Aa port of C/V (2).
T2-2-24

3) The return oil from arm cylinder (R) side

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

Normal recirculation position

From arm 2 inverse

proportional valve

From arm out P/V

Neutral position
(Anticavitation position)

SM1394

Reference:
In light-load arm-in operation (normal
recirculation, conflux), when the attachment
to which the circuit in P1 pump side is
applied is operated, the meter-in path of arm
2 spool is closed, resulting in single flow
operation.
Spool position at arm in, light load and combined operation
(This position is not shown in hydraulic diagram)
Arm 2 spool

Normal recirculation opsition

Meter-in passage (Close)

Neutral position

SM1395

HYDRAULIC SYSTEM

E175B-E195B

ARM CIRCUIT: Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function
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SM1273

T2-2-25

E175B-E195B

HYDRAULIC SYSTEM
This section describes the following operations.
12.3 Arm in, heavy load operating pilot circuit
(recirculation cut)
12.4 Arm in, heavy load operating sequence
confluxed main circuit

4) The return oil returns directly into tank circuit

because arm 2 spool is switched to
recirculation cut position.
Position of arm 2 spool
Recirculation cut position

From arm out P/V

12.3 ARM IN, HEAVY LOAD OPERATING PILOT

CIRCUIT
(1) Operation:
1) 1)In arm-in operation, when the heavy
loading is applied to arm and the P2 pump
pressure increases to the set pressure, the
voltage output by P2 pump pressure sensor
(SE-23) is converted to signal (signal
processing)
by
mechatro
controller,
consequently the current of arm 2 solenoid
proportional valve is controlled according to
the load pressure and the arm variable
recirculation is cut.
When the recirculation is cut, internal
confluence is held similarly to that in light
load operation.
2) Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.

12.4 ARM IN, HEAVY LOAD OPERATING

RECIRCULATION CUT MAIN CIRCUIT
(1) Purpose:
Speed up for arm in operation
(2) Principle:
Cut the recirculation and reduce rod pressure.
(3) Operation:
1) P2 pump delivery oil flows in the travel left
section through P2 port of C/V (2) and
branched off in by-pass circuit and parallel
circuit. Consequently the arm spool is
switched and pushes and opens load check
valve LCa through parallel circuit, and flows
in the arm spool.
2) On the other hand, P1 pump delivery oil
flows in P1 port of C/V (2), and flow in travel
right tandem passage through travel straight
section. Then because arm 2 spool was
switched, the delivery oil opens load check
valve LCAT2, and confluences with P2
pump delivery oil in the valve section, and is
flowed into arm cylinder head (H) side
through Aa port of C/V(2).
3) The return oil from arm cylinder (R) side
flows in Ba port of C/V(2) and is flowed to
arm lock valve CRar, but because the arm
lock valve CRar is open, the return oil goes
through arm lock valve CRar and flows in
arm 2 spool.
T2-2-26

From arm 2 inverse

proportional valve

Neutral position
SM1396

HYDRAULIC SYSTEM

E175B-E195B

ARM CIRCUIT: Arm in (Heavy load) operation, Arm confluence & recirculation cut function
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SM1274

T2-2-27

E175B-E195B

HYDRAULIC SYSTEM
This section describes the following operations.
12.5 Arm out pilot circuit
12.6 Arm out 2 pumps conflux main circuit
12.7 Natural fall protection with arm lock valve
12.5 ARM OUT PILOT CIRCUIT
(1) Operation:
1) When the arm out operation is performed,
the secondary pilot proportional pressure
gets out of port 8 of the left pilot valve (9),
and acts upon the low pressure sensor (SE8). At the same time, the oil is branched off
in two flows and act upon the PBa1 and
PBa2 ports of C/V (2).
2) The operating proportional secondary
pressure flowed in PBa1 port of C/V (2)
switches the arm 1 spool.
3) Then, the operating secondary pressure
flowed in PBa2 port of C/V (2) switches the
arm 2 spool valve.
12.6 ARM OUT 2 PUMPS CONFLUX MAIN
CIRCUIT
(1) Purpose:
Arm out operation speed up.
(2) Principle:
The oil delivered by the P1 pump is confluxed
with that delivered by the P2 pump in C/V (2).
(3) Operation:
1) P1 pump delivery oil opens load check valve
(LCAT2) by switching arm 2 spool and
confluxes with P2 pump delivery oil just
short of the arm lock valve.
2) And, P2 pump delivery oil flows through arm
1 spool and confluences with P1 delivery oil,
opens lock valve of arm lock valve CRar with
free flow and is flowed into arm cylinder rod
(R) side through Ba port of C/V(2).
3) On the other hand, the return oil from arm
cylinder (H) side flows in Aa port, and
returns into tank circuit through arm 1 spool
and arm 2 spool.
The return line which does not pass through
boost check valve is used for this return
circuit to reduce the pressure loss.

T2-2-28

12.7 NATURAL FALL PROTECTION WITH ARM

LOCK VALVE
(1) Purpose:
To prevent the arm from falling naturally by the
weight of the arm and bucket.
(2) Principle:
Complete seat of the return circuit against the
arm spool of the arm cylinder (R) side circuit.
(3) Operation:
1) When the secondary pressure for arm
operation disappears and the arm cylinder
stops, the pressure on the rod (R) side
passes through the selector of the lock valve
from the Ba port of C/V, acts the back
pressure on the lock valve CRar and seats
the lock valve.
2) Since the oil flow into the arm spool from the
lock valve is shut off completely, natural fall
of the arm due to oil leaks through the arm
spool is prevented.

HYDRAULIC SYSTEM

E175B-E195B

ARM CIRCUIT: Arm out operation, Confluence function

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SM1275

T2-2-29

E175B-E195B

HYDRAULIC SYSTEM

13. COMBINED CIRCUIT

This section describes only the difference in
combined operation.
13.1 Boom up / travel, pilot circuit
13.2 Boom up / travel, main circit
13.1 BOOM UP / TRAVEL, PILOT CIRCUIT
(1) Operation:
<Operation: Different point of pilot circuit from
independent operation >
1) The mechatro controller outputs command
current
to
travel
priority
solenoid
proportional valve (PSV-C) and to shortcircuit solenoid proportional valve (PSV-R)
after signal processing.
And the solenoid proportional valve outputs
secondary pressure and acts on PTb port
and short-circuit valve.
2) Then the pressure of PTb port switches the
travel priority valve. And the secondary
pressure of solenoid valve in short-circuit
valve switches spool of short-circuit valve 1
step.
13.2 BOOM UP / TRAVEL, MAIN CIRCUIT
(1) Purpose:
To insure straight travel movement during travel
operation even if the attachment is operated.
(2) Principle:
The travel action and the attachment action are
actuated by separate pumps.
(3) Operation:
1) P1 pump delivery oil flows through P1 port of
C/V(2) and branches off in P1 parallel circuit
and spool of short-circuit valve.
P2 pump delivery oil flows through P2 port of
C/V(2) and branches off in P2 tandem circuit
and spool of short-circuit valve.
2) The delivery oil flowed into P1 parallel circuit
of P1 pump opens check valve CT1 and
LCb and flows in boom spool, which exerts
on boom up operation.
The delivery oil flowed into travel priority
spool of P1 pump opens check valve CT2
because the travel priority spool is shifted,
and flows in boom conflux spool and exerts
on boom up operation with the internal oil
conflux.
(In travel straight operation, P1 pump
delivery oil exerts on operation of
attachment.)
3) The delivery oil flowed into P2 tandem circuit
of P2 pump flows in left travel spool to travel
leftward.
The delivery oil flowed into travel priority
spool of P2 pump flows in right travel spool
T2-2-30

because the travel straight spool is shifted

and exerts on the right travel operation.
(In travel straight operation, P2 pump
delivery oil exerts on travel operation.)
4) However, a portion of the flow is led to the
spool of short-circuit valve notch restriction.
The speed of attachments like travel, boom,
etc. is adjusted by the circuit of restriction.

HYDRAULIC SYSTEM

E175B-E195B

COMBINED CIRCUIT: Boom up & Travel forward 1st speed operation, Travel priority function.
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SM1276

T2-2-31

E175B-E195B

HYDRAULIC SYSTEM
In this section, the independent operation is omitted
and describes difference in combined operation.
13.3 Swing / Arm in light load, pilot circuit
13.4 Swing / Arm in, swing priority main circuit

Position of arm 2 spool

Position of forced recirculation
Meter-in passage
(Close)

Arm 2 spool

13.3 SWING / ARM IN LIGHT LOAD, PILOT

CIRCUIT
(1) Operation:
1) On operating swing (left) and arm in motions
simultaneously, mechatro controller outputs
command current to travel priority solenoid
proportional valve (PSV-C) and arm 2 (PSVA) solenoid inverse proportional valve
according to signal processing, and this
proportional valve outputs secondary
pressure, which acts on PTb port and PAa2
port of C/V(2).
2) PTb port pressure switches the travel
priority spool, and the PAa2 port pressure
switches the arm 2 spool to the forced
recirculation position.
13.4 SWING / ARM IN, SWING PRIORITY MAIN
CIRCUIT
(1) Purpose:
Stable swing speed.
(2) Principle:
Raise the oil pressure flowing to arm cylinder,
and give a priority of the delivery of P2 pump to
swing operation.
(3) Operation:
1) The swing main circuit operates with P2
pump flow. But on P2 pump circuit side, the
flow goes to the swing circuit and arm circuit
simultaneously because the swing circuit
and arm circuit are parallel. Then since the
return oil from arm cylinder rod (R) side is
restricted in the arm 2 spool because the
arm 2 spool is switched to forced
recirculation position, the pressure of return
oil is raised, causing the rise of circuit
pressure on the arm cylinder head (H) side.
2) At the same time meter-in of arm 2 spool
closes and arm in conflux is therefore
cancelled, and delivery oil from P2 pump
and P1 pump are combined in the parallel
circuit on P2 pump side because the travel
straight spool was switched.
The conflux oil of P1 and P2 delivery oil in
high pressure flows in swing side taking
priority over all others.
This operation is called "Swing Priority
Circuit".

T2-2-32

From arm 2
inverse
proportional valve

Neutral position

From
arm out
P/V

Normal recirculation position

SM1392

HYDRAULIC SYSTEM

E175B-E195B

COMBINED CIRCUIT: Swing / Arm in operation, swing priority function

4

18

11
15

14
19

12
9
17

7
6

10

16
16
13

SM1393

T2-2-33

E175B-E195B

HYDRAULIC SYSTEM

14. PRESSURE DRAINING (RELEASING)

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

T2-2-34

14.2 PRESSURE RELEASING MAIN CIRCUIT

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

HYDRAULIC SYSTEM

E175B-E195B

PRESSURE DRAINING (RELEASING) CIRCUIT: at pressure release mode

4

18

11
15

14

19
12
9

17

7
6

10

16
16
13

SM1397

T2-2-35

E175B-E195B

T2-2-36

HYDRAULIC SYSTEM

ELECTRICAL SYSTEM

E175B-E195B

ELECTRICAL SYSTEM MAIN COMPONENTS

ELECTRICAL SYSTEM (Overall system)

F
B

D
D

A - Cab Control
B - Mechatro Controller and Fuse&Relay box
C - Batteries, Batteries Relay, Fuse link

SM1251

D - Hydraulic System Electrical Components

E - Engine Electrical Components
F - Light, Horn, ect

T2-3-1

E175B-E195B

ELECTRICAL SYSTEM

A - CAB CONTROL
Electrical components

10

2
16

3
4
14
5

13
12

11

7
8

15

9
17

SM1252

1 - Cluster gauge
2 - Power Boost switch
3 - Starter switch
4 - Engine speed throttle
5 - Work lights switch
6 - Single/Double flow switch
7 - Heavy Lift switch (opt.)
8 - Load momentum switch (opt.)
9 - Cigarette lighter

10 - Hour meter
11 - Climate controls panel
12 - Quick coupling switch (opt.)
13 - Tuner
14 - Cab work lights switch (opt.)
15 - Parking brake release switch
16 - Horn switch
17 - KPSS switch

T2-3-2

ELECTRICAL SYSTEM

E175B-E195B

Cluster Gauge

SM0003

1 - Coolant temperature indicator

2 - Fuel level indicator
3 - Screen change button
4 - Select button
5 - Auto-Idle button
6 - Work Mode button

7 - Windshield washer button

8 - Wiper button
9 - Buzzer cut-off button
10 - Travel speed button
11 - Display

T2-3-3

E175B-E195B

ELECTRICAL SYSTEM

Cluster gauge wiring harness

10
12

14

VIEW I

15
16

13

5
4

17

19

10
a-a

20

b-b

DETAIL a-a

c-c

11
I

7
E

8
W

Br

18

VIEW E

DETAIL c-c
DETAIL b-b
1 - Starter switch (SW-1)
2 - Engine speed throttle (SE-16)
3 - Work light switch (SW-55)
4 - Single/Double flow switch (SW-15)
5 - Heavy Lift switch (SW-35) (opt.)
6 - Over load alarm select switch (SW-12) (opt.)
7 - (opt.)
8 - Cigarette lighter (E-14)
9 - Cluster gauge (C-2)
10 - Starter switch (GND) (SW-1)

SM0098

11 - Wiper motor (M-3)

12 - 12 V socket (E-23)
13 - Speaker right (E-9)
14 - Connector for cab work light (SW-26)
15 - Connector for room light (L-5)
16 - Connector for wiper interlock switch (SW-19)
17 - Speaker left (E-8)
18 - Hour meter (E-3)
19 - Connector with A label (CN-5F)
20 - Connector with B label (CN-6F)

T2-3-4

ELECTRICAL SYSTEM

E175B-E195B

B - MECHATRO CONTROLLER AND FUSES&RELAY BOX

SM1253

1 - Mechatro Controller Unit (C-1)

2 - Fuse & Relay box (E-1)
3 - DC-DC Converter (E-22)

T2-3-5

E175B-E195B

ELECTRICAL SYSTEM

Fuse & Relay box

FUSES

SM0008

FUSES BOX

FUSES BOX

FUSE No.

PROTECTED CIRCUIT

Rating
(A)

FUSE No.

PROTECTED CIRCUIT

Rating
(A)

FUSE 1

Cab Work Light

20

FUSE 19

Air Conditioner

FUSE 2

Cab Work Light

20

FUSE 20

Work Light

20

FUSE 3

Monitor

FUSE 21

DC-DC Converter

10

FUSE 4

Wiper , Washer

20

FUSE 22

Opt.8 (Bucket Control)

FUSE 5

Option 1

20

FUSE 23

Opt.8 (Roof Wiper)

15

FUSE 6

Option 3

20

FUSE 24

Option

20

FUSE 7

Air Conditioner

15

FUSE 25

Safety Look Lever

10

FUSE 8

Air Conditioner

FUSE 26

Mechatro Controller

FUSE 9

Opt. (Hand Control)

FUSE 27

Mechatro Controller

20

FUSE 10

Relay, Hour Meter

FUSE 28

Engine Controller (ECU)

15

FUSE 11

Cigarette Lighter

10

FUSE 29

Engine Controller (ECU)

15

FUSE 12

Horn, Horn Relay

10

FUSE 30

Monitor (Back Up)

FUSE 13

Radio

10

FUSE 31

Fuel Supply Pump

15

FUSE 14

Starter Key Switch

20

FUSE 32

Mechatro Contr. (Back Up)

FUSE 15

Room Lamp, Tuner

FUSE 33

Spare

FUSE 16

Opt.2 (Auto Grease)

10

FUSE 34

Spare

10

FUSE 17

Option 4

10

FUSE 35

Spare

15

FUSE 18

Solenoid Valve

10

FUSE 36

Spare

20

T2-3-6

ELECTRICAL SYSTEM

E175B-E195B

RELAYS

SM0009

1 - Window washer motor relay (RLY 32)

2 - Wiper motor reversing relay (RLY 30)
3 - Cab working light relay (RLY 9)
4 - Cab working light relay (RLY 11)
5 - Working light relay (RLY 6)
6 - Alternator relay (RLY 28)
7 - Auto-Idle stop relay (RLY 24)
8 - Lever look relay (RLY 26)
9 - Auto-Idle stop relay (RLY 23)
10 - Engine emergency stop relay (RLY 25)
11 - Horn relay (RLY 5)
12 - Nibbler close relay (RLY 16)
13 - Reserve relay (RE-RLY 1)
14 - Reserve relay (RE-RLY 2)
15 - Wiper motor relay (RLY 31)

16 - Wiper motor relay (RLY 29)

17 - Discharge pressure relay (RLY 17)
18 - Grease (forward) relay (RLY 27)
19 - Grease (reverse) relay (RLY 35)
20 - Safety relay (RLY 4)
21 - Bucket control relay (RLY 10)
22 - Travel alarm relay (RLY 8)
23 - Revolution right relay (RLY 12)
24 - Nibbler open relay (RLY 15)
25 - Revolution left relay (RLY 13)
26 - Reserve relay (RE-RLY 5)
27 - Reserve relay (RE-RLY 6)
28 - Reserve relay (RE-RLY 4)
29 - Reserve relay (RE-RLY 3)

T2-3-7

E175B-E195B

ELECTRICAL SYSTEM

C - BATTERIES, BATTERIES RELAY, FUSES LINK

6
3
1

SM1254

1 - Batterie relay (R-1)

2 - Fuse Link 1, 2, 3, 4 (E-25)
3 - Starter motor relay (R-2)
4 - Fuel filter heater relay (R-40)

5 - Batteries (E-12)
6 - Pre-Heater relay (R-3)
7 - Fuse Link 5 (E-26)

Fuses located into radiators compartment

Fuse No.

Protected circuit

Value (A)

FUSE 1

Fuses powering (1 6)

60

FUSE 2

Fuses powering (17 - 32)

60

FUSE 3

Alternator

100

FUSE 4

Starter relay, fuel heater filter relay

60

FUSE 5

Fuses powering (10 - 15)

60

T2-3-8

ELECTRICAL SYSTEM

E175B-E195B

D HYDRAULIC SYSTEM ELECTRICAL COMPONENTS (E175B)

14

26

27

28
15
2

1
30

29

13

16
17
18
19

12
5

11

9
10

25

24

23

22

21

20
SM1255

1 - Extra valve selector press sensor (SE-29) (opt.)

2 - Pomp P2 proportional solenoid valve (PSV-P2)
3 - Pump P1 proportional solenoid valve (PSV-P1)
4 - Swing sensor (SE-5)
5 - Lever lock solenoid valve (SV-4)
6 - Power boost solenoid valve (SV-2)
7 - P2 Unload proportional solenoid valve (PSV-B)
8 - Travel priority prop. solenoid valve (PSV-C)
9 - P1 Unload proportional solenoid valve (PSV-D)
10 - Arm 2 inverse prop. solenoid valve (PSV-A)
11 - Two speed select solenoid valve (SV-3)
12 - Swing parking brake solenoid valve (SV-1)
13 - Short-circuit proportional solenoid valve (PSV-R)
14 - Extra dis-press solenoid valve (SV-11) (opt)
15 - Extra dis-press sensor (SE-28) (opt)

16 - P1 opt. sensor valve (SE-20)

17 - Travel right sensor (SE-9)
18 - Travel left sensor (SE-10)
19 - P2 Opt. sensor valve (SE-11)
20 - Bucket digging sensor (SE-1)
21 - Bucket dump sensor (SE-2)
22 - Boom raising sensor (SE-3)
23 - Boom lowering sensor (SE-4)
24 - Arm in sensor (SE-7)
25 - Arm out sensor (SE-8)
26 - Pump P1 sensor (SE-22)
27 - Pump P2 sensor (SE-23)
28 - Relief adjustment prop. solenoid valve 1 (PSV-E)
29 - Relief adjustment prop. solenoid valve 2 (PSV-I)
30 - Selector E&N solenoid valve (SV-13)

T2-3-9

E175B-E195B

ELECTRICAL SYSTEM

D HYDRAULIC SYSTEM ELECTRICAL COMPONENTS (E195B)

14

28
15
13

1
30

29

27

26
16
17
18
19

12

11

10

25

24

23

22

21

20
SM1256

1 - Extra valve selector press sensor (SE-29) (opt.)

2 - Pomp P2 proportional solenoid valve (PSV-P2)
3 - Pump P1 proportional solenoid valve (PSV-P1)
4 - Swing sensor (SE-5)
5 - Lever lock solenoid valve (SV-4)
6 - Power boost solenoid valve (SV-2)
7 - P2 Unload proportional solenoid valve (PSV-B)
8 - Travel priority prop. solenoid valve (PSV-C)
9 - P1 Unload proportional solenoid valve (PSV-D)
10 - Arm 2 inverse prop. solenoid valve (PSV-A)
11 - Two speed select solenoid valve (SV-3)
12 - Swing parking brake solenoid valve (SV-1)
13 - Short-circuit proportional solenoid valve (PSV-R)
14 - Extra dis-press solenoid valve (SV-11) (opt)
15 - Extra dis-press sensor (SE-28) (opt)

16 - P1 opt. sensor valve (SE-20)

17 - Travel right sensor (SE-9)
18 - Travel left sensor (SE-10)
19 - P2 Opt. sensor valve (SE-11)
20 - Bucket digging sensor (SE-1)
21 - Bucket dump sensor (SE-2)
22 - Boom raising sensor (SE-3)
23 - Boom lowering sensor (SE-4)
24 - Arm in sensor (SE-7)
25 - Arm out sensor (SE-8)
26 - Pump P1 sensor (SE-22)
27 - Pump P2 sensor (SE-23)
28 - Relief adjustment prop. solenoid valve 1 (PSV-E)
29 - Relief adjustment prop. solenoid valve 2 (PSV-I)
30 - Selector E&N solenoid valve (SV-13)

T2-3-10

ELECTRICAL SYSTEM

E175B-E195B

E ENGINE ELECTRICAL COMPONENTS

15
18
17
1
19

13

14

16
12

8
11

3
10

1 - Air filter restriction switch (SW-8)

2 - Engine coolant level switch (SW-24)
3 - Stepping Motor (M-2)
4 - Starter motor assembly (M-1)
5 - Thermo-switch for heater (SW-52)
6 - Coolant thermo sensor (SE-14)
7 - Engine coolant temperature switch (SW-6)
8 - Alternator assembly (E-2)
9 - Engine revolution sensor (SE-13)
10 - Engine oil pressure switch (SW-7)

6-7

11 - Air compressor (E-21)

12 - Cold start air heater (E-12)
13 - Fuel filter heater (E-20)
14 - Engine stop solenoid (SV-15)
15 - Fuel sensor (SE-15)
16 - Engine oil level sensor (SE-12)
17 - Water separator restriction switch (SW-36)
18 - Water separator heater (E19)
19 - Fuel filter heater switch (E-20)

T2-3-11

SM1257

E175B-E195B

ELECTRICAL SYSTEM

F ELECTRICAL COMPONENTS (Lights, Horns)

SM1258

1 - Frame Working light (L-2

2 - Boom Working light left (L-1)
3 - Boom Working light right (L-6)

4 - Horn high (E5)

5 - Horn low (E6)
6 - Engine room light (L-11)

T2-3-12

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM

T2-3-13

E175B-E195B

E175B-E195B

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 1)

Item

Description

Code

Fuse box

E-1

Key starter switch

SW - 1

Fuse link box

E - 25

Auto-Idle stop relay 1

R - 23

Starter motor

M-1

Starter relay

R-2

Safety relay

R-4

Alternator relay

R - 28

Battery relay

R-1

10

Fuse link

E - 26

11

Auto-Idle stop relay 2

R - 24

12

Alternator

E-2

13

Reserve relay

RY - 29

14

Battery

E - 12

15

Engine emergency stop relay

R - 25

16

Mega fuse

E - 24

17

Fuel filter heater relay

R - 40

18

Grid heater relay

R-3

19

Water separator heater

E - 19

20

Fuel filter heater

E - 20

21

Grid heater

E - 21

22

Engine stop solenoid

SV - 15

23

Diode

D - 21

24

Diode

D - 30

25

Diode

D - 20

26

Diode

D - 19

27

Diode

D - 13

28

Diode

D - 14

29

Diode

D-9

30

Diode

D - 12

31

Diode

D - 11

32

Diode

D -18

33

Hour meter

E-3

34

KSB soleniod

---

35

Mechatro Controller

C-1

T2-3-14

ELECTRICAL SYSTEM

E175B-E195B

ELECTRICAL SYSTEM DIAGRAM (No. 1)

19
17

20
31
16

26

18

21

10
25
14
3
9
4

15

11

29

23

30

22

35

34

24

12
13
5
6

32

33

28
27

8
SM0093

T2-3-15

E175B-E195B

ELECTRICAL SYSTEM
ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 2)

Item

T2-3-16

Description

Code

35

Mechatro Controller

C-1

36

Cluster gauge

C-2

37

Water separator restriction switch

SW - 36

38

Accel potentio pressure sensor

SE -16

39

Bucket digging sensor

SE - 1

40

Bucket dump sensor

SE - 2

41

Boom raising sensor

SE - 3

42

Boom lowering sensor

SE - 4

43

Arm in sensor

SE - 7

44

Arm out sensor

SE - 8

45

Swing sensor

SE - 5

46

Travel right sensor

SE - 9

47

Travel left sensor

SE - 10

48

Pump P1 sensor

SE - 22

49

Pump P2 sensor

SE - 23

50

P1 option sensor (2PB)

SE - 20

51

P2 option sensor (Hammer)

SE - 11

52

Engine coolant temperature switch

SW - 6

53

Engine coolant thermo sensor

SE - 14

54

Fuel level sensor

SE - 15

55

Engine speed sensor

SE - 55

56

Power boost switch right

SW - 22

57

Power boost switch left (opt.)

SW - 23

58

Swing parking release switch

SW - 4

59

Swing parking brake solenoid valve

SV - 1

60

Two-speed select solenoid valve

SV - 3

61

Power boost solenoid valve

SV - 2

62

P2 Unload proportional solenoid valve

PSV - B

63

Travel priority proportional solenoid valve

PSV - C

64

P1 Unload proportional solenoid valve

PSV - D

65

Arm two-speed inverse proportional solenoid valve

PSV - A

66

Pump P1 proportional solenoid valve

PSV - P1

67

Pump P2 proportional solenoid valve

PSV - P2

68

OPT. Relief adjustment proportional solenoid valve 1

PSV - E

69

OPT. Relief adjustment proportional solenoid valve 2

PSV - I

70

Short-circuit proportional solenoid valve

PSV - R

71

Short-circuit proportional solenoid valve

M-2

ELECTRICAL SYSTEM

E175B-E195B

ELECTRICAL SYSTEM DIAGRAM (No. 2)

37

35

58
59
60
61

38

62

39

63

40

64

41

65

42

66

43

67

44
45
46
47
48
49
50
51
52
53

36

54

68

55

69
70

56

71
SM0094

57
T2-3-17

E175B-E195B

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 3)

Item

T2-3-18

Description

Code

35

Mechatro Controller

C-1

72

Engine oil pressure switch

SW - 7

73

Air filter restriction switch

SW - 8

74

Engine oil level sensor

SE -12

75

Engine coolant level switch

SW - 24

76

Conflux/single select switch

SW - 15

77

Lever lock switch

SW - 11

78

Lever lock relay

R- 26

79

Operating lever lock solenoid valve

SV - 4

80

Heavy lift switch

SW - 35

81

Extra dis. Pressure relay opt.

R - 17

82

Extra dis. Pressure solenoid valve opt.

SV - 11

83

Extra dis. Pressure sensor opt.

SE - 28

84

Prevent spark relay

R - 31

85

Wiper motor relay

R - 29

86

Wiper motor reversing relay

R - 30

87

Window washer motor relay

R - 32

88

Wiper motor

M-3

89

Washer motor

M-4

90

Wiper interlock switch

SW - 19

91

Selector detect sensor opt.

SE - 29

92

Selector solenoid opt.

SV - 13

93

Air conditioner ampl.

C-4

94

Receiver drier

E - 10

95

Air compressor clutch

E - 11

96

Cigarette lighter

E - 14

97

Room light

L-5

98

Horn relay

R-5

99

Horn high

E-5

100

Horn low

E-6

101

Horn switch right opt.

SW - 5

102

Horn switch left opt.

SW - 10

ELECTRICAL SYSTEM

E175B-E195B

ELECTRICAL SYSTEM DIAGRAM (No. 3)

35
93
72
94

73

95

82

74

81
75

83

96

88

76
84

85

97

86
77

79

78

87

80

89

90
98
91

99
100
101
102

92

SM1259

T2-3-19

E175B-E195B

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 4)

Item

Description

Code

Mechatro Controller

C-1

103

Revolution left nibbler relay

R - 13

104

Revolution right nibbler relay

R - 12

105

Diode

D - 16

106

Diode

D - 17

107

Revolution right nibbler switch

SW - 33

108

Revolution left nibbler switch

SW - 34

109

Revolution right nibbler solenoid valve

SV - 6

110

Revolution left nibbler solenoid valve

SV - 7

35

T2-3-20

111

Pressure sensor boom head (for overload alarm)

SE - 26

112

Overload alarm select switch

SW - 12

113

Working light relay

R-6

114

Working light switch

SW - 55

115

Boom working light right

L-6

116

Boom working light left

L-1

117

Frame working light

L-2

118

Engine room light switch

SW - 16

119

Engine room light

L - 11

120

Fuel supply pump (automatic fuel stop)

M - 11

121

Auto grease motor opt.

M-8

122

Fleet link opt.

123

Antenna GPS

124

Antenna GSM

ELECTRICAL SYSTEM

E175B-E195B

ELECTRICAL SYSTEM DIAGRAM (No. 4)

35

115
113
116
117

112
114
111
118

104

107

119

109
120

105
106

121
110

103

108

123

124

122

SM0096

T2-3-21

E175B-E195B

ELECTRICAL SYSTEM
ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 5)
Item
35

T2-3-22

Description

Code

Mechatro Controller

C-1

125

12 V Socket

E - 23

126

DC DC converter

E - 22

127

Tuner

E-7

128

Antenna

129

Speaker left

E-8

130

Speaker right

E-9

131

Quick coupler operation solenoid valve

SV - 14

132

Quick coupler operation switch

SW - 64

133

Diode

D - 22

134

Thermo switch for heater

SW - 52

135

Seat heater opt.

E - 26

136

Cab working light relay 1

R-9

137

Cab working light relay 2

R - 11

138

Cab working light switch

SW - 26

139

Cab working light front 1

L-7

140

Cab working light front 2

L-8

141

Cab working light front 3

L - 15

142

Cab working light front 4

L - 16

143

Cab working light back 1

L - 18

144

Cab working light back 2

L - 17

145

6P Connector

146

Diode

D - 23

ELECTRICAL SYSTEM

E175B-E195B

ELECTRICAL SYSTEM DIAGRAM (No. 5)

135

134

131

136
139

146

138

140
141

133
132

142
137

143
144

128

127
129

126

130

145

125

SM1260

T2-3-23

E175B-E195B

ELECTRICAL SYSTEM

WIRING HARNESS
CLUSTER GAUGE WIRING HARNESS ASSEMBLY READING KEY

ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable

are from X side
SM0199

SM0251

T2-3-24

ELECTRICAL SYSTEM

E175B-E195B

CLUSTER GAUGE WIRING HARNESS ASSEMBLY

SM0099

T2-3-25

E175B-E195B

ELECTRICAL SYSTEM

PLATFORM WIRING HARNESS ASSEMBLY READING KEY

ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable

are from X side
SM0253

T2-3-26

SM0199

ELECTRICAL SYSTEM

E175B-E195B

PLATFORM WIRING HARNESS ASSEMBLY

SM0252

T2-3-27

E175B-E195B

ELECTRICAL SYSTEM

UPPER FRAME WIRING HARNESS ASSEMBLY READING KEY

ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable

are from X side
SM0255

T2-3-28

SM0199

ELECTRICAL SYSTEM

E175B-E195B

UPPER FRAME WIRING HARNESS ASSEMBLY

SM0254

T2-3-29

E175B-E195B

ELECTRICAL SYSTEM

ENGINE WIRING HARNESS (KSB & STOP) READING KEY

SM0257

WIRING DIAGRAM

SM0258

ASSEMBLY CABLES ON THE CONNECTORS

To engine coolant temperature sensor (SE-14)

To operators compartment wiring assembly, connector [CN-2M]

To KSB solenoid

To engine stop solenoid (SV-15)

T2-3-30

- The connector view on the cable

are from X side
SM0199

ELECTRICAL SYSTEM

E175B-E195B

ENGINE WIRING HARNESS (KSB & STOP)

SM0256

T2-3-31

E175B-E195B

T2-3-32

ELECTRICAL SYSTEM

COMPONENT OPERATION

M0103

COMPONENT OPERATION

E175B-E195B

SECTION AND GROUP CONTENTS

Section 3

COMPONENT OPERATION

Group 1
Group 2
Group 3
Group 4
Group 5
Group 6
Group 7
Group 8

Hydraulic Pump Assy

Pilot Valve
Control Valve
Swing Device
Travel Device
Swivel Joint
Cylinders
Air Conditioner system

SECTION 3

E175B-E195B

COMPONENT OPERATION

CONTENTS
Group 1 - Hydraylic pump assy
Outline .................................................... T3-1-1
General view and hydraulic ports
E175B ............................................ T3-1-1

Arm 2 spool (308) .............................. T3-3-14

Boom spool (301)............................... T3-3-14
Lock valve selector (211) ................... T3-3-15
Bypass cut valve (605)....................... T3-3-16
Swing shuttle valve cover (204) ......... T3-3-17

General view and hydraulic ports

E195B ............................................ T3-1-1

Hydraulic circuit diagram......................... T3-3-18

Hydraulic circuit diagram .................. T3-1-3

Operation ................................................ T3-3-19

Specifications E175B ......................... T3-1-4

Specifications E195B ......................... T3-1-4
Hydraulic pump ...................................... T3-1-5
Operation .......................................... T3-1-9
Regulator ............................................... T3-1-11
Construction E175B ........................... T3-1-11
Construction E195B ........................... T3-1-12
Operation .......................................... T3-1-13
Adjusting the regulator ....................... T3-1-14
Causes of fault resulting from
regulator ........................................ T3-1-15

Group 4 - Swing device

Outline..................................................... T3-4-1
General view ...................................... T3-4-1
Construction ............................................ T3-4-4
Swing motor ....................................... T3-4-4
Swing reduction unit........................... T3-4-6
Hydraulic motor ....................................... T3-4-7
Valve casing section ............................... T3-4-8
Operation of relief valve ..................... T3-4-8

Control curve of pump E175B................. T3-1-16

Brake section .......................................... T3-4-11

Control curve of pump E195B................. T3-1-17

Swing reduction unit................................ T3-4-12

Group 2 - Pilot valve

Group 5 - Travel device

Pilot valve (ATT) ..................................... T3-2-1

Outline..................................................... T3-5-1

Outline ............................................... T3-2-1

Specifications..................................... T3-5-1

Construction....................................... T3-2-2

Hydraulic motor E175B ...................... T3-5-2

Operation ........................................... T3-2-3

Planetary gearbox E175B .................. T3-5-2

Pilot valve (travel) ................................... T3-2-5

Ports E175B....................................... T3-5-2

Outline ............................................... T3-2-5

Hydraulic motor E195B ...................... T3-5-3

Construction and operation................ T3-2-6

Planetary gearbox E195B .................. T3-5-3

Ports E195B....................................... T3-5-3

Group 3 - Control valve

Control valve ........................................... T3-3-1
Control valve ports ............................. T3-3-3
Specifications .................................... T3-3-4
Construction and operation................ T3-3-5
Main relief valve (601) ....................... T3-3-12
Over load relief valve (602, 603, 606) T3-3-13

Hydraulic circuit E175B...................... T3-5-4

Hydraulic circuit E195B...................... T3-5-4
Direction of rotation E175B ................ T3-5-5
Construction E175B ................................ T3-5-6
Track drive E175B ............................. T3-5-6
Hydraulic motor E175B ...................... T3-5-7
Direction of rotation E195B ................ T3-5-9
Construction E195B ................................ T3-5-9

Track drive E195B ............................. T3-5-9

Hydraulic motor E195B ...................... T3-5-10
Brake.................................................. T3-5-10

Group 6 - Swivel joint

Outline..................................................... T3-6-1
Construction ............................................ T3-6-2
Operation ................................................ T3-6-3

Group 7 - Cylinders
Outline..................................................... T3-7-1
Construction ............................................ T3-7-2
Boom cylinder E175B-E195B ............ T3-7-2
Arm cylinder E175B ........................... T3-7-3
Arm cylinder E195B ........................... T3-7-4
Bucket cylinder E175B....................... T3-7-5
Bucket cylinder E195B....................... T3-7-6
Positioning E175B-E195B ................. T3-7-7
Operation ................................................ T3-7-8

Group 8 - Air conditioner system

Basic system of air conditioner
(HVAC air conditioner) ....................... T3-8-1
Air cycle................................................... T3-8-1
Auto air conditioner system outline ......... T3-8-2
Component and construction .................. T3-8-3
Operation ........................................... T3-8-7
Disassembly and assembly..................... T3-8-13
Precautions to be exercised in
operation ........................................ T3-8-13
Disassembly and assembly of unit..... T3-8-14
Charging refrigerant ................................ T3-8-18
Precautions to be exercised in
operation ........................................ T3-8-18
Operating procedure .......................... T3-8-19
Electric circuit .......................................... T3-8-23
Wiring diagram and connectors ......... T3-8-23
Structure and operation of each
functional parts and the inspection .... T3-8-25
Troubleshooting ...................................... T3-8-28
Self diagnosis function on display of
panel .................................................. T3-8-35
Explanation of monitor mode .................. T3-8-37

HYDRAULIC PUMP ASSY

E175B-E195B

OUTLINE
General view and hydraulic ports E175B

Dr2

a3
A3

B3
Dr1
Psv1
a1

a2

a5

A1

a4
Dr1

Psv2
Dr1

Dr1

A2

PH1

PH2

B1

a4 Psv1 Psv2 a5

2
a5

Psv2

Psv1

1
A3
Dr1

(Dr1)

Dr1

Dr2
a3

B1

B1

Dr3
B3
Dr1

(Dr1)

a1

a2

PH2

Dr1

3
SM1013

1Main pump assy

2Regulator assy (Q.ty 2)
3Gear pump assy (for pilot)
Solenoid proportional reducing valve (Q.ty 2)
45PTO unit
A1 - Delivery port SAE 6000 psi 3/4''
A2 - Delivery port SAE 6000 psi 3/4''
B1 - Suction port SAE 2500 psi 2 1/2''
Dr1 - Drain port G 1/2-19
Dr2 - Drain port G3/4-20
PSV1 - Servo assist port G 1/4-13

PSV2 - Servo assist port G 1/4-13

PH1 - Pressure sensor port G 3/8-17
PH2 - Pressure sensor port G 3/8-17
a1 - Gauge port G 1/4-15
a2 - Gauge port G 1/4-15
a3 - Gauge port G 1/4-14
a4 - Gauge port G 1/4-13
a5 - Gauge port G 1/4-13
A3 - Gear pump delivery port G 1/2-19
B3 - Gear pump suction port G 3/4-20.5
Dr3 - Gear pump drain port G 3/8-15

T3-1-1

E175B-E195B

HYDRAULIC PUMP ASSY

OUTLINE
General view and hydraulic ports E195B

Dr2

a5
A3
PH1

PH2

a1

a2

B3
Dr1
a3

Psv1
A2

A1

Psv2

a4

4
Psv1
a3

Psv2

Psv1

a4

1
A3
(Dr1)

a5

B1
Dr3
Dr1

PH1

PH2

B3
PH2

A1

A2

a2

A2
SM1019

1Main pump assy

2Regulator assy (Q.ty 2)
3Gear pump assy (for pilot)
Solenoid proportional reducing valve (Q.ty 2)
45PTO unit
A1 - Delivery port SAE 6000 psi 3/4''
A2 - Delivery port SAE 6000 psi 3/4''
B1 - Suction port SAE 2500 psi 2 1/2''
Dr1 - Drain port G 1/2-19
Dr2- Drain port G3/4-20.5
PSV1 - Servo assist port G 1/4-15

PSV2 - Servo assist port G 1/4-15

PH1 - Pressure sensor port G 3/8-17
PH2 - Pressure sensor port G 3/8-17
a1 - Gauge port G 1/4-15
a2 - Gauge port G 1/4-15
a3 - Gauge port G 1/4-15
a4 - Gauge port G 1/4-15
a5 - Gauge port G 1/4-14
A3 - Gear pump delivery port G 1/2-19
B3 - Gear pump suction port G 3/4-20.5
Dr3 - Gear pump drain port G 3/8-15

T3-1-2

HYDRAULIC PUMP ASSY

E175B-E195B

Hydraulic circuit diagram

3
SM1014

1234-

Main pump assy

Regulator assy (Q.ty 2)
Gear pump assy (for pilot)
Solenoid proportional reducing valve (Q.ty 2)

T3-1-3

E175B-E195B

HYDRAULIC PUMP ASSY

Specifications E175B
Main pump

Gear pump for pilot

Pump

Item

K7V63DTP112R-V

ZX10LPRZ2-07G

Type

Variable displacement plunger

pump: regulator attached type

Fixed displacement type gear

pump

65.2 x 2

10

2200

Max. displacement capacity

cm3

Revolution

rpm
(Clockwise
seen from
shaft end)

Pressure

Rated
Rated
ATT boost

34.3

MPa

Max. flow

L/min

Max. input Power

(at 2000 rpm)
Max. input torque
(at 1200 rpm)

143 x 2 at 7.8 MPa

22

kW

78.3

3.4

Nm

340

14.7

Model
Regulator

Mass

5.0

37.8

KR76-0E13-V

Control
function

Electric flow control, positive flow control, total power control at

emergency mode and power shift control

Others

With solenoid proportional reducing valve

(KDRDE5K-31/30C50-123)

kg

88

Specifications E195B
Item

Main pump

Gear pump for pilot

Pump

K5V80DTP1KBR-0E02-V

ZX10LPRZ2-07G

Type

Variable displacement plunger

pump: regulator attached type

Fixed displacement type gear

pump

Max. displacement capacity

cm3

80 x 2

10

Revolution

rpm
(Clockwise
seen from
shaft end)

2200

Pressure

Rated
Rated
ATT boost

34.3

MPa

Max. flow

L/min

Max. input Power

(at 2000 rpm)
Max. input torque
(at 1200 rpm)

176 x 2 at 7.8 MPa

22

kW

91.9

3.2

Nm

399

15

Model
Regulator

Mass

5.0

37.8

KR38-0E03-V

Control
function

Electric flow control, positive flow control, total power control at

emergency mode and power shift control

Others

With solenoid proportional reducing valve

(KDRDE5K-31/30C50-111)

kg

89.5

NOTE: the max. input power and the max. input torque of the main pump include those of the gear pump.

T3-1-4

HYDRAULIC PUMP ASSY

E175B-E195B

HYDRAULIC PUMP
MAIN PUMP E175B
806 535 533 789 733 732 532 214 548 531 702 792 534 901 808 954 724 717 723 402 151 981 983
152

953

211

490

255

261

256
734

774

263

111

127
710
406
123
468
824 251 212 271 153
727

415
156

157 313 124 711

116 312 886 314 401

05

401
402
406
415
468
490
531,532
533
806
808

M16
M16
M6
M8
G 1/2
NPTF1/16
M20X1.5
M30
M12
M16

Nm
240
240
12
29
110
8.8
240
220
60
130

141

272 113

04

A-A

SM1015

111
113
116
123
124
127
141
151
152
153
156
157
211
212
214
251
255
256
261
263
271

Drive shaft (F)

Drive shaft (R)
Gear #1
Roller bearing (Q.ty 2)
Needle bearing (Q.ty 2)
Bearing spacer (Q.ty 2)
Cylinder block (Q.ty 2)
Piston (Q.ty 18)
Shoe (Q.ty 18)
Retainer plate (Q.ty 2)
Spherical bushing (Q.ty 2)
Cylinder spring (Q.ty 12)
Shoe plate (Q.ty 2)
Swash plate (Q.ty 2)
Tilting bushing (Q.ty 2)
Swash plate support (Q.ty 2)
Lock pin (Q.ty 2)
Set spring (Q.ty 2)
Seal cover (F)
Seal cover (R)
Pump casing (F)

272
312
313
314
401
402
406
415
468
490
531
532
533
534
535
548
702
710
711
717
723

Pump casing (R)

Valve block
Valve plate (R)
Valve plate (L)
Socket bolt; M16x150 (Q.ty 2)
Socket bolt; M16x190 (Q.ty 2)
Socket bolt; M6x16 (Q.ty 4)
Socket bolt; M8x20 (Q.ty 4)
Plug; G1/2 (Q.ty 4)
Plug; (Q.ty 9)
Tilting pin; (Q.ty 2)
Servo piston (Q.ty 2)
Plug (Q.ty 2)
Stopper (L) (Q.ty 2)
Stopper (S) (Q.ty 2)
Feed back pin (Q.ty 2)
O-ring; 1B G30 (Q.ty 2)
O-ring; 1B G80
O-ring; G95
O-ring; 1B G125 (Q.ty 2)
O-ring; 1B P11 (Q.ty 4)

T3-1-5

724
727
732
733
734
774
789
792
806
808
824
886
901
953
954
981
983
04
05

O-ring; 1B P8 (Q.ty 12)

O-ring; 1B P18 (Q.ty 4)
O-ring; 1B P14 (Q.ty 2)
O-ring; P28 (Q.ty 2)
O-ring; G85
Oil seal
Back up ring; P14 (Q.ty 2)
Back up ring; G30 (Q.ty 2)
Nut; M12 (Q.ty 2)
Nut; M16 (Q.ty 2)
Snap ring (Q.ty 2)
Spring pin (Q.ty 4)
Eye bolt M10 (Q.ty 2)
Set screw; M12x23 (Q.ty 2)
Set screw; M16x34 (Q.ty 2)
Plate
Pin (Q.ty 2)
Gear pump
PTO unit

E175B-E195B

HYDRAULIC PUMP ASSY

MAIN PUMP E195B

535
808
953
886
717
406

789

732

532

548
531

214

702 792
534
724

901

711

312

719

124

151 152 113

954
252
710

774
111
A

261
127
123
710
824
251
490

262
406
401
212

401
406
466
467
490
531
532
808

211

153

M16
M6
G 1/4
G 1/2
NPTF1/16
M20x1.5
M20x1.5
M16

156

157

313

466
725

116

Nm
240
12
36
110
8.8
240
240
130

885

314

981
983

141

467
728

271

04

05
A-A

SM1020

111
113
116
123
124
127
141
151
152
153
156
157
211
212
214
251
252
261

Drive shaft (F)

Drive shaft (R)
Gear #1
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)
Set plate (Q.ty 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
Swash plate support
Seal cover (F)

262
271
312
313
314
401
406
466
467
490
531
532
534
535
548
702
710
711

Seal cover (R)

Pump casing (Q.ty 2)
Valve block
Valve plate (R)
Valve plate (L)
Socket bolt; M16x175 (Q.ty 8)
Socket bolt; M6x16 (Q.ty 8)
VP Plug; G1/4 (Q.ty 2)
VP Plug; G1/2 (Q.ty 4)
Plug; (Q.ty 15)
Tilting pin; (Q.ty 2)
Servo piston (Q.ty 2)
Stopper (L) (Q.ty 2)
Stopper (S) (Q.ty 2)
Feed back pin (Q.ty 2)
O-ring; G30W (Q.ty 2)
O-ring; G85W (Q.ty 2)
O-ring; G95W

T3-1-6

717
719
724
725
728
732
774
789
792
808
824
885
886
901
953
954
04
05

O-ring; G120W (Q.ty 2)

O-ring; G115W (Q.ty 2)
O-ring; P8W (Q.ty 18)
O-ring; P11W (Q.ty 2)
O-ring; P18W (Q.ty 4)
O-ring; P16W (Q.ty 2)
Oil seal
Back up ring; P16 (Q.ty 2)
Back up ring; G30 (Q.ty 2)
Nut; M16 (Q.ty 4)
Snap ring (Q.ty 2)
Valve plate pin (Q.ty 2)
Spring pin (Q.ty 4)
Eye bolt M10 (Q.ty 2)
Set screw; M16x30 (Q.ty 2)
Set screw; M16x34 (Q.ty 2)
Gear pump
PTO unit

HYDRAULIC PUMP ASSY

E175B-E195B

GEAR PUMP (FOR PILOT)

16

700

433
354

434

15
353

B3

435
312
14

Dr4

710
732

312
433
434
435
466

M14 x 1.5
M8
M8
M10
G 1/4

10

11
12

13

434

a3

Nm
29
17
17
33
16

A3

850
355
466
725

SM1016

10 11 12 13 14 15 16 312 353 354 355 433 -

Poppet
Seat
Ring
Spring
Adjust screw
Gear case
Front case
Lock nut; M141.5
Drive gear
Driven gear
Filter
Flange socket; M840 (Q.ty 2)

434 435 466 700 710 725 732 850 a3 A3 B3 Dr4 -

T3-1-7

Flange socket; M855 (Q.ty 2)

Flange socket; M1035 (Q.ty 2)
Vp plug; G1/4 (Q.ty 2)
Ring
O-Ring
O-Ring (Q.ty 2)
O-Ring
Locking ring
Gauge port; G1/4 16 Nm
Delivery port; G3/8 34 Nm
Suction port; G3/4 74 Nm
Drain port; G3/8 34 Nm

E175B-E195B

HYDRAULIC PUMP ASSY

PTO GEAR CASE

711

468

125

118
11

262
728

117
414
126
128

825
710

10
12

435
886

826

SM0749

10 11 12 117 118 125 126 128 262 -

Idle shaft
Gear case
Pin
2nd gear
3rd gear
Ball bearing (Q.ty 2)
Roller bearing
Bearing spacer (Q.ty 2)
Cover

414 435 468 710 711 728 825 826 886 -

T3-1-8

Socket bolt; M10x20 (Q.ty 2)

Flange socket; M1020 (Q.ty 4)
Vp plug: G3/4
O-Ring
O-Ring
O-Ring
Snap ring
Snap ring
Pin (Q.ty 2)

HYDRAULIC PUMP ASSY

E175B-E195B

Operation
The pump assy is equipped with two pumps
arranged on the same axis that are connected with
gear (116) and distribute the rotating power to the
gear trains on a different axis. Thus the engine
rotation is transmitted to front shaft (111) that drives
the two pumps and, at the same time, drives the
pilot gear pump arranged on another shaft.
The pump assy consists largely of:
- the rotary group, the main part of the pump that
makes rotary on;

111

116

- the swash plate group that changes the delivery

rate;
- the valve block group that selects between oil
suction and delivery;
- the PTO group that transmits the drive power to
the gear pump.
SM0750

ROTARY GROUP
The rotary group consists of shaft (111), cylinder
block (141), piston (151), shoe (152), plate (153),
spherical bushing (156), and cylinder spring (157).
The shaft is supported by bearings (123) and (124)
at its both ends. The shoe, which is caulked to the
piston, forms a spherical joint and relieves it of thrust
force that is generated by load pressure.
Further, the piston is provided with a pocket so it
moves lightly on shoe plate (211), taking hydraulic
balance.

The sub group of the piston-shoe is pressed against

the shoe plate by the cylinder spring, via the retainer
plate and the spherical bushing, so that it moves
smoothly over the shoe plate. The cylinder blocks
(141) are also pressed against valve plates (313) or
(314) by the action of cylinder spring (157).

111

312

141

211

151

153

156

314

124

124

313

116

157

152
SM0245

T3-1-9

E175B-E195B

HYDRAULIC PUMP ASSY

SWASH PLATE GROUP

The swash plate group consists of swash plate
(212), shoe plate (211), swash plate support (251),
tilting bushing (214), tilting pin (531),and servo
piston (532). The swash plate is the cylindrical part
that is formed on the opposite side of the shoe
sliding surface and is supported by the swash plate
support.
The hydraulic force controlled by the regulator flows
into the hydraulic chamber that is provided on both
sides of the servo piston. This moves the servo
piston to the right and left. The result is that the
swash plate swings on the swash plate support via
the spherical part of the tilting pin and changes the
tilting angle (a).

532
531

214

212

211

251
SM0246

VALVE BLOCK GROUP

The valve block group consists of valve block (312),
valve plates (313) (314), and valve plate pin (885).
The valve plates having two crescent-shaped ports
are installed to valve block (312) to feed oil and
recycle it from cylinder block (141). The oil switched
over by the valve plate is connected with the
external pipe by way of the valve block.

313
312

111
885

141

PTO GROUP
The PTO group is composed of 1st gear (116), 2nd
gear (117) and 3rd gear (118). The 2nd and the 3rd
gear are supported by bearings (125) and (126)
respectively and installed to the valve block.
Now, if the shaft is driven by the engine, the cylinder
block rotates together by the spline linkage. If the
swash plate is inclined, the pistons arranged in the
cylinder block make reciprocating motion with
respect to the cylinder while rotating with the
cylinder block. If we keep an eye on a single piston,
it makes a motion away from the valve plate (oil
suction process) in the first 180 and a motion
toward the valve plate (oil delivery process) in the
remaining 180. If the swash plate is not inclined
(zero tilting angle), the piston does not stroke i.e.
delivers no oil.
The shaft rotation is taken up by the 1st gear (116)
and transmitted to the 2nd gear (117) and the 3rd
gear (118), in that order, to drive the gear pump that
is linked to the 3rd gear.
T3-1-10

314

116

SM0247

117

126

125

118

125

SM0248

HYDRAULIC PUMP ASSY

E175B-E195B

REGULATOR
Construction E175B

B-B

541

543

755
545

496
325
624

627

466
755

631

CL

643

897

P1

415

731

924

407

801
402

724

656
733
646
651
652

496

418

601

726

496
543

616

545

614

755

875

541

724

708

611

754
754

658

887

SM1017

325 - Valve casing

402 - Screw; M6x16 (Q.ty 4)
407 - Screw; M6x30 (Q.ty 4)
415 - Screw; M8x40 (Q.ty 4)
418 - Screw; M5x12 (Q.ty 2)
466 - Plug; G 1/4
496 - Plug (Q.ty 9)
541 - Seat (Q.ty 2)
543 - Stopper 1 (Q.ty 2)
545 - Steel ball (Q.ty 2)
601 - Casing
611 - Feedback lever
614 - Center plug
616 - Prevention plug
624 - Spring seat
627 - Adjusting stem
631 - Sleeve
643 - Pilot piston

646 - Pilot spring

651 - Sleeve
652 - Spool
656 - Cover
658 - Plug
708 - O-Ring
724 - O-Ring (Q.ty 5)
726 - O-Ring
731 - O-Ring
733 - O-Ring
754 - O-Ring (Q.ty 2)
755 - O-Ring (Q.ty 3)
801 - Nut; M10
875 - Pin; 5x10L
887 - Pin
897 - Pin
924 - Set screw; M10x20

The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
T3-1-11

E175B-E195B

HYDRAULIC PUMP ASSY

Construction E195B

418

415

325

496

897

624

CL

496
601
543
15
545
541

14
466
614 407
755
10
611

643
631
12

651
652

627

646

P1

658
13

A-A

924
801
402
656
13
11
887

SM1021

10 - O-Ring; G75W
11 - O-Ring; P8W (Q.ty 5)
12 - O-Ring; P25W
13 - O-Ring; P18W (Q.ty 2)
14 - O-Ring; P11W (Q.ty 2)
15 - O-Ring; P12.5W (Q.ty 2)
325 - Valve casing
402 - Screw; M6x16 (Q.ty 4)
407 - Screw; M6x30 (Q.ty 4)
415 - Screw; M8x40 (Q.ty 4)
418 - Screw; M5x12 (Q.ty 2)
466 - Plug; G 1/4
496 - Plug (Q.ty 9)
541 - Seat (Q.ty 2)
543 - Stopper 1 (Q.ty 2)
545 - Steel ball (Q.ty 2)

601 - Casing
611 - Feedback lever
614 - Center plug
624 - Spring seat
627 - Adjusting stem
631 - Sleeve
643 - Pilot piston
646 - Pilot spring
651 - Sleeve
652 - Spool
656 - Cover
658 - Plug
801 - Nut; M8
887 - Pin
897 - Pin
924 - Set screw; M8x20

The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.

T3-1-12

HYDRAULIC PUMP ASSY

E175B-E195B

Operation
SUMMARY
Regulator (KR76-0E13 for E175B or KR38-0E03 for
E195B) for the inline axial piston pump (K7V for E175B
or K5V for E195B) series is of electric flow control type
that regulates the tilting angle (delivery rate) of the
pump as the command current I to the solenoid
proportional reducing valve is varied. This regulator is
of positive flow control type that increases the delivery
flow Q as the command current I increases.
If an electric current is put in by this control according
to the flow needed for the operation, the pump delivers
at a flow rate that is only required by the pump,
consequently holding down unwanted power
consumption.

SM0250

POSITIVE FLOW CONTROL

As shown in the figure on the right, the regulator
regulates the delivery rate of the pump by command
current I.
Flow rate increase
As the command current I rises, the secondary
pressure of solenoid proportional reducing valve
increases. This causes spool (652) to move via pilot
piston (643) and stops where the hydraulic pressure
pushing the spool rightwards balances with the action
of pilot spring (646). If the spool (652) moves, port CL
opens to the tank port. This causes the pressure of the
large diameter part of servo piston (532) to go away.
This causes the servo piston (532) to the left by
delivery pressure P1 of the small diameter part,
resulting in an increase in the tilting angle. Feedback
lever (611) is linked with the servo piston and sleeve
(651). As the servo piston moves to the left, the
feedback lever rotates on point A which causes the
sleeve to the right. As the servo piston moves to the
right, the feedback lever rotates on point A to move the
sleeve to the right. The result is that the opening of the
spool sleeve begins to close gradually and the servo
piston settles down when the opening of the spool
sleeve closes completely.

652

643

646

611

CL

651

A
532
P1

Flow rate decrease

As the command current I decreases, the secondary
pressure of the solenoid proportional valve decreases.
This causes the spool to move to the left. When the
spool (652) has moved, delivery pressure P1 reaches
port CL via spool and is admitted to the large diameter
chamber of the servo piston. Delivery pressure P1 is
admitted to the small diameter part of the servo piston
at all times. The servo piston moves rightward by areal
difference to decrease tilting angle. As the servo piston
moves to the right, the feedback lever rotates on point
A to move the sleeve to the left. The sleeve keeps
moving till the opening of the spool sleeve closes and
settles down when the spool sleeve closes completely.
T3-1-13

SM1018

E175B-E195B

HYDRAULIC PUMP ASSY

Adjusting the regulator

The maximum flow, minimum flow and flow control
characteristics of the regulator may be controlled by
the adjust screw of the regulator.

ADJUSTING THE MAXIMUM FLOW

(See HYDRAULIC PUMP-construction)
For adjustment, loosen the hex nut (808) and tighten
(or loosen) the set screw (954) on the large diameter
part of the servo piston. Tightening it decreases the
flow and loosening it increases the flow.
Only the maximum flow changes with other control
characteristics unchanged.
Adjust screw No

954

No. of turns for tightening

1/4

Pilot pressure Pi (Input current I)

Min. increase in delivery flow L/min

I (Pi)
Q

No change
3.5

ADJUSTING THE MINIMUM FLOW

(See HYDRAULIC PUMP-construction)
For adjustment, loosen hex nut (808) and tighten (or
loosen) the set screw (953) on the small diameter
part of the servo piston. Tightening it increases the
flow and loosening it decreases the flow. Other
characteristics do not change the same way as the
adjustment of the maximum flow. Note that if the set
screw is tightened too much, the power requirement
at the maximum delivery pressure (at relieving)
increases in some cases.
Adjust screw No

SM0996

953

No. of turns for tightening

1/4

Pilot pressure Pi (Input current I)

Min. increase in delivery flow L/min

ADJUSTING
THE
CHARACTERISTICS
Construction)

I (Pi)

No change
3.5

FLOW
CONTROL
(See
REGULATOR-

For adjustment, loosen hex nut (801) and tighten

(loosen) the set screw (924). If the set screw is
tightened, the control curve moves rightwards.
Adjust screw No

924

No. of turns for tightening

1/4

Increase Pilot pressure Pi MPa

0.13

Decrease in delivery flow L/min

11.9

I (Pi)

T3-1-14

SM0998

HYDRAULIC PUMP ASSY

Causes of fault resulting from regulator
When trouble due to this regulator occurs, disassemble
and inspect it referring to "Chapter W2-2".
WHEN THE ENGINE IS OVERLOADED
Load every unit of pump, and check on pumps on
the right and left sides for possible damages. When
pumps on both sides are failed, check on them for
the following failures 1), 2). When pump on the one
side is failed, start checking from para. 3).
1.

Check that the command current I of the

solenoid proportional reducing valve is normal.

2.

The secondary pressure of

proportional reducing valve is high.
Check amplifier dither.
Replace solenoid proportional
valve.

solenoid

reducing

3.

Spool (652) and Sleeve (651) are stuck

Disassemble and clean.

4.

Pilot piston (643) is stuck

Disassemble and clean.

MAX. DELIVERY RATE CAN NOT BE ATTAINED

1.

Confirm that the secondary pressure of the

solenoid proportional reducing valve is normal.

2.

Pilot piston (643) is stuck

Disassemble and clean.

3.

Spool (652) and sleeve (651) are stuck

Disassemble and clean.

NOTE: when the damage of part is severe, replace

the part with new one.

T3-1-15

E175B-E195B

E175B-E195B

HYDRAULIC PUMP ASSY

Q (L/min)

CONTROL CURVE OF PUMP E175B

250

H Mode

200

150

Q (2200 min-1)
[2]

[2]

[1]

[1]

[2]

[2]

[1]

[1]

100

50
min. Q (2200 min-1 )

10

15

20

25

30

35

40

Pd (MPa)

Q (L/min)

SM1022

250

S Mode

200

150
Q (2000 min-1)
[3]

[3]

[3]

[3]

100

50
min. Q (2000 min-1 )

10

15

20

25

30

35

40

Pd (MPa)
SM1023

[1] 78 kW H mode at traveling or optional working

[2] 62 kW H mode at operating attachment
[3] 56 kW S mode at operating attachment and travelling

T3-1-16

HYDRAULIC PUMP ASSY

E175B-E195B

Q (L/min)

CONTROL CURVE OF PUMP E195B

250

H Mode

200
Q (2200 min-1)
[2]

[2]

[1]

[2]

[2]

[1]

[1]

150
[1]

100

50
min. Q (2200 min-1 )

10

15

20

25

30

35

40

Pd (MPa)

Q (L/min)

SM1024

250

S Mode

200
Q (2000 min-1)
[3]

150

[3]

[3]

[3]

100

50
min. Q (2000 min-1 )

10

15

20

25

30

35

40

Pd (MPa)
SM1025

[1] 78 kW H mode at traveling or optional working

[2] 69 kW H mode at operating attachment
[3] 56 kW S mode at operating attachment and travelling

T3-1-17

E175B-E195B

HYDRAULIC PUMP ASSY

NOTE:

T3-1-18

PILOT VALVE

E175B-E195B

PILOT VALVE (ATT)

OUTLINE
5-PF3/8
T=49.0 (36.1)

Single operating angle Single operating angle

(Port 2, 4) (Port 1, 3)
The adjust nut
(opposing flats : 22) :
Fix adjust nut
(opposing flats : 22)
when the lever is installed by
means of spanner or the like.
Then tighten the mating lock
nut to 41 + 3 N.m (302.2 lbf.ft).

PF1/4
T=29.4 (21.7)

VIEW A

T=Tightening torque
: N.m (lbf.ft)

PV48K2004

Model

Refer to the curve below

Operating torque

6.9 MPa (1000 psi)

Max. primary pressure

5.0 MPa (725 psi)

Primary pressure

20 L/min (5.3gal/min)

Rated flow

Approx. 1.9 kg (4.2 lbs)

Weight

PORT 1, 3

PORT 2, 4

3.0(2.2)

SINGLE OPERATING TORQUE

2.21(1.63)

(290)2.0

2.0(1.5)

SECONDARY PRESSURE

(145)1.0

1.0(0.74)
0.94(0.69)

(87)0.6

1.17 (0.86)
0.98 (0.72)

0 1.1 2
4
6 7
PUSH ROD STROKE (mm)
0

(464)3.2

(435)3.0

2.29(1.69)

2.0(1.5)

SECONDARY PRESSURE

(145)1.0

1.0(0.74)

(87)0.6

1.17 (0.86)
0.98 (0.72)

0
P

3.0(2.2)

SINGLE OPERATING TORQUE

(290)2.0

5
10
15 19
Operating angle (deg.)

4.0(3.0)
Operation torque [N.m (lbf.ft)]

(464)3.2

(435)3.0

(580)4.0
Secondary pressure [MPa (psi)]

4.0(3.0)
Operation torque [N.m (lbf.ft)]

Secondary pressure [MPa (psi)]

(580)4.0

1.1

2
4
6
8
PUSH ROD STROKE (mm)
5
10
15
20
Operating angle (deg.)

0.94(0.69)

9.4

25

3 2

HYDRAULIC SYMBOL
SM0591

T3-2-1

E175B-E195B

PILOT VALVE

CONSTRUCTION

****312
302
501

***301

*212
213

151

211

214

216- 2

216- 1

241- 2

241- 1

201- 2
201- 1

**217
101

221

PORT 2,4

PORT 1,3
SM0592

No.

Parts

101

Casing

151

Q.ty

Tightening
torque
Nm (lbfft)

No.

216-2

Parts
Spring seat

Q.ty
2

Plate

**217

Washer 2 (Shim)

201-1 Spool

221

Spring

201-2 Spool

241-1

Spring

241-2

Spring

***301 Joint: M14

211

Plug

*212

Push rod

213

Seal

214

O-ring: 1B P20

216-1 Spring seat

4
2

302

Circular plate

****312 Adjust nut: M14

501

Boots

Note: * apply grease on top section;

** secondary pressure adjusting shim
*** apply grease on rotating and sliding sections. Be careful the assembling drirection
**** apply Loctite #277

T3-2-2

Tightening
torque
Nm (lbfft)

47.1 (34.7)

1
1
1

68.6 (50.6)

PILOT VALVE

E175B-E195B

OPERATION
1.

Lever in neutral (See Fig.SM0593)

The action of spring (509) (for secondary
pressure setting) that determines the output
pressure of the pilot valve does not act upon
spool (201).
Therefore, spool (201) (for return) is pushed up
by spring (221) [spring seat (216)]. The output
ports (2, 4) connect with the T port. The result
is that the output pressure is equal to the tank
pressure.

216
509
221
201
PORT (2,4)

2.

When the pilot lever is tilted (See Fig.SM0594)

When the lever is tilted and the push rod (511)
strokes, the spool (201) [spring seat (216)]
moves downward to make the port P to connect
with the port 2, 4, with the result that the oil of
the pilot pump flows to the port 2 ,4 to produce
a pressure.

PORT (1,3)

SM0593

511

216

201
PORT (2,4)

PORT (1,3)
SM0594

3.

Lever held (See Fig.SM0595)

When the pressure at ports (2, 4) rises to a level
equivalent to the action of spring (509) that is
set by tilting the lever, the hydraulic pressure
balances the spring action.
When the pressure of ports (2, 4) rises above a
set value, ports (2, 4) and the P port close while
ports (2, 4) and the T port open.
When the pressure at ports (2, 4) falls below a
set value, ports (2, 4) and the P port open while
ports (2, 4) and the T port close. Thus the
secondary pressure is kept constant.

509

T PORT
P PORT

PORT (2,4)

T3-2-3

PORT (1,3)

SM0595

E175B-E195B
4.

PILOT VALVE

Operation in the area where the tilting angle of

the lever is large. (varies with the model)
If the lever is inclined beyond a certain angle on
certain models, the top end of the spool
contacts the bottom of the bore of the push rod.
This keeps the output pressure connected with
the P port pressure.
Furthermore, on a model in which a spring seat
and a spring are built in the push rod, the
bottom of the bore of the push rod contacts the
spring if the lever is turned beyond a certain
angle.
This causes the secondary pressure gradient to
change by the spring action. Thereafter, the
bottom of the bore of the push rod contacts the
top end of the spring seat, keeping the output
pressure connected with the P port.

T3-2-4

PILOT VALVE

E175B-E195B

PILOT VALVE (TRAVEL)

OUTLINE
Outside view

Port size

Tightening torque
Port name
N.m (lbf.ft)

PF3/8

PF1/4

30 (22)

Function

LH travel forward port

LH travel reverse port

RH travel forward port

RH travel reverse port

Tank port

LH travel pressure sensor port

RH travel pressure sensor port

Pilot primary pressure port

16.7 (12.3)

SM0596

Specifications
P

Type

6TH6NRZ

Primary pressure

4.9MPa (711psi)

Secondary pressure

0.54~2.35MPa (78~341 psi)

Rated flow

25 L/min (6.6 gal/min)

Weight

Approx. 8kg (18 lbs)

1

2
3
Hydraulic symbol

Performance characteristics
Secondary pressure
[MPa (psi)]

Secondary pressure

2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
(4.7 + 0.5)
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)

Operating
torque

[N.m (lbf.ft)]

1 30'
2 30'

11 30'
12 30'

Pedal angle (degree)

Operating torque
Control diagram

SM0598

T3-2-5

4
SM0597

E175B-E195B

PILOT VALVE

CONSTRUCTION AND OPERATION

The hydraulic remote control valve in TH6NR type is operated with directly-operated pressure-reducing valve.
The pilot control equipment TH6NR in double foot pedal type is made up of the actuating section which is
equipped with 2 foot supports (1), 4 pressure-reducing valves (11), 4 damper system (12) and body (6).
Every pressure-reducing valve is made up of control spool (2), control spring (3), return spring (4) and plunger
(5).
The damper system is made up of plunger (8), orifice (9) and return spring (10).
In stationary condition, the pedal is held in neutral position by return spring (10).
In operation, the foot pedal pushes the plunger (5) used for pressure-reducing valve and plunger (8) used for
dumper system.
The hydraulic oil fed into damper chamber is restricted in the orifice (9) by the pressure corresponding to the
operating speed. [Similarly, when the foot pedal returns to the neutral position with the return spring, the
hydraulic oil trapped in the damper chamber is forced out. Consequently the return speed is controlled by the
flow rate of hydraulic oil led through orifice (9).]
Simultaneously, the plunger (5) is pushed against return spring (4) and control spring (3). The control spring
(3) first moves the control spool (2) downwards, and then closes the passage between control port and the
return pipe to tank port (T). At the same time, the control port is connected to passage (7). When the control
spool reaches to the position the force of control spring (3) balances the pressure of control port (1 or 2), it
starts retaining the condition.
The pressure of control port is proportional to the stroke of plunger (5) and the position of pedal (1) according
to the mutual relations between the control spool (2) and control spring (3). The closed circuit pressure control
makes proportional control of selector valve and high responsibility of hydraulic pump and motor possible in
relation with the characteristics of foot pedal (1) position and control spring (3)

5
3
8

3
11

10
12

4
10
2
9

9
7

2
control ports 1-3

P line

control ports 2-4

T line
SM0599

T3-2-6

CONTROL VALVE

E175B-E192B

CONTROL VALVE
CONTROL VALVE OUTSIDE VIEW (1/2)

PAa2

PAo
PBo

PBa2

OPTION

ARM2
PAc

PLC2

PBa1

BUCKET

ARM1
PAb

PAs

BOOM

(P3)

(P4)

PBr

PCa

TRAVEL RIGHT

SWING
T3

P2 UNLOAD

PTb PBL
TRAVEL LEFT

TRAVEL PRIORITY

PBo

PBa2

VIEW A

PAL

PCb

CT1

T2
PTb

PAr

PBL

PBb

XAb

PBc

MU1

PAa2

PBs
PSs

PAa1

TRAVEL
STRAIGHT

Br

PBr

PAb

Bb (ROD)

CP1

PCb
P1 UNLOAD
Ar

Ab
LCb (HEAD)
CRb
LCc

PAc

Ac (HEAD)

Bc(ROD)

PAo
LCAT2

PBa2
PBp1

CMR1 CMR2

LCAP2

PL

PAr
TRAVEL RIGHT
PBb
BOOM
PBc
BUCKET

PCc

PAa2
ARM2

PBp2

SM1294

T3-3-1

E175B-E195B

CONTROL VALVE

CONTROL VALVE OUTSIDE VIEW (2/2)

PTb

PCa

PBL

(MU2)
P2
(P6)

(P5)

P1

PAL

PCb

CT2

T1
PAL

TRAVEL
LEFT

PB1

BOOM
CONFLUNCE

AL
DR

Pss
PAa1

ARM 1

LCs

Aa (HEAD)

CRa

Bs

OPTION

PB1
PBb

XAb

PBs

PAs
PBc

PSs
PAa1

PAa2

PAo

PBa1
LCa

PAo

PAr

P2
UNLOAD

SWING

T2

PAL

PBL

BL

CCb
As

PBs

PCb

CP2

Ao
LCo

Ba
(ROD)

PBo

MU1
PBp1

Bo

PBp2

SM1295

T3-3-2

CONTROL VALVE

E175B-E192B

CONTROL VALVE PORTS

Port size

Tightening torque

Ports

PF3/4

150~180 Nm (111~133 lbfft)

MU1

Pluged

MU2

Pluged

PF1/2

PF3/8

98~120 Nm (72~89 lbfft)

69~78 Nm (51~58 lbfft)

Description

Ar

Right travel motor port (forward)

Br

Right travel motor port (reverse)

AL

Left travel motor port (forward)

BL

Left travel motor port (reverse)

As

Swing motor port (right)

Bs

Swing motor port (left)

Ab

Boom cylinder head side port (up)

Bb

Boom cylinder rod side port (down)

Aa

Arm cylinder head side port (in)

Ba

Arm cylinder rod side port (out)

Ac

Bucket cylinder head side port (digging)

Bc

Bucket cylinder rod side port (dump)

Ao

Optional pilot port

Bo

Optional pilot port

(T3)

Pluged

(P3)

Pluged

(P4)

Pluged

(P5)

Pluged

(P6)

Pluged

PAa1

Arm 1 (in) pilot port

PBa1

Arm 1 (out) pilot port

PAb

Boom (up) pilot port

PBb

Boom (down) pilot port

PAc

Bucket (digging) pilot port

PBc

Bucket (dump) pilot port

PAL

Travel left (forward) pilot port

PBL

Travel left (reverse) pilot port

PAr

Travel right (forward) pilot port

PBr

Travel right (reverse) pilot port

PAs

Swing (right) pilot port

PBs

Swing (left) pilot port

PAa2

Arm 2 (in) pilot port

PBa2

Arm 2 (out) pilot port

PAo

Option pilot port

PBo

Option pilot port

DR

Drain port

T3-3-3

E175B-E195B

CONTROL VALVE

Port size

Tightening torque

Ports

PF1/4

34~39 Nm (25~29 lbfft)

Pss

Swing pilot high pressure select port

PLc2

Lock valve select pilot port

PBp1

Bypass cut valve (P1 side) pilot port

PBp2
PL

M10
M12

49~65 Nm (36~48 lbfft)

83~110 Nm (61~81 lbfft)

Description

Bypass cut valve (P2 side) pilot port

Attachment boost port

PB1

Boom (up) conflux pilot port

PTb

Travel priority pilot port

PCa

Unload valve (P2 side) pilot port

PCb

Unload valve (P1 side) pilot port

PCc

Bucket (digging) stroke limiter pilot port

XAb

Lowering boom for emergency

P1

Pump port (P1 side)

P2

Pump port (P2 side)

T1

Tank port 1

T2

Tank port 2

SPECIFICATIONS
Item
Model

Specifications E175B

Specifications E195B

KMX13YD/B44061

KMX15YD/B44071

143 (37.78) 2

176 (46.49) 2

Maximum flow rate [L/min (gal/min)]

Maximum set pressure [MPa (psi)]
Main relief valve set pressure [MPa (psi)]
When power boost pressure

37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)

Std 34.3 (4970) [at 602 L/min Std 34.3 (4970) [at 702 L/min
(15.952gal/min)]
(18.52gal/min)]
37.8 (5480) [at 552 L/min
37.8 (5480) [at 602 L/min
(14.52 gal/min)]
(15.92 gal/min)]

Overload relief valve set pressure

(Boom head, Bucket head, Arm rod) [MPa (psi)]

39.7 (5760) [at 30 L/min (8 gal/min)]

Overload relief valve set pressure

(Boom rod, Bucket rod, Arm head) [MPa (psi)]

37.8 (5480) [at 30 L/min (8 gal/min)]

T3-3-4

CONTROL VALVE

E175B-E192B

CONSTRUCTION AND OPERATION

Construction
Control valve (1/6)

PAa2

PAo

275 x 4
274 x 4

213

(P3)

(P4)

212

PBa2

PBo

A
B
273 x 10

273 x 10
T2

P1 unload
(Travel priority)

PCb

PAL

PAr

PB1

PBb

PBs

PCc

PAa1

PAa2

PAo

Travel left

C
Travel right

Boom conflux
(P2 unload)

D
Boom

E
Bucket

PBc

J
C
D

Swing

Pss

Arm 1

F
Arm 2

MU1

PBp1

Option

PBp2

H
A

T3-3-5

SM1288

E175B-E195B

CONTROL VALVE

Control valve (2/6)

K
155

163

101
P2

T1

T2

CT2

K
PAL

PBL

PB1

PCa

PBs

PAs
Pss
PAa1

PBa1

PAo

PBo

PBp2

SECTION A-A
166

161

154

(P4)

161 155 163 164

567 155 163

(MU2)

(P6)

973

102

P1

973

CT1
PTb

PCb

973

973
PBr

PAr

PAb

PBb

973

973

PBc

PAc

PCc

973

973

PBa2

PAa2

973

PBp1

161

(P3)

164 163 155 161

T3-3-6

SECTION B-B
161
SM1289

CONTROL VALVE

E175B-E192B

Control valve (3/6)

202
333
331
336
328
325
601
331
261
309

P1 unload

201
333
331
339
327
325

Travel left

PCb

PAL

MR

331
261
306

PL

157
161
161
512
522
556
561
561
556
522
512

AL

CP2

CMR2

551
561
BL

CMR1

307
261
331
325
328
336
331
333
202

264
PBL

551
561
166
164
166

205
SECTION C-C

PTb

201
333
331
339
327
325
603
331
261
166
164
162
306
511
521

Travel priority

Travel right
Par

202
333
331
336
322
321

Travel left
PB1

AbR

331
261
305
Dr
Ar

CCb

511
521
551
561

CP1

551
561
Br

310

161
166
264

(T3)

PBr

205
SECTION D-D

PCa
SM1290

511
521

P2 unload

T3-3-7

567
154
261
331
325
328
336
331
333
202

E175B-E195B

CONTROL VALVE

Control valve (4/6)

203
333
331
339
320
319
279 x 3
211
331
216
261
266
266 x 4
160
301
561
556
524
514
551
561
521
511

Swing
PBs

Boom
PBb

204
333
331
336
322
321
266
331
261
166

Pss

XAb

303
161

CRb
Ab

As

LCb

LCs

511
524
556
561

Bs

Bb

161
264
264

602

PAb

205

SECTION E-E

266

160
221
561
218
209
333
331
339
320
319
602
331
261

206

PAs

BbR

Bucket
PCc

201
333
331
336
322
321

Arm 1
PAa1

PBc

BcR

602

AaR

331
261
161

304
Bc

511
521
551
561

Aa

LCc

LCa

Ac
CRa
Ba

PLc2

264
603
205
SM1291

PAc
AcR

SECTION F-F

T3-3-8

PBa1

511
521
551
561
161
561
556
524
514
156
167
160 x 2
302
264
211
205

CONTROL VALVE

E175B-E192B

Control valve (5/6)

201
333
331

Arm 2

Option

PAa2

201
333
331
337

PAo

339
326

330
329
604
331
261
311

325
331
261

AoR

161

MU1

308
162
515
521
551
561
561

Ao

511
LCAP2

521
LCo

551

LCAT2

561

551
521
511

Bo
Ba

162
162
162

264
PBa2

264

606
205

PBo

SECTION G-G

205

BaR

605

605
PBp1

PBp2

Bo

BoR

166
153

SECTION H-H

T3-3-9

604
SM1292

E175B-E195B

CONTROL VALVE

Control valve (6/6)

T2

P1

T1

511
521
CT1

551
561
511
P2

521

(MU2)

CT2

551
561

162
SECTION J-J

278 x 5
160
266
207
267

267

528
527
T1

T2

517

SECTION K-K

T3-3-10

518

SM1293

CONTROL VALVE

Tightening torque
Nm (lbfft)

25~29 (19~21)

No.

Parts Name

Q.ty

No.

Parts Name

Q.ty

101 Casing A

309 P1 unload spool

102 Casing B

310 P2 unload spool

153 Plug

311 Option spool

319 Spring

320 Spring

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

110~130 (81~96)

Tightening torque
Nm (lbfft)

E175B-E192B

155 Plug PF1/2

13~17 (9~12)

156 Plug PF 1/8

321 Spring

20~24 (15~18)

159 Plug PT1/4

322 Spring

7.8~9.8

160 Plug PT1/16

325 Spring

161 O-ring

13

326 Spring

162 O-ring

327 Spring

163 O-ring

328 Spring

164 O-ring

329 Spring

166 O-ring

330 Spring

167 O-ring

331 Spring seat

24

333 Spacer bolt

12

201 Cover

202 Cover

336 Stopper

203 Cover

337 Stopper

204 Cover

339 Stopper

205 Cover

511 Poppet

11

512 Poppet

514 Poppet

209 Cover

515 Poppet

211 Lock valve selector sub

517 Boost check valve

212 Plate

518 Poppet

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

16~18
Loctite #262

check

213 Plate

521 Spring

11

216 Boom lowering valve

522 Spring

218 Piston

524 Spring

221 Plug

527 Spring

261 O-ring

12

528 Spring

264 O-ring

130~150 (96~111)

551 Plug

12

266 O-ring

130~150 (96~111)

556 Plug

267 O-ring

561 O-ring

18

25~34 (18~25)

273 Socket bolt

40

98~120 (72~89)

274 Socket bolt

130~150 (96~111)

69~78 (51~58)

567 O-ring

601 Main relief valve

98~120 (72~89

275 Socket bolt

69~78 (51~58)

602 Over load relief valve

9.8~14 (7.2~13)

278 Socket bolt

69~78 (51~58)

603 Over load relief valve

9.8~14 (7.2~13)

279 Socket bolt

69~78 (51~58)

604

301 Boom spool sub

98~120 (72~89)

605 By-pass cut valve

302 Arm 1 spool

69~78 (51~58)

606 Over load relief valve

303 Swing spool

304 Bucket spool

305 Boom conflux spool

306 Travel spool

307 Travel priority spool

308 Arm 2 spool sub

Plug assy for relief valve

hole

140~180 (103~133) 973 Socket bolt

T3-3-11

E175B-E195B

CONTROL VALVE

Main relief valve (601)

123

512

124

125

521

561

541

121

562

122

611

103

663

621

664

104

163

661

614

673

613

652

671
SM0827

Main relief valve (Two step relief)

Tightening
torque
Nm (lbfft)

No.

69~78 (51~58)

103

Plug; M27

562

Back up ring

104

Adjust screw

611

Poppet

121

C-ring

613

Stopper

122

Spacer

614

Piston

123

C-ring

621

Spring

124

Filter stopper

652

Adjust screw

125

Filter

661

O-ring

163

O-ring

663

O-ring

512

Plunger

664

O-ring

521

Spring

28~31 (21~23)

671

Lock nut; M14

541

Seat

46~52 (34~38)

673

Lock nut; M24

561

O-ring

Parts

Qty

Tightening
torque
Nm (lbfft)

T3-3-12

No.

Parts

Qty

CONTROL VALVE

E175B-E192B

Over load relief valve (602, 603, 606)

301

564

563

511

521
123

124

161

562

125

522

611

561

101

621

671

102

541

162

661
612

651
SM0828

Over load relief valve

Tightening
torque
Nm (lbfft)

No.

69~78 (51~58)

101

Body; M27

541

Seat

69~78 (51~58)

102

Plug; M27

561

O-ring

161

O-ring

562

Backup ring

162

O-ring

563

O-ring

123

C-ring

564

Backup ring

124

Filter stopper

611

Poppet

125

Filter

612

Spring seat

301

Piston

621

Spring

511

Plunger

651

Adjust screw

521

Spring

661

O-ring

522

Spring

671

Lock nut; M14

Parts

Qty

Tightening
torque
Nm (lbfft)

28~31 (21~23)

T3-3-13

No.

Parts

Qty

E175B-E195B

CONTROL VALVE

Arm 2 spool (308)

351

371

361

340 319

308

317

340

361

371

350
SM0829

Arm 2 spool
Tightening
torque
Nm (lbfft)

No.

Parts

Qty

Tightening
torque
Nm (lbfft)

No.

Parts

Qty

308

Spool

16~18 (33~35)
Loctite #638

350

Plug

317

Plunger

16~18 (33~35)
Loctite #638

351

Plug

319

Plunger

361

O-ring

340

Spring

371

Backup ring

Boom spool (301)

301

317

340

361

371

350
SM0830

Boom spool
Tightening
torque
Nm (lbfft)

No.

Parts

Qty

Tightening
torque
Nm (lbfft)

No.

16~18 (12~13)
Loctite #638

350

Plug

Parts

Qty

301

Spool

317

Plunger

361

O-ring

340

Spring

371

Buckup ring

T3-3-14

CONTROL VALVE

E175B-E192B

Lock valve selector (211)

101
164

171

201

321

PLc

166

541

Dr

167

511

161
SM0831

Lock valve selector

Tightening
torque
Nm (lbfft)

Qty

Tightening
torque
Nm (lbfft)

No.

Casing

10~14
(7.4~10.3)

171

Socket bolt

161

O-ring

49~59 (36~44)

201

Plug

164

O-ring

321

Spring

166

O-ring

511

Spool

167

O-ring

541

Sleeve

No.
101

Parts

T3-3-15

Parts

Qty

E175B-E195B

CONTROL VALVE

Bypass cut valve (605)

302

301

402

401

Pi

Dr

201

202

101

102

SM0832

Bypass cut valve

Tightening
torque
Nm (lbfft)
98~120 (72~89)

No.

Parts

Qty

Tightening
torque
Nm (lbfft)

No.

Parts

Qty

101

Plug

301

Plunger

102

O-ring

302

Spring

201

Poppet

401

Plug

202

Spring

402

O-ring

69~78 (51~58)

T3-3-16

CONTROL VALVE

E175B-E192B

Swing shuttle valve cover (204)

PBs

555

Pss

SECTION B-B

A
166

542

541

PBs

G1/4

G3/8

B
Pss

554

202

PAs

SECTION A-A

SM0833

Swing shuttle valve cover

Tightening
torque
Nm (lbfft)

No.

Parts

Qty

Tightening
torque
Nm (lbfft)

No.

Parts

Qty

166

O-ring

542

Seat

202

Cover

25~29 (18~21)

554

Plug

541

Steel ball

7.9~9.8
(5.9~7.2)

555

Plug

T3-3-17

E175B-E195B

CONTROL VALVE

HYDRAULIC CIRCUIT DIAGRAM

123456-

Travel priority
P1 Unload
Travel right
Boom
Bucket
Arm 2

789101112-

T3-3-18

Option
Arm 1
Swing
P2 Unload
Boom conflux
Travel left

CONTROL VALVE

E175B-E192B

OPERATION
1.

In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through
unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic
tank through tank port T1. And when the operation of unloading valve is impossible due to failure of electric
control system, because the by-pass cut valve (605) located on the downstream of center by-pass
passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through travel priority spool
(306), and then flows though the center by-pass passage (52) which passes through travel right, boom,
bucket and arm 2 and the by-pass cut valve (605) on P1 side, and flows into low pressure circuit (D) and
boost check valve (517), and then returns to the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure
circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to
the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is impossible,
because the by-pass cut valve (605) located on the downstream of center by-pass passage (55) opens,
the hydraulic oil through hydraulic pump P2 port passes through main passage, and then flows though the
center by-pass passage (55) which passes through travel left, swing, arm 1 and option and the by-pass
cut valve (605) on P2 side, and flows into low pressure circuit (D) and boost check valve (517), and then
returns to the hydraulic tank through tank port T1.

(D)
605

52

517

306

T1

P2
P1

309
55

310

605
(D)(*)
SM1297

In neutral position
(*) Connected to low pressure circuit of P2 side casing

T3-3-19

E175B-E195B
2.

CONTROL VALVE

Actuation in travel operation

a) In travel independent operation
On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed
into travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left motor.
The pilot pressure enters ports PAr and PAL, and the right and left travel spools (306) move rightward
the force of springs (325) (327) and the secondary pressure of solenoid proportional valves [X1] and
[X2] acts on ports PCb and PCa and switches unloading spools (309) (310).
The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows
into main circuit, and flows through between the perimeter of right travel spool (306) and casing and is
fed into A side of right travel motor through port AR. The hydraulic oil delivered by hydraulic pump P2
flows through between the perimeter of left travel spool (306) and casing and is fed into A side of left
travel motor through port AL similarly to the stream of hydraulic oil delivered by hydraulic pump P1.
But in the meantime, the return oil from the B sides of left and right travel operations passes through
between the perimeter of right and left travel spools (306) and casing through ports Br and BL and flows
into low pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank through
tank port T1. On traveling reverse (at the time when the pilot pressure actuates on ports PBr and PBL
of control valve), the actuation is similar to that in forward travel operation.
Left travel motor

AL
327

325

BL
CP2

306

PBL

PAL

SM1298

In left reverse travel (at PBL is pressurized)

T3-3-20

CONTROL VALVE

E175B-E192B

b) In travel priority operation

When actuator other than travel operation and the travel operation are operated simultaneously in the
said item a) "In travel independent operation" the pilot signal from the outside acts on port PTb and the
travel straight spool (307) moves upward.
With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is
used for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B
and into main passage, and is used for right and left travel operations as hydraulic oil realizing the
actuator and travel simultaneous operation. (Travel priority function) At circuit (I) position, a part of
hydraulic oil delivered by hydraulic oil P1 passes through circular notch on travel priority spool (307)
and enters from P1 to B enabling the hydraulic oil to be supplied from actuator side to travel side. And
at circuit (II) position, the circular notch on travel priority spool (307) closes and the pump line on the
travel sides is independent from pump line on actuator.

CMR2

P2

B
CMR1

CMR2

CMR1

P1

P2

B
P1

307

307

325

325

328

328

PTb

PTb
P2 P1

P2 P1
PTb

Dr

Dr
B

PTb
Dr

Dr

A
B

Circuit (I)

Circuit (II)
A - to each actuator
B - to travel right
Movement of travel priority spool

T3-3-21

A
SM1299

E175B-E195B
3.

CONTROL VALVE

Actuation in bucket operation

a) In bucket digging operation
On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves
leftward the force of springs (319) (320), and simultaneously the secondary pressure of solenoid
proportional valve [XI] acts on port PCb and switches unloading spool (309).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens
load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing
through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac).
In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter
of bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517),
and returns to the hydraulic tank through tank port T1.
And when the flow rate of hydraulic oil delivered by hydraulic pump P1 with engine running in low idling
is low, the pilot signal from the outside enters port PCc and piston (218) moves rightward. With this
actuation, the maximum leftward stroke of bucket spool (304) is limited, consequently the area of
passage between the perimeter of bucket spool (304) and casing minimizes. Consequently the flow
rate of return oil from bucket cylinder rod side (R) reduces and bucket cylinder moving speed is limited
preventing cavitation which may be occurred on bucket cylinder head side (H). (Stroke limiter ON)

53

218
PCc

PAc

PBc

(D)
320

319

304

Bc
511

(R)

Ac

LCc

(H)

In bucket digging operation (Stroke limiter ON)

T3-3-22

SM1300

CONTROL VALVE

E175B-E192B

b) In bucket dumping operation

On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves
rightward the force of springs (319) (320), and simultaneously the secondary pressure of solenoid
proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered
by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511),
and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage,
and supplied to bucket cylinder rod side (R) through port (Bc).
In the meantime, the return oil from bucket cylinder head side (H) passes through between the
perimeter of bucket spool (304) and casing and flows through low pressure circuit (D), and returns to
the hydraulic tank through tank port T1. The return oil does not pass through boost check valve (517).
Downstream of boost check valve

(D*)

53

218
PCc

PAc

PBc

Bc
320

319

304

511

(R)

Ac

LCc

(H)

(D*) Downstream of boost check valve

In bucket dumping operation

T3-3-23

SM1301

E175B-E195B
4.

CONTROL VALVE

Boom
a) In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves
rightward against the force of springs (319) (320), and simultaneously the secondary pressure of
solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309).
And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of
springs (321) (322) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa
and switches unloading spools (310).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens
load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing
through U-shaped passage, and supplied to the both boom cylinders head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter
of boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517),
and returns to the hydraulic tank through tank port T1.

301

(D)

(R)

(R)

(H)

(H)

Bb

514

511

53
LCb

Ab

(A)

319

320

CRb

PAb

PBb

SM1302

(A): BH chamber
In boom up operation (Boom spool)

T3-3-24

CONTROL VALVE

E175B-E192B

b) In boom up conflux operation

The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel
passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter
of boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens
conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and
confluents the hydraulic oil from the hydraulic pump P1 side.

PB1

322

321
511

CCb

(B)

56

305

SM1303

(B): Conflux passage to Ab port of P1 casing

In boom up conflux operation (Boom conflux spool)

T3-3-25

E175B-E195B

CONTROL VALVE

c) In boom down operation

On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves
leftward against the force of springs (319) (320) and the secondary pressure of solenoid proportional
valve [X1] acts on PCb and switches unloading spool (309). And simultaneously the spool of lock valve
selector (211) is switched, and the poppet (514) is released because the spring chamber of lock valve
poppet CRb (514) is connected to the drain circuit.
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and
opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and
casing through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb).
In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port
(Ab). Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool
(301) is released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH
chamber and passes through between the perimeter of boom spool (301) and casing, and flows
through low pressure circuit (D) and boost check valve (517), and the returns to the hydraulic tank
through tank port T1. And a part of the return oil flows into the inside of boom spool (301) through
circular notch of boom spool (301). Since the return oil contains sufficient pressure with the self weight
of boom, arm, etc. the return oil passes through inside passage of boom spool (301) and pushes and
opens poppet (317) leftward as shown in the figure and flows through the circular notch, and then
supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation function)

301

317

(R)

(R)

(H)

(H)

53
Bb

LCb

Ab

(A)

514

511

319

320

CRb

PBb

PAb

(D)
(A): BH Chamber

In boom down operation

T3-3-26

SM1304

CONTROL VALVE
5.

E175B-E192B

Arm operation
a) In arm out operation
On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302)
moves leftward against the force of springs (321) (322), and simultaneously the secondary pressure of
solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs
(325) (326) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and
switches unloading spools (309).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens
load check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool
(302) and casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass
passage (52) and pushes and opens load check valve LCAP2 (515) and enters U-shaped passage,
and pushes and opens load check valve LCAT2 (511) provided with orifice, and flows into U-shaped
passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and
casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil
from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side
(R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of
arm 1 spool (302) and casing and passes though low pressure circuit (D) and casing inside passage
(HH) and then flows into low pressure circuit (D) through between the perimeter of arm 2 spool (308)
and casing.
The return oil in low pressure circuit (D) returns to hydraulic tank through tank port T1 without passing
through boost check valve (517).
(R)

(H)
322 321

302

Aa

511 LCa

(AR) CRar Ba

514

211

56
PBa1

PAa1
Arm 1
Arm 2

P1

(D')

LCAT2
LCAP2

(D)
(D')

HH

(D')

RH

52

RR

PBa2
Dr

Dr
PBa2

PAa2

P1

PAa2

Ba
(ROD)

(F)
Aa (HEAD)

53
(G)

MU1

326

325

308

515

LCAP2 LCAT2

511

(F): To arm 1 spool

(G): To pilot cut valve
In arm out operation

T3-3-27

SM1308

E175B-E195B

CONTROL VALVE

b) In arm in operation (At light load: arm recirculation function)

On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302)
moves righrtward against the force of springs (321) (322), and simultaneously the secondary pressure
of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same
time, since the spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet
CRar (514) is connected to the drain circuit and the retention of poppet (514) is released.
And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308)
moves rightward against the force of springs (325) (326) and the secondary pressure of solenoid
proportional valve [X1] acts on port PCb and switches unloading spools (309). But in light load
operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in the
position of circuit (I).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens
load check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool
(302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic
pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAP2
(515) and enters U-shaped passage, and also the oil from parallel passage (53) pushes and opens load
check valve LCAT2 (511) provided with orifice and flows into U-shaped passage. And then the
hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing from U-shaped
passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic oil
from hydraulic pump P2 side.
The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa).
In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba).
Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302)
is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The
return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside
passage (RR), but because arm 2 spool (308) does not connect to low pressure passage (D) at circuit
(I), the entire flow rate flows into arm 1 spool (302).
The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing, and
flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular
notch (a) of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than
that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool
(308) passes through check valve (317) and flows into casing inside passage (HH) and the supplied
to arm cylinder head side (H) again. (Arm recirculation function)
And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319), and
flows through boost check valve (517) through load pressure circuit (D) and returns to the hydraulic tank
through tank port T1.

T3-3-28

CONTROL VALVE

E175B-E192B

(R)

(H)

322

302

321

511

Aa

LCa

(AR) CRar

Ba

514

211

56
PAa1

PBa1
Arm 1
(D')

HH

(D)

52 RR

RH

Arm 2
PAa2

PBa2

[XR]

53
MU1

326

325

LCAP2 LCAT2

308 319 515

511

P1
LCAT2

(D')

LCAP2

(D)

P1
PBa2
Dr

PAa2
Dr

Circuit (I)

(F)
Aa (Head)

Ba
(Rod)
(G)

(F): To arm 1 spool

(G): To pilot cut valve

In arm in operation (At light load: arm recirculation function)

T3-3-29

SM1309

E175B-E195B

CONTROL VALVE

c) In arm in operation (In heavy load operation)

The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but
in heavy load operation (work required large power); the function causes the power loss. This control
valve selects the presence of recirculation function in light and heavy load operation with solenoid
proportional valve [XR]. (Variable recirculation function)
The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the
same as that in light load operation, differs from that of return oil. In heavy load operation, solenoid
proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from
arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve
poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes
and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led
to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR). But because arm 2
spool (308) is connected to low pressure passage (D) at circuit (II), almost all the return oil passes
through between the perimeter of arm 2 spool (308) and casing and flows through boost check valve
(517) through low pressure (D) and returns to the hydraulic tank through tank port T1.
The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing
and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through
circular notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head
side (H) is higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside
passage (HH), but flows through check valve (319) and passes through boost check valve (517)
through low pressure (D) and returns to the hydraulic tank through port T1.
(R)

(H)

322

302

321

Aa

511

LCa

(AR) CRar

Ba

514

211

Circuit (II)
P1

56

PAa1

(D')
(D)

PBa1

HH

RH

(D)

52 RR

Arm 2

P1
PBa2
Dr

Ba

PAa2

PBa2

[XR]

LCAP2

PAa2
Dr

Arm 1
(D')

LCAT2

53

(F)
Aa(Head)

(Rod)

(G)

MU1

326 325

308 319 515

LCAP2 LCAT2

511

(F): To arm 1 spool

(G): To pilot cut valve

In arm in operation (In heavy load operation)

T3-3-30

SM1310

CONTROL VALVE
6.

E175B-E192B

Swing operation
On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves
leftward or rightward against the force of springs (321) (322), and simultaneously the secondary pressure
of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through
shuttle valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot
pressure acts on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and
then is led to port Pss.
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load
check valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through
U-shaped passage and is supplied to swing motor A side or B side through port (As) or (Bs).
In the meantime, the return oil from swing motor A side or B side passes through between the perimeter
of swing spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and
boost check valve (517), and then returns to the hydraulic tank through tank port T1.

204

PAs
PBs
Pss

Bs
(D)

As

LCs
56

511
B

(D)

303

321

322

Swing motor
Swing operation

T3-3-31

SM0847

E175B-E195B
7.

CONTROL VALVE

Spool actuation for operation in option

This spool is used to control the attachment in option like Nibbler (Crusher), etc.
When the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters
ports PAo, and option spool (311) moves against the force of springs (329) (330), and simultaneously the
secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool
(310).
The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and
opens load check valve LCo (511), and flows through between the perimeter of option spool (311) and
casing through U-shaped passage and is supplied to actuator for attachment through port (Ao).
In the meantime, the return oil from actuator for attachment swing passes through between the perimeter
of option spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost
check valve (517), and then returns to the hydraulic tank through tank port T1.
The operation where the pilot pressure acts on PBo port is the same as the above.
* The oil passage is branched toward the end side of control valve at the mid course from option spool
(311) to port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of
control valve, this oil passage is used as passage to connect to N&B selector valve.

604

511

311

LCo

Ao
330

Bo

329
AoR

(O)

BaR
56

PAo

PBo

(D)
Spool actuation for operation in option

T3-3-32

SM1305

CONTROL VALVE
8.

E175B-E192B

Lock valve operation

The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R)
and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding
pressure caused by each cylinder.
a) At boom spool neutral position (Arm spool makes the same operation.)
When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the left
side as shown in the figure. At this position, passages Sa and Sb are connected each other at the inside
of bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of lock valve
poppet, the holding pressure receiving from boom cylinder head side (H) passes from passage Sa to
bushing (541) spool (511) and is connected through passage Sb, consequently the lock valve poppet
(514) is kept pressed the lower side as shown in the figure and restricts the leaking to the minimum.

RH

514

BH

Sb

Dr

PLc

511

541

CRb
Ab

(a)

PLc Sa Sb

(b)

321

Dr

SECTION A-A

Sa
319

320

PBb

Dr

301

(D)

1. Return oil from boom cylinder head

2. Lock valve selector

Lock valve operation (At boom spool neutral position)

T3-3-33

SM1306

E175B-E195B

CONTROL VALVE

b) In boom down operation (In arm in operation)

Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511)
moves rightward as shown in the figure. After the spool (511) was moved, orifice (a) of bushing (541)
first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving
from boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514).
And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR
through spring chamber (319).
With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of
bushing (541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet
(514) down as shown in the figure is released. And since lock valve poppet (514) receives holding
pressure from boom cylinder head side (H) to the pressure receiving section in ring type which is made
up of guide diameter and seat diameter of lock valve poppet (514), lock valve poppet (514) is pushed
upward and is open.
The said operation, in boom down operation, is performed before making the opening (meter out
opening) which is used to return the return oil from the boom cylinder head side of boom spool (301) to
the tank open, the operation has no effect on the operability of boom down operation.
In case of arm-in operation, the operation is the same.

RH

514

BH

Sb

PLc

Dr

541

CRb

(a)

Ab

511

(b)

PLc Sa Sb
A

321
Dr

SECTION A-A
Sa
319

320

PBb

Dr

301

(D)

1. Return oil from boom cylinder head

2. Lock valve selector

Lock valve selector operation (At boom down operation)

T3-3-34

SM1307

CONTROL VALVE
9.

E175B-E192B

By-pass cut valve

This by-pass cut valve is located on the most downstream of center by-pass passage (52) on P1 side and
center by-pass passage (55) on P2 side. And this by-pass cut valve controls the flow rate of hydraulic oil
from each center by-pass passage to low pressure passage (D).
a) In normal operation
On starting the engine, the secondary pressure of solenoid proportional valves [X1] and [X2] act on pilot
ports PBp1 and PBp2 of by-pass cut valve (605). This secondary pressure is the same as that actting
on pilot port PCb of P1 unloading spool (309) and pilot port PCa of P2 unloading spool (310).
The following explains the by-pass cut valve on P1 side, the operation of by-pass cut valve on P2 side
is the same. The secondary pressure of solenoid proportional valve [X1] enters PBp1 and plunger (301)
moves downward against the force of spring (302). The taper section at the top end of plunger (301) is
seated on the seat of plug (101), shutting off the spring chamber of poppet (201) and spring chamber
(b) of plug (101).
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and
enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring
chamber (b) of plug (101) are disconnected, spring chamber (a) of poppet (201) is the same pressure
as center by-pass passage (52) and poppet (201) is pushed the seat section of casing shutting off
center by-pass passage (52) and low pressure passage (D).
Consequently, in normal operation, center by-pass passage (52) is always disconnected from low
pressure passage (D) and the hydraulic oil delivered by hydraulic pump P1 does not flow through center
by-pass passage (52), but returns to the hydraulic tank through P1 unloading spool (309).

[X1]
PBp1

301

302

(C)

(b)

Dr

101

201

(a)

(D)
52

SM0969

By-pass cut valve (In normal operation)

T3-3-35

E175B-E195B

CONTROL VALVE

b) At the time when failure occurred

When the electric system is failed and consequently the secondary pressure of solenoid proportional
valves [X1] and [X2] is not produced, plunger (301) is moved upward by the force of spring (302). Since
the taper section at the top end of plunger (301) is lifted up from the seat section of plug (101), spring
chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other.
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and
enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring
chamber (b) of plug (101) are connected each other, the hydraulic oil in spring chamber (a) of poppet
(201) passes through from seat section of plug (101) to spring chamber (b) and flows into passage (Dr)
through passage (c). Consequently the pressure in spring chamber (a) of poppet (201) lowers, poppet
(201) receives the pressure of center by-pass passage (52) and is lifted up against the force of spring
(202), and the hydraulic oil from center by-pass passage (52) flows into low pressure passage (D)
through poppet (201) of by-pass cut valve (605). Therefore when the electric system is failed, P1
unloading spool (309) is shifted to the neutral position and the passage to low pressure passage (D) is
cut off, but because center by-pass passage (52) is connected to low pressure passage (D) through
by-pass cut valve (605), the abnormal rise of the pump pressure is prevented.

PBp1

301

302

(C)

(b)

Dr

101

201

(a)

(D)

202

52

SM0970

By-pass cut valve (In condition of failure)

T3-3-36

CONTROL VALVE

E175B-E192B

10. Boost check valve, By-pass check valve

a) Boost check valve
The boost check valve is located between low pressure passage (D) and tank port T1 and generates
boost pressure necessary for the low pressure passage.
a. In normal operation
The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against
the force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the
pressure generated by spring (527) is used as the boost pressure for the low pressure passage.
But the return oil used for the arm out and bucket dumping operation does not pass through boost
check valve (517), but returns from low pressure passage (D) to hydraulic tank through tank port
T1.
b. In make up operation
When supplying to make up the flow rate through low pressure passage (D) after the swing
operation is suspended, if the hydraulic oil quantity in low pressure passage (D) is not enough, the
deficient hydraulic oil is made up from hydraulic tank into low pressure passage (D).
When the deficient hydraulic oil in low pressure passage (D) is not sufficient, the pressure of low
pressure passage (D) is lowered. If the pressure of low pressure passage (D) is lowered to the
pressure at tank port T1, poppet (102) housed in boost check valve (517) receives the pressure at
tank port T1 on the receiving section in ring type which is made up of guide diameter and seat
diameter of poppet (102), and is pushed upward and opens, and the hydraulic oil flows from the
hydraulic tank to low pressure passage (D) to make up the deficient flow rate.

527
528
(D')

T2
T1

518

102

517

(D)

528

527

T2

518

102

T1

517

(D)

2
SM0971

1. In normal operation
2. In make up operation

Boost check valve operation

T3-3-37

E175B-E195B

CONTROL VALVE

b) By-pass check valve

Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass
check valve actuates and prevents the pressure at tank port T1 from going up higher than the specified
pressure, and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank
are protected from possible damage.
When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve
(518) is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly
returns to the hydraulic tank through tank port T2.

527

528
(D')
T2

518
T1

102

(D)

517

By-pass check valve operation

T3-3-38

SM0992

CONTROL VALVE

E175B-E192B

11. Emergency manual valve for leaving attachment

Needle valve (Emergency manual valve for lowering attachment) is equipped internally between Ab port
of boom cylinder head side and boom lock valve. For safety, this valve lowers risen attachment to the
ground, if the machine stops with engine trouble. Only in case that the boom is lowering, the pressure in
the cylinder of attachment can be released by operating arm or bucket control lever.
a) Functional explanation
In normal cases, the needle valve was blocked completely to prevent pressure leak of boom circuit.
a. Lowering of boom
Loosen lock nut at first and loosen the needle valve to the end of contact.
IMPORTANT: needle valve is provided the mechanism of stopper against falling out. But the mechanism might
cause break by undue force.
The oil of boom cylinder (1) head side (H) flows into drain passage (4) through orifice, and boom
lowers slowly. The time of boom lowering to the ground takes about 4 to 8 minutes in accordance
with machine position and holding pressure
b. Function of actuator
Oil pressure of XAb port is reduced by releasing holding pressure of boom cylinder head side to
drain passage (4) through orifice.
Operation of actuator with pilot control valve is possible by leading medium pressure via orifice from
XAb port to shuttle valve (7). In this function, this leading of medium pressure ensures primary
pressure of remote control (source of pressure). This function ensures that the cylinder movement
of boom, arm, bucket and others can be actuated only downward by self weight. Consequently the
releasing of pressure becomes possible.
But after attachment is lowered to the ground by lowering boom, holding pressure disappears, and
remote control, via pilot valve, becomes impossible.
c. Boom cylinder with holding valve
If the boom cylinder has holding valve, loosen above-mentioned needle valve together with port
relief valve of holding valve, and boom cylinder starts boom lowering.
Spool of holding valve moves to open side by back pressure of port relief valve, and holding
pressure of boom cylinder is led to Emergency manual valve for lowering attachment, operation of
actuator by pilot valve is possibile.

T3-3-39

E175B-E195B

CONTROL VALVE

Emergency manual valve for lowering attachment operation

(R)

1
(H)

Ab

3
4
6
5

XAb

8
9

123456789-

SM0993

Boom cylinder head side

Control valve
Hydraulic oil tank
Drain passage
Needle valve
Lock nut
Shuttle valve
To lever lock solenoid valve
To control pilot valve

T3-3-40

SWING DEVICE

E175B-E195B

OUTLINE
General view

3%

7+5($')25
(<(%2/70
'(37+

5(/,()9$/9(
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3$

60

Symbol

Port name

Port size

Tightening torque
Nm (lbfft)

A, B

Main port

PF 3/4

167 (123)

DB

Drain port

PF 3/8

74 (55)

Make-up port

PF 3/4

167 (123)

Pressure measuring port

PF 1/4

36 (27)

Parking brake release port

PF 1/4

36 (27)

Gear oil level gauge

PF 1/2

65 (48)

IP

Gear oil filling port

PF 3/4

98 (72)

PA, PB
PG

T3-4-1

E175B-E195B

SWING DEVICE

PB

ANTI-REACTION

PA VALVE BLOCK
DB

A,(B)

PG

IP
FILLING PORT
PT3/4

Grease
fitting

SM0571

PG
DB

PB

PA

A
Hydraulic diagram

T3-4-2

SM0572

SWING DEVICE

E175B-E195B

Specification
Machine

E175B

M5X130CHB10A598/
M5X130CHB10A
285-122
58B/305-99
Swash-plate type, fixed-displacement plunger
motor

Model

Hydraulic motor

Type

Antireaction
valve block

E195B

Displacement

cm3

Working pressure

MPa (psi)

Max. flow

L/min
(US gpm)

Braking torque

Nm (lbfft)

583818 (430603)

Release pressure

MPa (psi)

2.3~5.0 (333~725)

Relief set pressure

MPa (psi)

Mass

kg (lbs)

121.6

Type
Mass

Hydraulic motor assy mass

99.2
34,3 (4974)

143 (37.8)

28 (4060)
49 (108)

Reduction unit

2KAR6P72/250-712

kg (lbs)

2.5 (5.5)

kg (lbs)

5.5 (114)
Planetary 2-stage

Reduction ratio

Total mass

30 (4350)

2KAR6P72/240-712

Speed reduction type

15.38
Gear oil SAE90 (API class GL4 grade)

Lubicate oil
Lubicate oil volume

176 (46.5)

L (US gal)

Grease

3.0 (0.8)
Extreme pressure lithium base # 2 grease

Grease volume

kg (lbs)

Mass

kg (lbs)
kg (lbs)

T3-4-3

Approx. 1.0 (2.2)

144.2 (318.0)

144.4 (318.4)
196 (432)

E175B-E195B

SWING DEVICE

CONSTRUCTION
Swing motor

993
VALVE CASING SECTION

702 712

ANTI
CAVITATION
PLUNGER

Arrangement of brake spring

351
355

051 RELIEF VALVE

469
488

051-1
ANTI-REACTION
VALVE BLOCK

401

052
151
303 162
171 161
985

163

712

985

444

984

131

451

472

390 391
VIEW I

702
707
706
100
980
743
742
111

400-1
400-2

121
994

123
122

114
124 443

491

052

400
SECTION A-A

301

101
SM0573

T3-4-4

SWING DEVICE

E175B-E195B

Tightening

No.

051

Parts

Relief valve; M33x1.5

051-1 O-ring; 1B G30

Q.ty

torque
Nm
(lbfft)
177 (130)

Tightening

No.

400

Parts

Anti-reaction valve; M22x1.5

Q.ty

400-1 O-ring; 1B P20

400-2 Backup ring

torque
Nm
(lbfft)
69 (51)

052

Anti-reaction valve sub

100

Casing for anti-reaction valve

401

Socket bolt; M2045

101

Drive shaft

443

Roller bearing

111

Cylinder

444

Roller bearing

114

Spring plate

451

Pin

121

Piston

469

ROMH plug; M30x1.5

122

Shoe

472

O-ring; W1516,WG40

123

Set place

488

O-ring; 1B P28

124

Shoe plate

491

Oil seal

131

Valve plate

702

Brake piston

151

Plug; PF1/4

706

O-ring; W1516,WG38

161

O-ring; 1B P11

707

O-ring; W1516,WG41

162

O-ring; 1B P12

712

Brake spring

16

163

O-ring; 1B P6

742

Friction plate

171

Socket bolt; M855

743

Separator plate

301

Casing

980

Plug; PF1/4

0.9 (0.66)

303

Valve casing

984

Plug; PF3/8

1.7 (1.2)

351

Plunger

985

Plug; PF3/4

4.4 (3.2)

355

Spring

993

Plug; PT1/2

65 (48)

390

Name plate

994

Plug; PT3/4

98 (72)

391

Rivet

36 (27)

29 (21)

T3-4-5

430 (318)

334 (246)

E175B-E195B

SWING DEVICE

Swing reduction unit

Be careful about installation
direction of retaining ring.
Caulk these 2 places
Apply Three Bond #1360
with punch.
or equivalent. 23
OIL FILLING PORT PT3/4
LEVEL PORT PT1/2
19 2

Apply Loctite #515.

28

15

16 3
SURFACE OF
Be careful about
LUBE OIL
15
installation direction
of spring pin.
18
VIEW
(II) (4 places)
5

6
7
4
8
Apply Loctite #515.

17

Be careful about
installation direction 20
of retaining ring.
10
Apply Loctite #515.
12

18

Drive this spring pin

22 into 1mm lower than
the surface of spider.
9
25
26

31
Install the filling port
of this fitting toward
motor side.

24
13

32

27 Apply seal tape or

Loctite #577.

Fill up this space

with grease.
11
30
21
1

SM0574

Tightening

No.

Parts

Q.ty

torque
Nm
(lbfft)

Tightening

No.

Parts

Q.ty

Pinion shaft

17

Needle bearing

#1 sungear

18

Washer

#1 pinion

19

Retaining ring

#2 sungear

20

Retaining ring

#2 pinion

21

Sleeve

Ring gear

22

Spring pin 8x25

Spider assy

23

Capscrew; M14X135

11

Spider

24

Cap

Shaft

25

Tube L=112

10

Spherical bearing

26

Elbow

11

Spherical bearing

27

Plug

12

Oil seal

28

Retaining ring

13

Housing

30

Oil seal

15

Thrust washer

31

Grease fitting; PT 1/8

16

Needle bearing

32

Relief fitting; PT 1/8

T3-4-6

torque
Nm
(lbfft)

181 (134)

69.1 (51)

SWING DEVICE

E175B-E195B

HYDRAULIC MOTOR
Operation
If the high pressure oil flows into the cylinder
through the inlet port (a) of valve plate (131), as
shown on the figure on the right, the hydraulic
pressure acts upon piston (121) and creates force F
in the axial direction.
The force F may be divided into force F1 vertical to
shoe plate (124) via shoe (122) and force F2 at right
angles with the shaft.
The force F2 is transmitted to cylinder block (111)
via pistons (121) and causes drive shaft to turn so
as to produce a rotating moment.
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to drive
shaft by turns by pistons connected to inlet port of
high pressure oil.
If the oil supply and discharge directions are
reversed, the drive shaft rotates in the opposite
direction.
Theoretical output torque T can be given by the
following equation.

T=

Cylinder block (111)

F2

F1
F

Drive shaft (101)

Shoe
plate
(122)

Shoe
(122)

Valve
plate
(131)

Piston
(121)

SM0575

PXq
2X

Low pressure oil

p: Effective differential pressure MPa

q: Displacement per revolution cc/rev

OUTLET

High pressure oil

INLET

(a)

SM0576

T3-4-7

E175B-E195B

SWING DEVICE

VALVE CASING SECTION

Operation of anti-cavitation check plunger
Since the system using this type of motor is not
equipped with a valve having a counterbalance
function, the motor is rotated beyond the oil feed
rate in some cases.
The system has check plunger (351) and sucks in
deficient oil, in order to prevent cavitation from
occurring due to oil deficiency.

351

M port

Operation of relief valve

1.

Consider where the relief valve is pressurized.

The pressure at the P, R ports is equal to the
tank pressure at the beginning, as shown in Fig.
SM0578.
The relief valve begins to operates when the
hydraulic pressure that is determined by the
product of the pressure-receiving area A1 of
plunger (301) and the pressure P balances the
hydraulic pressure that is determined by the
product of the pressure-receiving area A2 of
the plunger (301) and the pressure Pg of
chamber g.
Thereafter, the pressure of chamber g rises and
the piston 1 (302) begins to stroke. The load to
spring (321) increases by this movement of the
piston.
As the result, the relief pressure P is raised and
controlled in the pressure boost time t1 from P1
till Ps.
This process is explained in the following in the
relationships between the movements of the
components and the relief pressure:
a) Condition shown in Fig.SM0579.
If the P port of the relief valve is pressurized,
pressure is built up in chamber g via the
restrictor m of plunger (301).
The hydraulic pressure acting on plunger
(301) increases and when it balances the
load Fsp of spring (321), the relief valve
performs relieving action by the pressure
P1.
This relationship is expressed as:
P1A1=Fsp1+Pg1A2
where Fsp1:
primary set load value of spring (321).

T3-4-8

(Make-up port)

DIRECTIONAL VALVE
SM0577

Chamber h
Orifice m

Spring (321)

Piston 1 (302)

Pressure
receiving
area A1

R
Plunger (301)

Chamber g
A3 A2
A4
Orifice n
SM0578

Orifice m

Spring (321)

Chamber h
Pin (303) Piston 1 (302)

P
R
Plunger (301)

Orifice n

Chamber g
SM0579

SWING DEVICE
b) Condition shown in Fig.SM0580.
The pressure of chamber g acts upon the
pressure-receiving area A3-A4 of piston 1
(302). When the hydraulic pressure rises
above the load of spring (321), the piston 1
begins to move to the left.
On that occasion, since the machine turns to
the left while discharging the oil of chamber
h arranged between piston 1 and adjust plug
(401) into chamber g via orifice n provided in
piston 1 (302), chamber h serves as a
dumping chamber.
The load of the spring increases slowly till
piston 1 reaches the end of the adjust plug.
The relief pressure P rises smoothly.

E175B-E195B

Orifice m

Chamber h
Pin (303) Piston 1 (302)

P
R
Plunger (301)

Orifice n

Chamber g
SM0580

Orifice m

c) Condition shown in Fig.SM0581

The machine does not travel to the left
further when piston 1 (302) arrives at the
end of adjust plug (401). Therefore, the
relief valve keeps its normal relieving action
whereby the relief pressure is held at P2.
In the processes a. to c. above, the relief
pressure changes as shown in Fig.SM0582.

Spring (321)

Spring (321)

Pin (303)

Piston 1 (302)

P
R
Plunger (301)

Orifice n

Chamber g
SM0581

2.

Function when the relief valve pressure is

reduced.
Let us consider the pressure of the P port is
reduced.
When the pressure at port P is reduced to zero,
the pressure of chamber g falls to the tank
pressure level. The result is that the plunger
(301) which is now open moves to the left and
is seated on seat (341). At the same time, the
piston 1 (302) moves to the right by the action
of spring (321) and returns to the condition of
Fig.SM0580.
SM0582

T3-4-9

E175B-E195B
3.

SWING DEVICE

Operation of anti-reaction valve

a) Neutral condition
Fig.SM0583 illustrates the relationship
between the neutral condition of the antireaction valve and the hydraulic circuits.
Now, let us consider a braking condition in
which brake pressure generates on the AM
port side.
b) When brake pressure occurs:
If pressure (P) generates at the AM port, it
passes through the passage L, the hole on
the shaft of seat (313) and the passage m of
plunger (311) and is led to the n chamber.
When the pressure P rises above a value
(Ps) set by spring (321), plunger (311)
compresses spring (321) and shifts it to the
left.
Seat (313) compresses weak spring (322)
as pushed by plunger (311) and moves to
the left.
c) At anti-reaction action
When inertia load stops moving (point Y Fig.
SM0587), brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward
the right return side by the action of spring
(321). Seat (313) tries to move to the right by
the action of spring (322), but since
chamber p provides damping action by
orifice g, the return of the seat makes a time
delay with regard to the return of the
plunger.
Consequently, seat t opens. This makes a
passage connecting the AM port and BM
ports or both ports of the hydraulic motor by
way of trk. The result is that the
pressures at the AM and BM ports become
equal (Pb), falling into the condition at point
Z in Fig.SM0582. This prevents the
hydraulic motor from swing shock by the
closing pressure of the AM port.

ANTI REACTION
VALVE
ANTI REACTION
VALVE
SM0583

k
322

313

321

311

SM0584

P=PS
L

322

313
p

321

311

321

311

SM0585

P<PS
L
k
322 313

SM0586

PS
PB

T
SM0587

T3-4-10

SWING DEVICE

E175B-E195B

BRAKE SECTION
Operation
The cylinder (111) is jointed by drive shaft (101) and
a spline. Separator plate (743) is fixed in its
circumferential direction by circular grooves
provided in casing (301).
Now, if the friction plate (742) splined to the outer
circumference of the cylinder is pressed against
casing (301) via separator plate (743) and brake
piston (702) by the action of brake spring (712),
frictional force is created between friction plate (742)
and casing (301) and between separator plate (743)
and brake piston (702). The frictional force bounds
the drive shaft to brake the motor.
In the meantime, when brake release pressure
applied to the oil chamber formed between brake
piston (702) and casing (301) overcomes the spring
force, the brake is released as brake piston (702)
moves till friction plate (742) is separated from
casing (301).

T3-4-11

712

702
712

743

702

742

111

301

743

742

301

101
SM0588

E175B-E195B

SWING DEVICE

SWING REDUCTION UNIT

Operation
The swing reduction unit is used to reduce the
rotating speed which is transmitted by the hydraulic
motor and to convert it to the strong turning force
(torque).
This swing speed reduction unit is equipped with
planetary speed reducing mechanism.
The planetary mechanism is made up of sun gear,
planetary pinion, planetary shaft, spider and ring
gear, as shown in in Fig.SM0589.
For the operation of the 1st stage planetary, the
hydraulic motor rotates #1 sun gear (2). Sun gear
(2) is engaged with planetary pinion (3) and rotates,
but since ring gear (6) is fixed, planetary pinion (3)
revolves about sun gear (2) with the planetary shaft
and spider (7).
The role of spider is to hold the planetary pinion and
planetary shaft and transmits the power from the
planetary pinion to the spider through the planetary
shaft.
The #1 spider (7) is linked with #2 sun gear (4) by
the involute spline, and transmits the power to the
2nd stage planetary mechanism.
For the operation of the 2nd stage planetary, the
power is transmitted to sun gear (4) planetary
pinion (5) spider (8) similarly to the 1st stage.
The #2 spider (8) is linked with pinion shaft (1) by the
involute spline, and pinion shaft (1) is engaged with
the swing gear fixed on the undercarriage (lower
frame) and rotates.

Ring gear (Fixed)

Planetary shaft

Spider
Sun
gear

Planetary pinion

SM0589

Swing motor
3

2
6

7
4
8
13
5

10

11

SM0590

T3-4-12

TRAVEL DEVICE

E175B-E195B

OUTLINE
Characteristics

Item

E175B

Reduction gear unit

Epicycloidal, three-stage planetary type

Model

710 C3 K

Gearbox ratio

1 : 63.1

Travel motor

Displacement

MAG 85 VP 17

MAG 170 VP

high speed

50.4 cm3/rev

81.2 cm3/rev

low speed

87.3 cm3/rev

129.3 cm3/rev

130,4 L/min (34.45 US gpm)

220 L/min (58.1 US gpm)

high speed

17368 Nm (12809 lbfft)

24469 Nm (18045 lbfft)

low speed

30087 Nm (22189 lbfft)

38949 Nm (28725 lbfft)

static

234 Nm (173 lbfft)

581 Nm (428 lbfft)

dynamic

194 Nm (143 lbfft)

484 Nm (357 lbfft)

14 bar (207 psi)

11 bar (162 psi)

cracking

311 bar at 1.1 L/min

(3593 psi at 0.29 Us gpm)

311 bar at 1.2 L/min

(3593 psi at 0.32 Us gpm)

total flow

353 bar at 37 L/min

(5214 psi at 9.78 Us gpm)

353 bar at 40 L/min

(5214 psi at 10.57 Us gpm)

245 kg (540 lbs)

235 kg (518 lbs)

Max. flow
gearbox

1 : 55.2

Two speed, axial piston swash plate type

Model

Max.
torque

E195B

output

Parking brake torque

Min. pressure parking brake release

Relief valve set pressure

Mass

T3-5-1

E175B-E195B

TRAVEL DEVICE

Hydraulic motor (E175B)

Planetary gearbox (E175B)

Two speed hydraulic motor (axial piston swash plate

type) containing:
- Integrated counterbalance valve;

Planetary gearbox, 3 stages, rotating housing type.

The track drive is suitable to be used as track drive
for crawled machines equipped with open loop
hydraulic circuit.

- Crossover relief valve wich contains a shock

absorber to smoooth acceleration and stopping;
- Integrated flushing valve;
- Negative multidisc parking brake built-in directly
driven from ythe motor oil pressure (no additional
hose is required);
- Double speed function, allowing the motor to be
set to a fast or slow speed.

Ports E175B

7

7
3P

3
3V

3
3V

3

3

3P

7

7

60

P1

PF 3/4

P2

PF 3/4

T1

PF 1/2

T2

PF 1/2

Ps

PF 1/4

Pm1

PF 1/4

Pm2

PF 1/4

Service ports

Drain ports
2 speed control port
Pressure gauge ports

T3-5-2

TRAVEL DEVICE

E175B-E195B

Hydraulic motor (E175B)

Planetary gearbox (E175B)

Two speed hydraulic motor (axial piston swash plate

type) containing:
- Integrated counterbalance valve;

Planetary gearbox, 3 stages, rotating housing type.

The track drive is suitable to be used as track drive
for crawled machines equipped with open loop
hydraulic circuit.

- Crossover relief valve wich contains a shock

absorber to smoooth acceleration and stopping;
- Integrated flushing valve;
- Negative multidisc parking brake built-in directly
driven from ythe motor oil pressure (no additional
hose is required);
- Double speed function, allowing the motor to be
set to a fast or slow speed.

Ports (E195B)

SM0551

PF 3/4

Oil filling plug

PF 3/4

Oil draining plug

P1

PF 1

P2

PF 1

PF 1/2

Drain ports

Ps

PF 1/4

2 speed control port

Tin

PF 1/4

Oil motor filling port

Pm1

PF 1/4

Pm2

PF 1/4

Pp

PF 1/4

Service ports

Pressure gauge ports

T3-5-3

E175B-E195B

TRAVEL DEVICE

Hydraulic circuit (E175B)

3P

3
5*
3

77

3V

3P

60

Hydraulic circuit (E195B)

Ps

Pm2

T
P2

P1
Pp
Pm1

T3-5-4

SM0553

TRAVEL DEVICE

E175B-E195B

Direction of rotation (E195B)

When assembling the track drive on the machine and connecting the hoses, follow instructions shown in below
sketch for proper direction of rotation

3
3

60

Oil inlet port

Oil outlet port

Direction of rotation

P1

P2

Clockwise

P2

P1

Counterclockwise

T3-5-5

E175B-E195B

TRAVEL DEVICE

COSTRUCTION (E175B)
Track drive





























60

1- Socket screw M10x25 (Q.ty 10) 75 Nm (55 lbfft)

2- End cover
3- Plug M22x1.5 (Q.ty 2) 65 5 Nm (48 3.7 lbfft)
4- Washer
5- O-Ring
6- Plug
7- 1st stage sun gear
8- 1st stage reduction assembly
9- 2nd stage sun gear
10- 2nd stage reduction assembly
11- 3rd stage sun gear

12- Socket screw M20x100 (Q.ty 4) 585 Nm (431 lbfft)

13- 3rd reduction planet carrier
14- Bush (Q.ty 4)
15- Screw (Q.ty 16)
16- Washer (Q.ty 16)
17- Sprocket
18- Gearbox housing
19- Lifetime seal
20- Centering ring
21- Hydraulic motor

T3-5-6

TRAVEL DEVICE

E175B-E195B

Hydraulic motor (E175B)










































































 














 




 

60

T3-5-7

E175B-E195B

TRAVEL DEVICE
37- O-Ring (Q.ty 2)
38- Socket head screw M10x35 (Q.ty 4)
39- Flanged plug
40- Ball (Q.ty 2)
41- Spring (Q.ty 2)
42- O-Ring (Q.ty 2)
43- Plug
44- Flanged plug (Q.ty 2)
45- Relief valve (Q.ty 2)
46- Backup ring (Q.ty 4)
47- O-Ring (Q.ty 2)
48- Backup ring (Q.ty 4)
49- O-Ring (Q.ty 2)
50- O-Ring (Q.ty 2)
51- O-Ring (Q.ty 2)
52- Two speed spool
53- Spring
54- Spring seat
55- Spring seat
56- O-Ring (Q.ty 2)
57- Plug
58- Plug
59- Backup ring
60- O-Ring
61- Backup ring
62- Backup ring
63- Conical plug (Q.ty 11)
64- Orifice (Q.ty 2)
65- Orifice (Q.ty 2)
66- Base plate
67- Plug (Q.ty 3)
68- O-Ring (Q.ty 3)
69- Orifice (Q.ty 2)
70- O-Ring (Q.ty 2)
71- Plug (Q.ty 2)
72- Socket head screw M14x40 (Q.ty 9)

1- Flanged hub
2- O-Ring
3- Orifice
4- O-Ring (Q.ty 4
5- Seal ring )
6- Bearing
7- Motor shaft
8- Steel ball (Q.ty 2)
9- Two speed control spring (Q.ty 2)
10- Two speed control piston (Q.ty 2)
11- Swash plate
12- Piston (Q.ty 9)
13- Retainer plate
14- Spherical retainer plate holder
15- Pin (Q.ty 3)
16- Cylinder block
17- Spring holder
18- Spring
19- Collar washer
20- Circlip
21- Valve plate
22- Bearing
23- Brake disk
24- Backup ring
25- O-Ring
26- O-Ring
27- Backup ring
28- Brake piston
29- Pin (Q.ty 2)
30- Spring (Q.ty 8)
31- Pin (Q.ty 2)
32- O-Ring (Q.ty 2)
33- Counterbalance valve spool
34- Spring seat (Q.ty 2)
35- Spring (Q.ty 2)
36- Spring seat (Q.ty 2)

MOTOR DRAIN PRESSURE (E175B)

Continuous running

Less than 2 bar (30 psi)

Max. intermittent

Less than 5 bar (74 psi)

Brake
The track drive is supplied with a safety negative
disc brake fitted into the hydraulic motor (parking
brake).
Parking brake release is automatically operated
when high pressure oil is supplied to one of the two
ports of the hydraulic motor.

For this reason, there is no need of brake external

pilot.
The brake technical data are shown on the track
drive installation drwing.

T3-5-8

TRAVEL DEVICE

E175B-E195B

Direction of rotation
When assembling the track drive on the machine and connecting the hoses, follow instructions shown in below
sketch for proper direction of rotation

SM0555

Oil inlet port

Oil outlet port

Direction of rotation

P1

P2

Clockwise

P2

P1

Counterclockwise

COSTRUCTION (E195B)
Track drive

1
2

SM0556

1- Hydraulic motor
2- Reduction stages

T3-5-9

E175B-E195B

TRAVEL DEVICE

Hydraulic motor (E195B)

2
1

3
4

1234567-

SM0557

Hydraulic motor base plate

Motor shaft, Cylinder block
Brake unit
Brake valve
Relief valve assy
Flushing valve
Two speed spool

MOTOR DRAIN PRESSURE (E195B)

Continuous running

Less than 2 bar (30 psi)

Max. intermittent

Less than 5 bar (74 psi)

Brake
The track drive is supplied with a safety negative
disc brake fitted into the hydraulic motor (parking
brake).
Parking brake release is automatically operated
when high pressure oil is supplied to one of the two
ports of the hydraulic motor. For this reason, there is
no need of brake external pilot.
The brake technical data are shown on the track
drive installation drawing.

T3-5-10

CYLINDERS

E175B-E195B

OUTLINE
General view

gth

de

ten

x
ly e

Fu

en
dl

Fu

gth

en
dl

te

rac

et
ly r

Part No. and Manufacturing No.

Stamp position

SM0560

Specifications

Cylinder bore
Rod Dia.

Stroke

Center
distance of
pins
Full extend B /
Full retract A

(mm)

(mm)

(mm)

Boom
(E175B) (E195B)

110 / 80

1150

2815 / 1665

With cushion
on rod side

149/329

Arm (E175B)

125 / 90

1290

3060 / 1770

With cushion
on both sides

194/428

Arm (E195B)

130 / 95

1290

3083 / 1793

With cushion
on both sides

220/485

Bucket (E175B)

105 / 75

1025

2565 / 1540

With cushion
on rod side

128/282

Bucket (E195B)

110 / 80

1105

2730 / 1625

With cushion
on rod side

149/329

Positioning
(E175B) (E195B)

135 / 85

1012

2555 / 1543

Without cushion

196/432

Use

T3-7-1

Cushion

Dry weight

(kg)/(lbs)

E175B-E195B

CYLINDERS

CONSTRUCTION
Boom cylinder (E175B) (E195B)






 

3)




60

12345678-

Rod Assy
Tube Assy
Seals Rod
Head Assy
Backup Ring + O-Ring
Seal Cushion
Screw; M14x2 171 Nm (126 lbfft) (Q.ty 12)
Ring cushion

9- Seals Piston
10- Piston
11- Nut; M58x3 3790 Nm (2795 lbfft)
12- Shim
13- Screw; M12x1.75 56.910.7 Nm (42.07.9 lbfft)
14- Ball steel
15- Grease Fitting; M10x1
30- Wiper; (Q.ty 4)

T3-7-2

CYLINDERS

E175B-E195B

Arm cylinder (E175B)












    



60

1- Rod Assy
2- Tube Assy
3- Seals Rod
4- Head Assy
5- Backup Ring + O-Ring
6- Seal Cushion
7- Screw; M16x2 267 Nm (197 lbfft) (Q.ty 12)
8- Ring cushion
9- Seals Piston
10- Piston; M65x3 8200 Nm (6048 lbfft)

12- Shim
13- Screw; M12x1.75 56.910.7 Nm (42.07.9 lbfft)
14- Ball steel
15- Grease Fitting
17- Ring Cushion
18- Seal Cushion
19- Stopper
20- Collar; (Q.ty 2)
30- Kit Seals; (Q.ty 4)

T3-7-3

E175B-E195B

CYLINDERS

Arm cylinder (E195B)



   











60

1- Rod Assy
2- Tube Assy
3- Seals Rod
4- Head Assy
5- Backup Ring + O-Ring
6- Seal Cushion
7- Screw; M18x2.5 367 Nm (271 lbfft) (Q.ty 12)
8- Ring cushion
9- Seals Piston
10- Piston; M65x3 9345 Nm (6892 lbfft)

12- Shim
13- Screw; M12x1.75 56.910.7 Nm (42.07.9 lbfft)
14- Ball steel
15- Grease Fitting
17- Ring Cushion
18- Seal Cushion
19- Stopper
20- Collar; (Q.ty 2)
30- Kit Seals; (Q.ty 4)

T3-7-4

CYLINDERS

E175B-E195B

Bucket cylinder (E175B)

















60

1- Rod Assy
2- Tube Assy
3- Seals Rod
4- Head Assy
5- Backup Ring + O-Ring
6- Seal Cushion
7- Screw; M14x2.5 171 Nm (126 lbfft) (Q.ty 12)
8- Ring cushion
9- Seals Piston

10- Piston
11- Nut; M52x3 4810 Nm (3547 lbfft)
12- Shim
13- Screw; M12x1.75 56.910.7 Nm (42.07.9 lbfft)
14- Ball steel
15- Grease Fitting M10x1
16- Grease Fitting M10x1
30- Kit Seals; (Q.ty 4)

T3-7-5

E175B-E195B

CYLINDERS

Bucket cylinder (E195B)

    







60

12345678-

Rod Assy
Tube Assy
Seals Rod
Head Assy
Backup Ring + O-Ring
Seal Cushion
Screw; M14x2.5 171 Nm (126 lbfft) (Q.ty 12)
Ring cushion

910111213141530-

T3-7-6

Seals Piston
Piston
Nut; M52x3 5730 Nm (4226 lbfft)
Shim
Screw; M12x1.75 56.910.7 Nm (42.07.9 lbfft)
Ball steel
Grease Fitting (Q.ty 2)
Kit Seals; (Q.ty 4)

CYLINDERS

E175B-E195B

Positioning (E175B) (E195B)






   

3)



60

1- Rod Assy
2- Tube Assy
3- Seals Rod
4- Head Assy
5- Backup Ring + O-Ring
7- Screw; M18x2.5 367 Nm (271 lbfft) (Q.ty 12)
9- Seals Piston

10- Piston
11- Nut; M70x3 10280 Nm (7582 lbfft)
12- Shim
13- Screw; M12x1.75 56.910.7 Nm (42.07.9 lbfft)
14- Ball steel
15- Grease Fitting
30- Kit Seals; (Q.ty 4)

T3-7-7

E175B-E195B

CYLINDERS

Hydraulic cylinder construction

(for boom, arm and bucket cylinders)
By construction the hydraulic cylinder consists
mainly of cylinder tube assy (1), piston rod assy (2)
that takes out the motion of pistons reciprocating in
the cylinder tube assy, and cylinder head (3) that
serves as both a lid and a guide. Cylinder tube assy
(1) is equipped with a pin mount (clevis) that
connects piston rod assy (2) with other parts.
In addition to these main components, seal ring (16)
and back-up ring (17) are located between cylinder
tube assy (1) and piston rod assy (2); buffer ring (6),
U ring (7) back-up ring (8) and wiper ring (9) are
located between piston rod assy (2) and cylinder
head (3); and an O-ring (10) and a back-up ring (11)
are placed between cylinder tube assy (1) and
cylinder head (3).

Operation
If pressurized oil is fed alternatively to the oil inlet
and outlet provided in the cylinder, force acts on the
piston which in turn causes the piston rod (2) to
extend and retract.

CUSHION RING (13)

CHAMBER A
TANK

PATH (B)

PISTON (15)
ROD (2)

Operation of cylinder with cushion

ROD
SIDE

HEAD
SIDE

CUSHION ON ROD SIDE

The cushion mechanism is provided to prevent the
generation of shock when the moving speed of
piston (15) is not reduced and strikes cylinder head
(3).
An oil in chamber "A" returns to the tank by passing
through paths "B" at a fixed flow rate in a
intermediate stroke state of pressing bottom side.
Next, in a state of just before stroke end, cushion
ring (13) plunges into path "B".
At this time, an oil in chamber "A" passes clearance
"D" and mouth gap "C", an oil flow volume returning
to tank suddenly drops and the piston part
movement slows down.

CYLINDER HEAD (3)

CUSHION STROKE

SM0565

CLEARANCE D

TANK

MOUTH GAP C

SM0566

T3-7-8

CYLINDERS

E175B-E195B

CUSHION ON HEAD SIDE

This construction is similar to the one of cushion on
rod side. In a state of intermediate stroke pressing
rod side, an oil in chamber "A" returns to tank by
passing through path "B" at a fixed flow rate.
Next, in a state of just before stroke end, cushion
bearing (23) plunges into path "B". At this time, an
oil in chamber "A" path clearance "D" and cushion
seal (24) are mouth gap "C", an oil flow volume
returning to tank suddenly drops and the piston part
movement slows down.

CUSHION SEAL (24)

PATH B

TANK

CUSHION BEARING (23)

CLEARANCE D
CHAMBER A
SM0567

T3-7-9

E175B-E195B

CYLINDERS

NOTES:

T3-7-10

SWIVEL JOINT

E175B-E195B

OUTLINE
General view
Y

C
D
A
F

B
D

VIEW Y

C
B
A

VIEW Z

SM0568

Specifications
High pressure ports A,B,C,D

Low pressure ports E

Low pressure ports F

Working pressure

34.3 MPa

Max. impact pressure

51.5 MPa

Rated flow

255 L/min

Working pressure

0.49 MPa

Rated flow

50 L/min

Working pressure

5 MPa

Rated flow

30 L/min
15 min-1

Revolution

Ports size

A,B,C,D (body)

PF 1

A,B,C,D (stem)

PF 3/4

PF 1/2

PF 1/4

Length (height)

368 mm

Weight

24.5 kg

T3-6-1

E175B-E195B

SWIVEL JOINT

CONSTRUCTION

Y
E
2
H

13
D

H
6

B
D
VIEW Y

C
B

12
F

5
7

SECTION HH

4
SM0569

123456-

Body
Stem
Thrust plate
Cover
Seal (Q.ty 5)
Seal

7- O-Ring
8- Capscrew; M8x20 (Q.ty 2) 30.4 Nm
9- Capscrew; M8x30 (Q.ty 3) 30.4 Nm
12- Plug
13- O-Ring (Q.ty 2)

T3-6-2

SWIVEL JOINT

E175B-E195B

OPERATION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both
components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and
seal assy (6) and O-ring (7) that prevent external leaks.
Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves
are arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove.
The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2) keeps on flowing to
stem (2) or body (1) past the circumferential groove between body (1) and stem (2); the oil flow is never shut
off because of rotation. Further, an oil groove for lubrication that connects with the drain port is provided, in
order to prevent the body (1) from seizure with the stem (2).
This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.

T3-6-3

E175B-E195B

SWIVEL JOINT

NOTE:

T3-6-4

AIR CONDITIONER SYSTEM

E175B-E195B

BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER)

Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and an
inside /outside air switching unit. And this unit changes hot air to cool air.
AIR CYCLE

Heater
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange
is performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from
grille through duct.

Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange
is performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled
air blows off from grille through duct.

Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine
flows in the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the
operation is controlled by air mixing damper on the air-con unit.

T3-8-1

E175B-E195B

AIR CONDITIONER SYSTEM

AUTO AIR CONDITIONER SYSTEM OUTLINE

AIR CONDITIONER CONTROL PANEL

25.0

COMPRESSOR

COMPRESSOR DRIVE SOURCE

SOLAR RADIATION SENSOR

REFRIGERANT
PRESSURE SWITCH

AIR MIXED DAMPER SIGNAL

AIR-CON
AIR OUTLET SWITCHING SIGNAL

BLOWER REVOLUTION SIGNAL

CONTROLLER
INNER AIR SENSOR

EVAPORATION SENSOR

INNER AIR AND OUTER AIR

SWITCHING SIGNAL

MOTOR
ACTUATOR

VENT

OUTER AIR INTAKE

INNER AIR

MOTOR
ACTUATOR

AIR CONDITIONER UNIT

FACE

FOOT

MOTOR BLOWER
ACTUATOR CONTROLLER

SM0024

T3-8-2

AIR CONDITIONER SYSTEM

E175B-E195B

COMPONENT AND CONSTRUCTION

COMPONENT

27

30

33

27-1
40

32
39

27-6
27-3

27-5

27-2
35
35-6

35-7

35-1
35-5

35-2

35-8

34

35-9

35-10

SM0025

Air conditioner group

No.

Parts

Q.ty

No.

Parts

Q.ty

No.

Parts

Q.ty

27

Air conditioner assy

32

Compressor

35-6

D hose

27-1

Air conditioner unit

33

Pulley

35-7

L hose

27-2

Hose

34

Condenser

35-8

L hose: 15.5

27-3

Clamp

35

Air dryer assy

35-9

S tube: 16

27-5

Filter

35-1

Receiver dryer

35-10 L tube: 8.5

27-6

Tube assy

35-2

Bracket

39

Filter

30

Panel assy

35-5

S hose: 24.5

40

Solar radiation sensor

T3-8-3

E175B-E195B

AIR CONDITIONER SYSTEM

CONSTRUCTION
(1) Air conditioner unit
49

48

6
47

46
44
42

31

31

41

50

45

1
43

32

28

39

37

38

36
27
H

9
40
A

I
2

33

SM0022

Air conditioner unit (1/2)

T3-8-4

AIR CONDITIONER SYSTEM

1
1

31

E175B-E195B

14

16

15

31

61

C
D

7
G

1
1
26

20

13

59
29

11
21

22

23
1

24

60

17

18 A

I
C

10

31

19

12
3
31

1
25
52

SM0021

Air conditioner unit (2/2)

T3-8-5

E175B-E195B

No.

AIR CONDITIONER SYSTEM

Q.ty

No.

Q.ty

No.

Parts

Q.ty

Screw M516

Parts

23

19

Relay

Parts

40

KK-box lower packing

Main harness

20

Evaporator

41

Vent lever

MA air mix

21

Expansion valve

42

Face lever

Blower controller

22

O-ring

43

Foot joint lever

Upper casing

23

O-ring

44

MA mode lever

Air mix door

24

Screw M540

45

Foot lever

Air mix lever

25

Thermistor

46

Face lever cam

Lower casing

26

Thermistor holder

47

Vent lever cam

Air mix door sub

27

Heater core

48

Face rod

10

Air mix lever sub

28

Pipe holder

49

Vent rod

11

Blower

29

Thermistor

50

Foot rod

12

Lever MA air mix

31

Screw M430

52

Inner air filter

13

Intake door

32

Upper casing

55

Screw M625

10

14

MA intake lever

33

Lower casing

56

Screw M825

10

15

Intake lever

36

Foot door

59

Evaporator packing

16

Intake rod

37

Vent door

60

Casing packing A

17

Air mix rod

38

Face door

61

Casing packing B

18

Air mix rod sub

39

KK box upper packing

Receiver dryer
1 - Pressure switch
2 - Sight glass
3 - Desiccant
4 - Suction pipe
5 - Filter
6 - Receiver tank
A - Refrigerant INLET
B - Refrigerant OUTLET

2 -M6
1

3
4
5

SM0037

T3-8-6

AIR CONDITIONER SYSTEM

E175B-E195B

FUNCTION
Mechanism of cooling circuit
MECHANISM OF COOLING
In the cooling process, the refrigerant that flows
through the cooling circuit changes its phases from
liquid to gas and vice versa during which process
heat is transferred from the low temperature part
(compartment) to the high temperature part (outside
of the vehicle).

HFC-134a (R134a)
CH2FCF3

Chemical formula
Molecular weight

102.03

Boiling point

26.19 C

Critical temperature

101.14 C

Critical pressure

4.065 MPa

Kind of Refrigerant

Critical density

511 kg/m3

Many kinds of refrigerants that change in that way

are available, but the following requirements are
needed for use in such applications:
Latent heat of vaporization (heat of vaporization)
is large.
It is easy to liquefy (condense). (It does not
require very high pressure for condensation.)
It is easy to gasify (evaporate). (It evaporates
sufficiently at not too low pressure, i.e. cools
down an object.)
It has small specific heat. (Since the refrigerant
itself is cooled by the expansion valve, the loss
resulting from it must be held down to a
minimum.)
It has a high critical temperature and a low
solidification point.
It is stable chemically and does not corrode and
permeate into the circuit parts.
It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
It has small specific volume.
It is easy to find out leakage.
Out of refrigerants meeting the above-mentioned
requirements, ones having characteristics that suit
the intended cooling unit are chosen and used. If a
refrigerant other that those designated is used,
sufficient refrigeration will not be performed or the
equipment in which the refrigerant is used may be
broken. Therefore, always use a designated
refrigerant for the cooling unit.
Table shows the principal characteristics of the
R134a refrigerant that is used in this machine.

Density of saturated liquid (25 C)

CHARACTERISTICS OF REFRIGERANT
In general, the fluid (general term of gas and liquid)
has the following qualities:
1.

As a gas under certain pressure is cooled down,

it begins to condensate at a certain temperature
to take a liquid state. The temperature at which
condensation begins is unique to each
substance (fluid) at a given pressure. The
temperature determined by a given pressure is
called saturation temperature.

T3-8-7

Specific volume
vapor (25 C)

of

saturated

Latent heat of vaporization (0 C)

Flammability

1206 kg/m3
0.0310 m3/kg
197.5 kJ/kg
Non flammable

Ozone destruction coefficient

P (MPa)

R134a

3
LIQUID

GAS
1

15 18

35

50

T (C)
SM0038

E175B-E195B
2.

AIR CONDITIONER SYSTEM

Inversely to 1. above, the pressure at which a

gas condenses for a temperature is
determined. This pressure is called saturation
pressure.
Figure beside illustrates the relationships
between the saturation temperature and the
saturation pressure in the case of refrigerant
R134a used in the air-conditioner. At the
temperature and the pressure on the lower
righthand side of the curve in figure, the
refrigerant take a gaseous state, while at the
temperature and the pressure on the upper
lefthand side of the curve, the refrigerant takes
a liquid state.
Let us think of a case where an air-conditioner
is operated in the midst of summer. As the
refrigerant evaporates, it absorbs evaporation
heat from the air of the compartment. In order
to cool the inside of the compartment down to
25 C, the refrigerant must transform
(evaporate) from a liquid to a gaseous state at
a lower temperature. It can be seen from the
figure that R134a under a pressure above the
atmospheric pressure is capable of cooling the
inside of the compartment sufficiently. (If a
refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required
temperature is used, air is mixed into the
circuits, thereby deteriorating the performance
of the cooling unit.) In the process in which
gaseous refrigerant is brought back to a liquid
state, the refrigerant is cooled and condensed
by the outer air exceeding 35 C.
Accordingly the refrigerant is capable of
condensing at a pressure exceeding 1 Mpa, as
seen from the figure.

1
2

6
4

SM0039

1 - Inside of the compartment (cab)

2 - Evaporator
3 - Blower
4 - Compressor
5 - Cooling fan
6 - Inside of engine room
7 - Condenser
8 - Receiver dryer
9 - Expansion valve

Cooling circuit
The figure illustrates the cooling circuit of the car airconditioner.
In this circuit diagram, the portion that cools the air
of the compartment is the evaporator. The object air
is cooled off by utilizing the fact that the refrigerant
takes heat off the surrounding area as evaporation
heat as it evaporates in the cooling circuit. Since the
part at which vaporization of the refrigerant takes
place is the evaporator, cooled air is constantly
delivered to the circumference of the evaporator by
the blower fan. In the meantime, liquid refrigerant
(slightly wet vaporized refrigerant) is fed into the
evaporator, when "cooling" effect is attained. For
instance, in order to cool the air to 15 C, the
refrigerant can not absorb evaporation heat from the
air unless it evaporates at a temperature lower that
15 C. For that purpose, it can be seen from the
figure that the pressure of the refrigerant in the
evaporator must be less than 0.51 MPa.

Furthermore, the cooling effect deteriorates unless

the feed rate of the refrigerant is controlled so that
all of the refrigerant supplied to the evaporator
vaporizes and turns into dry vapor.

T3-8-8

AIR CONDITIONER SYSTEM

E175B-E195B

Consequently, the cooling circuit is so constructed

that the evaporator can cool down an object (air in
this case) sufficiently (i.e. so as to decrease the
pressure in the evaporator) and that an adequate
amount of refrigerant can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator
is held low by the throttling action of the expansion
valve and the suction action of the compressor. The
compressor acts as a pump that allows the
refrigerant to circulate. The compressive action of
the compressor and the heat exchange (heat
radiation) action of the condenser transform the
refrigerant in a dry vapor state back to a liquid state.
Component parts
EVAPORATOR
The evaporator is an important heat exchanger that
absorbs the heat of the compartment air (object) by
the utilization of the latent vaporization heat of the
low-temperature,
low-pressure
liquid-state
refrigerant. Therefore, it is necessary that
satisfactory heat transfer between the object and
the refrigerant take place in the evaporator.
To that end, the evaporator is equipped with fins on
the air side in order to increase the heat transfer
area of the air side and thereby perform excellent
thermal transfer between the refrigerant and the air.
The humidity in the air condenses as the air cools
down and adheres to the outside of the evaporator
as water drops. The cooling effect deteriorates if the
water drops freeze. Therefore, how to discharge
water is an important point.
The amount of refrigerant supplied to the evaporator
is controlled by the expansion valve which is
described in the following. In order to attain proper
control, it is necessary to reduce the pressure drop
of the refrigerant of the evaporator. Accordingly,
reducing the pressure drop is one element that
makes the evaporator attain its full performances.
EXPANSION VALVE

4
SM0026

1 - Evaporator
2 - O-ring
3 - Expansion valve
4 - Socket bolt M5 x 40

In order for the evaporator to fulfill its performances,

a proper amount of low-pressure low-temperature
liquid refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant completes
vaporization early in the evaporator which results in
deterioration of the cooling effect. If the feed rate is
too high, unvaporized liquid refrigerant returns to
the compressor (liquid back). This not only
deteriorates the cooling effect, but also damages
the compressor valves.

T3-8-9

E175B-E195B

AIR CONDITIONER SYSTEM

The expansion valve feeds the flowing highpressure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid
refrigerant (damp vapor of low dryness). The
expansion valve controls the feed rate of the
refrigerant at the same time.
The figure beside shows how the block type
expansion valve is constructed. The temperature
sensing part is provided in the shaft of the
expansion valve to directly detect the refrigerant
temperature at the outlet of the evaporator.
The diaphragm contains R134a in saturated state.
The pressure in the diaphragm changes according
to the temperature detected by the sensor. The
change in the pressure causes the force acting upon
the diaphragm to vary accordingly.
The
high-pressure
high-temperature
liquid
refrigerant that is fed from the receiver side reduces
the pressure abruptly as it passes through the valve
(throttling action). On that occasion, part of the
refrigerant evaporates by the very heat of the
refrigerant and cooled off. The result is that lowpressure low-temperature damp refrigerant vapor is
fed to the evaporator.
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust spring and
the pressing force of the diaphragm (the
temperature of the refrigerant at the outlet of the
evaporator to be sensed by the thermowell). The
feed rate is controlled automatically so that under
the pressure in the evaporator, the refrigerant is
properly overheated (3 ~ 8 degrees) and goes out of
the evaporator. This action is carried out by sensing
the refrigerant temperature at the outlet of the
evaporator as against the inlet pressure of the
evaporator and consequently controlling the feed
rate of the refrigerant.
This means that if the refrigerant pressure drop in
the evaporator is excessive, it is difficult to control
the overheating or the feed rate of the refrigerant.
For this reason, the smaller the pressure drop of the
evaporator, the better.
The expansion valve senses the pressure and the
temperature at the outlet of the evaporator and
controls the overheating of the refrigerant and the
refrigerant supply to the evaporator more securely.
The air-conditioner of this machine adopts a block
type expansion valve.

2
3
4

5
6
7
SM0040

1 - Diaphragm
2 - Evaporator side
3 - Refrigerant outlet
4 - Shaft
5 - Refrigerant inlet
6 - Ball valve
7 - Spring

T3-8-10

SM0041

AIR CONDITIONER SYSTEM

E175B-E195B

COMPRESSOR
The compressor performs the following three
functions in the cooling circuit:
1. Suction action
2. Pumping action
3. Compressive action
1.

The suction action, as combined with the

throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling effect.

2.

The pumping action serves to cause all the

refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling.

3.

The compressive action, as combined with the

action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as the
pressure increases. For instance, it becomes
possible to cool down the refrigerant by the use
of an outer air of 35 C and liquefy it. The
compressive action of the compressor works to
turn low pressure vaporized refrigerant to high
pressure vapor refrigerant. The condenser then
serves to cool down the refrigerant. However,
since the compressive action takes place only
for a short period, the refrigerant hardly
exchanges heat with outer air. That is to say, it
takes a near form of thermally insulated
compression, so that the refrigerant discharged
by the compressor turns into high-temperature
high-pressure vapor and is delivered to the
condenser.

SM0042

1 - D Hose
2 - S Hose
3 - Compressor

CONDENSER
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure by
the use of outer air and condenses the refrigerant.
The direction in which heat moves is from the
refrigerant to air, the opposite to the case of the
evaporator. Fins are equipped on the outer air side
to improve thermal transfer. If the refrigerant is not
cooled well by the condenser, the air in the
compartment can not be cooled sufficiently by the
evaporator. For that purpose, it is necessary to
secure ventilation required for the cooling of the
refrigerant.
SM0023

T3-8-11

E175B-E195B

AIR CONDITIONER SYSTEM

RECEIVER DRYER
1.

2.

3.

Receiver Tank
On the air-conditioner, the revolution of the
compressor varies greatly which causes the
proper flow of refrigerant in the cooling circuit to
vary. It is the receiver tank that receives the
variations. When the cooling circuit does not
need much refrigerant, the receiver tank stores
extra refrigerant temporarily and supplies it
when the cooling circuit needs much
refrigerant. The receiver tank also stores an
extra amount of refrigerant to be used for filling
balance and supplement small amounts of
leakage of the refrigerant through penetration
into rubber hoses.

2
3

Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil,
corrodes the metallic parts of the circuit or clogs
the circuit as the water freezes in the expansion
valve. It is desirable that the amount of water
mixed in the refrigerant should be held below a
concentration of 30ppm. The air-conditioner
uses a molecular sieve as desiccant suited for
the circuit, in order to absorb water content that
intrudes into the circuit when the dryer is
installed or when refrigerant is charged.

Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the
only means of confirming the inside of the
circuit visually.

4.

Filter

5.

Pressure Switch
This machine employs pressure switches of
high/low pressure type.
The pressure switch protects the circuit by
cutting off the power supply to the compressor
when high pressure increases abnormally high
(more than 3.14 MPa).
The pressure switch also detects the leakage of
refrigerant by cutting the power supply to the
compressor when the pressure of the circuit
falls below 0.196 MPa.

SM0043

1 - Refrigerant inlet
2 - Sight glass
3 - Refrigerant outlet
4 - Pressure switch
5 - Desiccant
6 - Suction pipe
7 - Filter
8 - Receiver tank

T3-8-12

AIR CONDITIONER SYSTEM

E175B-E195B

DISASSEMBLY AND ASSEMBLY

PRECAUTIONS TO BE EXERCISED IN
OPERATION
1.

Special Refrigerator Oil

This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils
other than SP20 may not be used. Since SP20
tends to absorb moisture and may corrode
paint and resin, the following points must be
noted:
1) Do not keep open all pipe connections on a
new compressor and the component parts
of the installed refrigeration circuit
(Remove valves and caps at the pipe
openings of the compressor, just before
connecting pipes. If you have removed a
pipe joint for repair, put a cap to both ports
immediately.)
2) Use care so SP20 does not adhere to the
painted surface and resin parts. In case
SP20 has adhered to such surfaces, wipe it
off immediately.

2.

3.

The receiver dryer is filled with desiccant to

absorb moisture in the circuit. Therefore,
remove the valve at the pipe port immediately
before connecting pipes.
Tightening Torque
1) Pipe Joints
When connecting pipe joints, coat the O-ring
with special oil (SP20) and fasten to the
tightening torque indicated in the table,
using a double spanner.
2) Screws and Bolts
Fasten to the tightening torque indicated in
the table

4.

5.

6.

Amount of Oil for Compressor

The compressor SD7H (HD type) is filled with
135cc (8.2cuin) of oil. If the oil volume is small,
seizure at high revolution and shortening of
service life will occur. If the oil volume is large,
the cooling ability will be deteriorated.
Once the air-conditioner is operated, part of the
oil is dispersed in the refrigeration circuit.
Therefore, when replacing the parts in right
Table, adjust the oil level to that of table.
Before performing operation, stop the engine
and turn off all power supplies to the equipment
related to the air-conditioner.
After the operation is over, confirm that all faults
have been repaired completely, by operating
the air-conditioner.

Unit: Nm (lbfft)
TIGHTENING
TORQUE

PIPE FASTENING PART

D hose and compressor (M8 bolt)

19.6~24.5 (14~18)

D hose and condenser

19.6~24.5 (14~18)

L hose and condenser

11.8~14.7 (8.7~11)

L hose and receiver dyer (M6 bolt)

7.8~11.8 (5.8~8.7)

L hose and air-conditioner unit

11.8~14.7 (8.7~11)

S hose and air-conditioner unit

29.4~34.3 (22~25)

Expansion valve

1.96~2.45 (1.4~1.8)

Unit: Nm (lbfft)
TIGHTENING
TORQUE

SCREW SIZE
N4, T4 machine screw, M4

0.78~1.18 (0.58~0.87

N5, T5 machine screw, M5

1.96~2.45 (1.4~1.8)

M6 (mounting part of L hose

joint)

7.85~11.8 (5.8~8.7)

M6 (except mounting part of L

hose joint)

9.8~11.8 (7.2~8.7)

M8 (mounting part of S,D hose

joints)

19.6~24.5 (14~18)

M8 (mounting part of A/C unit)

9.8~11.8 (7.2~8.7)

M8 (other than those mentioned

above)

11.8~15.7 (8.7~12)

M10

39.2~53.9 (29~40)

REPLACED PARTS

AMOUNT TO BE FILLED IN

EVAPORATOR

40 cc (2.4cuin)

CONDENSER

40 cc (2.4cuin)

COMPRESSOR

Drain out the volume of oil left in

the compressor to be replaced,
from the new compressor.

RECEIVER DRYER

20 cc (1.2cuin)

HOSES

20 cc (1.2cuin)

T3-8-13

E175B-E195B

AIR CONDITIONER SYSTEM

DISASSEMBLY AND ASSEMBLY OF UNIT

1.

Removing inner air filter

Slide the inner air filter (1) leftward and remove
it from the unit (2).

1
SM0027

2.

3.

Removing selector box

Remove 6 plus screws (3), remove connector
(4) connected to the mode actuator (5) on mode
selector box (6), and separate the mode
selector box from the unit (2).

Removing main harness

Pull out 3 harness clamps (7) from the unit (2),
and disconnect all connected connectors and
remove harness (8) on the body from the unit
(2).

4
6

SM0028

4.

Removing upper unit case

1) Remove air MIX rod (9) and air MIX rod sub
(10) from air MIX lever (11).
2) Remove 12 plus screws (12) which are used
to install the upper and lower unit casings
(2a).
Pull out the upper unit casing (2b) upward
giving attention to the thermistor harness so
as not to be caught by the casing.

11

12

2b
10
9

2a

T3-8-14

SM0029

AIR CONDITIONER SYSTEM

E175B-E195B

5. Replacing blower controller

1) Remove 2 plus screws (14) and remove the
blower controller (15) from the upper unit
casing (2b).
2) Install new blower controller by the reverse
procedure of removal.

2b

* Do not disassemble the blower controller.

14

15
SM0030

6.

Removing heater core

1) After draining the coolant, remove heater
hos e from the heater core (16).
2) Remove 1 plus screw (17), and remove pipe
clam (18) which is used to secure the heater
core and then remove the heater core (16)
from the lower unit casing (2a).
3) Install it by the reverse procedure of
removal.

7.

16

17
18
20

19

Replacing blower motor

1) Disconnect connector which is connected to
the blower motor and remove the blower
motor (19) from the lower unit casing (2a).
* Do not remove the fan from the blower
motor.

2a

SM0031

2) Install it by the reverse procedure of

removal.

8.

Replacing evaporator and expansion valve

1) Take the evaporator (20) with expansion
valve off from the lower casing.
2) Remove evaporator sensor (21) with sensor
holder (22) from the removed evaporator
(20).
3) Insert the sensor holder into the new
evaporator at the position shown in Fig.
SM0032 and install the evaporator sensor
(21) again.
A - 11th rows of fin

20

22
105mm
(4.1 inch)

21

SM0032

T3-8-15

E175B-E195B

AIR CONDITIONER SYSTEM

4) Remove 2 socket bolts M540 (23) with

Allen wrench (4 mm) and remove the
expansion valve from the evaporator (20).
5) Fit O-ring (24) (NF O-ring 5/8 and 1/2 one
each) to new evaporator.

20
A

* When assembling again, fit O-ring paying

attention so as not to be caught with others.
(Socket bolt M540 (2 pcs.) Tightening torque:
6.9Nm (5.1lbfft)

24

* Do not apply undue force to pipe of evaporator

outlet. This undue stress causes the leak of
refrigerant from "A" part of evaporator.
Moreover, when tube assembly (27-6) (see
Pag. T3-8-3 Fig. SM0025) connected with
expansion valve (25) is disconnected from
expansion valve, similar careful work is
necessary.
9.

25

23

Replacing motor actuator

SM0033

1) Replacing mode actuator

a) Remove connector (26) connected to the
motor actuator (27).
b) Remove FACE rod (28) and VENT rod
(29) which is used to connect MA mode
lever (30) and mode cam from the
holder.
c) Remove 3 plus screws (31) and remove
the motor actuator (27) with lever MA
mode from the unit.
d) Remove the lever MA mode from the
removed motor actuator, and install it on
new motor actuator by the reverse
procedure of removal.
2) Replacing air mixing actuator
a) Remove connector (32) connected to the
motor actuator.
b) Remove rod air MIX (33) which is used to
connect the motor actuator (27) and the
lever MA air MIX.
c) Remove 3 plus screws (34) and remove
the motor actuator (35) with MA lever air
MIX (36) from the unit.
d) Remove the MA lever air MIX from the
removed motor actuator, and install it on
new motor actuator by the reverse
procedure of removal.

29
28
30
31
27

SM0034

33

36

32

34

T3-8-16

26

35

SM0035

AIR CONDITIONER SYSTEM

3) Replacing inner and outer air switching
actuator
a) Disconnect connector (37) connected to
the motor actuator (38).
b) Remove intake rod (39) from MA intake
lever (40).
c) Remove 3 plus screws and remove the
motor actuator (38) with MA intake lever
(40) from the unit.
d) Remove the MA intake lever (40) from
the removed motor actuator, and install it
on new motor actuator by the reverse
procedure of removal.

E175B-E195B

40

39

41

37

38

T3-8-17

SM0036

E175B-E195B

AIR CONDITIONER SYSTEM

CHARGING REFRIGERANT
PRECAUTIONS TO BE EXERCISED IN OPERATION
1.

Always assign a person in charge of handling refrigerant.

Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person
familiar with how work is done for handling refrigerant.
WARNING

2.

Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
The refrigerant in liquid state is at very low temperature [approx. -26C (-15F)]. Therefore, handle
it with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
Storage and Transportation
1) Keep the service can (hereinafter called can) less than 40C (104F). Since high pressure gas of R134a
is filled in the can in a saturated liguefied state, the pressure in the can increases sharply as
temperature rises. The can may blast as the result.
It is for this reason why the can temperature must be kept below 40C (104F).
2) For storage, choose a cold dark place not exposed to direct sunlight.
3) If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes the inside
pressure to rise and may cause the can to blow out. Do not bring the can close to a fire.
4) The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the
compartment. The areas of the compartment which are exposed to direct sunlight may rise to a
dangerous temperature level. Do not bring the can into the compartment. Also, the inside of the trunk
room may rise to a dangerous temperature level even in the summer time. Use sufficient care,
therefore, taking the above into account.
5) Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.
- Do not drop or knock on the can.
- When transporting, loading or unloading cans and packages containing cans, do not throw or drop
them.
6) Store cans beyond the reach of children.

3.

Charging
1) When warming the can in which refrigerant is charged, do not fail to open the service can valve and the
low pressure valve of the gauge manifold and warm the can in warm water of 40C (104F or below (to
an extent that you do not feel hot when you put your hand in the water.) If the can is put in hot water or
heated by a direct fire, the pressure of the can may rise sharply, thereby blowing off the can.
2) When charging refrigerant while running the engine, do not open the high pressure valve (HI) of the
gauge manifold in any case.

4.

Others
Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to enter the
air-conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the components
of the air-conditioner correctly and speedily. Pay full attention to the entry of water and dust.

CAUTION

Be careful about overcharge of gas

Fasten pipes to a specified torque

T3-8-18

AIR CONDITIONER SYSTEM

E175B-E195B

OPERATING PROCEDURE
The change of refrigerant in the air conditioner
requires a "vacuum generation procedure" and a
"gas charging procedure".
- The "vacuum generation procedure" consists in
removing moisture from the air conditioner circuit.
In the event even a small quantity of moisture
remains in the system, it would freeze in the small
orifices of the expansion valve when in operation.
This causes a clogging of the circuit or the
formation of rust, with a series of operational
troubles. prior to filling the circuit with refrigerant,
apply the vacuum and cause the boiling and
vaporisation of the moisture. In this manner,
moisture is eliminated from the system.

- The "gas charging procedure" consists in the filing

the circuit with refrigerant, after applying a
vacuum. the filling of the gas is not only depending
upon the cooling performance of the air
conditioner, but it influences also the useful
working life of the circuit components. An
excessive overloading increases considerably the
pressure of the system and damages the cooling
performance. On the contrary, a too low charging,
results in an insufficient circulation of lubricant oil
in the compressor, causing the wear of the moving
parts of the compressor.
WARNING
The gas filling operation involves the handling of
highly compressed gases; it is dangerous to handle
the gas without complying strictly with the relevant
procedures. The procedures and the protections
described in this manual for the filling of refrigerant
gas must be strictly adhered to.

Vacuum making operatio

More than
30 min.
Begin vacuum
making
Lower than
-750m mHg

Refrigerant filling operation

Leave it as it is,
for five minutes.

Stop vacuum
making

Check
air-tightness

Fill in
refrigerant

Check for
gas leak

Fill in
refrigerant

Gauge indicates
abnormality
Charge refrigerant gas to a gauge
pressure of 0.1 MPa

Check and correct joints

SM0194

T3-8-19

E175B-E195B

AIR CONDITIONER SYSTEM

PROCEDURE FOR THE GENERATION

OF VACUUM
1.

Close high pressure valve (3) and low pressure

valve (1) on gauge manifold (2).

2.

Connect the red charging pipe (5) and the blue

one (6) to compressor service valves (8) "D"
and "S" as described in the figure.

WARNING
Never exchange by mistake the high pressure pipe
with the low pressure pipe when connecting them.
Install the pipe firmly until a click noise is heard.
Connect the quick release joint of the charging pipe
with the service valve of the compressor. If the
charging pipe is connected in the opposite direction,
mini-valve (9) of the compressor fails to open.
3.

5
4

S
8

Connect the central valve of the gauge manifold

with charging pipe (4) of the vacuum pump (7).

7
SM0016

IMPORTANT: some types of manifold are not

equipped with an open/close valve in the central
part.
4.

Open high pressure valve (3) and low pressure

valve (1) of gauge manifold (2).

5.

Start the vacuum pump and let it operate 30

minutes to generate the vacuum.

6.

At the end of the vacuum phase for the

prescribed time (vacuum value: lower than 750
mm Hg) close the high pressure valve (3) and
the low pressure valve (1) of the gauge
manifold (2).

7.

Cut-off the vacuum pump.

8.

With the high pressure valve (3) and the low

pressure valve (1) closed, check, after five
minutes, that the pressure gauge dial does not
return to zero.

NOTE: in the event the pressure gauge moves

toward zero, this indicates the presence of a
leakage. Tighten again the connecting joints and
apply the vacuum again, verifying that there are no
further leakages.

T3-8-20

9
SM0017

AIR CONDITIONER SYSTEM

E175B-E195B

PROCEDURE FOR THE CHARGING OF THE GAS

1.

2.

After applying the vacuum repeatedly,

exchange charging pipe (4) of the gauge
manifold (2), from the vacuum pump to the
service can (9).

2
11

Open the valve of service can (10). Close the

high and low pressure valves of the gauge
manifold. Press central bleeding valve (11) of
the side service opening on the low pressure
side of the gauge manifold using a screwdriver
in order to let out the air in the charging pipe by
the pressure of the refrigerant. Proceed with
this operation until a whistle is heard coming
from the bleeder.

4
10
9
SM0018

3.

Open high pressure valve (3) of the gauge

manifold and charge the refrigerant to a
pressure of 0.1 MPa.
Once the charge is completed, close high
pressure valve (3) of the gauge manifold and
service valve (10).

WARNING
Never start operating the compressor during this
work. The starting of the compressor causes the
blowing of the service can.
4.

Check that there are no leakages of gas in the

cycle, using a gas leakage tester. Retighten
and eliminate all points of leakage.

IMPORTANT: to check for gas leakages, always

use a tester for R134a. Do not use one for flon gas
service as it provides poor sensitivity.
5.

Make sure that high pressure valve (3) and low

pressure valve (1) of the manifold and service
valve can (10) are closed.

6.

Start the engine running it at 1500 100 rpm

and open fully the door and windows of the cab.

7.

Activate the air conditioner, setting it at

maximum ventilation speed and at lowest
temperature.

8.

During the charging of the gas, set the discharge

pressure of the compressor to 1.4 ~ 1.6 MPa.

T3-8-21

10
S
SM0019

E175B-E195B
9.

AIR CONDITIONER SYSTEM

Open low pressure valve (1) of the gauge

manifold and service valve can (10) and fill with
refrigerant until all air bubbles in sight window
(12) of the dryer disappear.
Total quantity of gas to be charged: 900 50 g.

01

10. Once the refrigerant change operation is

terminated, close low pressure valve (1) of the
gauge manifold and the service valve can (10).

CAUTION
Do not open the high pressure valve of the manifold
under any circumstance nor place the service can
upside down.

R0115

11. The level of refrigerant is correct only once the

air conditioner is activated and through the
inspection sight window, just a few air bubbles
are seen and, afterward, a white colour slightly
milky is seen.

IMPORTANT: when the air conditioner operates

with an insufficient quantity of refrigerant, this has a
negative effect on the compressor; on the contrary,
when the refrigerant is charged with an excessive
quantity, the cooling performance is lost. Also, the
pressure of the system increases abnormally.

12. Disassemble the manifold disconnecting the

charging pipes from the compressor, as
indicated here below.
a. Press the quick release coupling of the
charging pipe on the low pressure side
against the service valve of the compressor
so that the refrigerant doers not escape
leaking when loosening the connection. As
soon as the nut has been removed,
disconnect the charging pipe from the
service valve.
b. Wait for the pressure in the high pressure
site to decrease, indicated on the pressure
gauge, to a value of 1.0 MPa.
c. Disconnect the red charging pipe from the
high pressure side, in the same manner as
described for the low pressure.

A: Appropriate quantity of refrigerant

B: The system is overloaded
C: Insufficient quantity of refrigerant

T3-8-22

AIR CONDITIONER SYSTEM

E175B-E195B

ELECTRIC CIRCUIT
WIRING DIAGRAM AND CONNECTORS
Wiring Diagram

(A)(B)

2
(C)
12

(R)

(N)

155(BR)

(D)

150(BP)
FUSE 20A

15

85E(WB)

(E)

18(RG)

13

25(WG)

FUSE 5A

26(RL)

FUSE 15A

E24(B)

FUSE 5A

(Q)

(M)
FUSE BOX

(P)

(F)

(L)

11
(K)
14

(G)

10

7
9
(J)

(H)

8
SM0044

(I)
1 - CCU(Operation Panel + Controller)
2 - Evaporator Sensor
3 - Air Inlet Sensor
4 - Solar radiation Sensor
5 - Motor Actuator (for air mix)
6 - Motor Actuator (for Mode)
7 - Motor Actuator (Rec/Fresh)
8 - Compressor Relay

9 - Blower AMP
10 - Blower Motor
11 - Blower Off Relay
12 - Pressure Switch
13 - Main Key Switch
14 - Compressor
15 - Light Switch

T3-8-23

E175B-E195B

AIR CONDITIONER SYSTEM

Connectors

(B)

(A)

JAE
HOUSING : IL-AG5-22D-S3C1
TERMINAL : IL-AG5-C1-5000

(C)

MAKER : YAZAKI CORP.

HOUSING No. : 7123-2228
TERMINAL : 17111

(F)

JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000

(G)

(I)

MAKER : YAZAKI CORP.

HOUSING No. : 7123-2249
TERMINAL : 17111

(J)

(L)

MAKER : YAZAKI CORP.

HOUSING No. : 7123-2249
TERMINAL : 17111

(D)

MAKER : YAZAKI CORP.

HOUSING No. : 7123-2228
TERMINAL : 17111

JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000

MAKER : YAZAKI CORP.

HOUSING No. : 7123-2237
TERMINAL : 17111

(M) MAKER : YAZAKI CORP.

HOUSING No. : 7122-6060

REAR HOLDER : 7157-6260-30
TERMINAL : 7114-2871

JAE
HOUSING : IL-AG5-14D-S3C1
TERMINAL : IL-AG5-C1-5000

(E)

NIPPON AMP KK 174056-2

TERMINAL : 175062-1

(H)

JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000

(K)

MAKER : YAZAKI CORP.

HOUSING No. : 7123-6020
TERMINAL : 7116-2871

(N) MAKER : YAZAKI CORP.

HOUSING No. : 7123-6060-40

TERMINAL : 7116-2871
26

25 85E

150 E24 18

(P)

(Q)

MAKER : YAZAKI CORP.

7120-8019
CP3.96MA

NIPPON AMP KK
170889-1
170003-5

(R)

MAKER : SUMITOMO
HOUSING No. : 6189-0094
HARNESS SEAL : 7160-8234
TERMINAL : 1500-0110
150 155

SM0045

JAE : JAPAN AVIATION ELECTRONICS

INDUSTRY, LTD.

Br Lg O

LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE

T3-8-24

AIR CONDITIONER SYSTEM

E175B-E195B

STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION

1.

Control panel and control unit

The control unit is integrated into control panel,
and processes the signal input by each sensor,
etc. and the signal input by each switch through
control panel with the function of the built-in
micro computer, and comprehensively controls
each actuator (Inner and outer air flow select,
air mix), fan motor and compressor on the
output
side.
And
the
self-diagnosis
performance is provided to facilitate the trouble
shooting.

2.

Blower controller (TKS-B215A1)

The power transistor shifts the fan motor into
variable speed with base current from the
control unit.
TERMINAL
NO.
1

+
TESTER

SM0047

CONTINUITY

3
-

CONTINUED
(4.7 k
5%)

NOT CONTINUED

CONTINUED (DIODE
PARALLEL AND
FORWARD DIRECTION
FLOW)

Lg

In normal operation
1) Disconnect the connector of blower
amplifier.
2) Check continuity between terminals on the
blower amplifier side.

* The installing position is provided on the

left side of air-con unit.
SM0048

T3-8-25

E175B-E195B
3.

AIR CONDITIONER SYSTEM

Relay
Four-electrode relay is used for the blower OFF
relay and compressor relay.
1) Blower OFF relay
The blower OFF relay turns on after
receiving the signal from the control
amplifier.
When the blower OFF relay turns on, the
source voltage is supplied to the blower
motor and the blower motor starts running.

A
A

2) Compressor relay
The relay ONOFF is tripped by the control
amplifier and electronic thermostat control.
SM0049

3) Relay inspecting items

1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay
because this relay has polarity.
5. Inspection:
Inspect the continuity
between 3 and 4 according to the
conditions mentioned below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 12:
Not continued
4.

Air mix actuator

Air mix actuator is installed at the center of aircon unit, and opens and closes air mix damper
through the link.
The air mix actuator contains potentiometer
which is switched by being coupled to the shaft
of actuator.
When the target air mix door position is
determined through the temperature control
switch, the control unit reads the level of
potentiometer of the actuator, and determines
the rotating direction of motor in either normal
rotation or reverse rotation. Then as the motor
rotates, the contact point is moved, and when
the contact point is detached or the output
signal of control unit turns OFF, the motor stops
rotating.

T3-8-26

CONTROL AMPLIFIER

MOTOR ACTUATOR

LIMITER
COOL
POTENTIO 5V
POTENTIO
POTENTIO GND

HOT

SM0050

AIR CONDITIONER SYSTEM

5.

6.

The actuator for inner and outer

The actuator for inner and outer air flow select
is installed on the blower intake unit, and opens
and closes inner and outer air damper through
the link. The actuator for inner and outer air flow
select contains position detection switch which
is switched with the movement of shaft of the
actuator.
When the inner and outer damper position is
set by the inner and outer switch on the control
panel, the control unit reads the signal of the
position detection switch in the actuator and
determines the rotation direction of motor in
either normal rotation or reverse rotation. Then
as the motor rotates, the position detection
switch also rotates and makes it stop at the set
position of the inner and outer air damper.
Evaporator sensor
This sensor is used to control the evaporator
outlet temperature with the compressor ONOFF to protect the evaporator from freezing,
and this evaporator sensor functions as a
sensor of this control.

7.

AMPLIFIER

E175B-E195B

MOTOR ACTUATOR

INNER AIR SIDE

OUTER AIR SIDE
LIMITER

SM0051

Evaporator sensor inspecting items

(Specification)
Terminal resistance:
at 0 degree C: 7.2 k
at 25 degree C: 2.2k

Dual pressure switch

This dual pressure switch is attached on L-hose
and is used to turn OFF the compressor, and
employs dual type (for high and low pressure
control) to protect the cooler cycle from
possible failure at the time when abnormal
pressure was generated on the high pressure
side.

SM0052

SPECIFICATION OF DUAL PRESSURE SWITCH

0.02MPa(2.9psi)

0.59MPa(86psi)
SM0053

ON
OFF

3.14MPa
0.20MPa
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)

8.

Solar radiation sensor

This solar radiation sensor, which is used to
correct the solar radiation to the auto air
conditioner detects the strength and solar
orientation of sunbeam after transforming them
into current by means of photo diode.
Inspection: Check for the continuity between
terminals.
SM0054

T3-8-27

E175B-E195B

AIR CONDITIONER SYSTEM

TROUBLESHOOTING
Note : M/A is motor
actuator
* is any of the
numbers 0 ~ 9

Air temperature does not fall.

If AUTO switch or A/C switch is pushed, "HL.E" is indicated on the set

temp. display of the panel.
NO

YES
Connector for air mix M/A is disconnected or in
poor contact.
Air mix M/A is failed.
Main harness shows poor continuity.

"HL.*" is shown on the set temp. display

of the panel
NO

YES

A snow mark ( ) on the

panel is flashing.

A snow mark (
panel is flashing.
NO

) on

Inspect and correct or replace parts.

YES

Inner air sensor or harness is disconnected or shorted

Inner air sensor connector is disconnected or in poor
contact.
See section monitor mode.

Both inner air sensor and evaporation

sensor are disconnected or shorted.
Controller failed.
See section monitor mode.

Inspect and correct or replace parts.

A
NO
Blowout temp. falls if temp. is set at 18.0 C
(64.4 F) (COOLMAX) and the blowout mode is
changed to vent mode.
NO
Air mix damper is in
COOLMAX.

NO

YES
Evaporation
sensor
connector
is
disconnected or in poor contact.
Evaporation sensor is disconnected or
shorted.

YES

Inspect and correct or replace parts.

Cool air flowing into inner

air sensor

Inspect and correct or replace parts.

YES

If M/A is at stop halfway,

eliminate cause, correct and
measure operating force.
(less than 14.7N: OK)

NO
Turn compressor clutch on
and off. Inspect and correct
electric circuits.
Refer to Troubleshooting for
refrigeration cycle.
NO

Controller is faulty
or inner air sensor
is faulty.

Inspect and replace.

YES

Inspect, correct or replace M/A lever

link.
After cleaning lever link, apply grease.

M/A failed or controller

is out of order.
Replace.

T3-8-28

YES
Inspect duct or
eliminate cause for
cool air intrusion.

AIR CONDITIONER SYSTEM

E175B-E195B

Air temperature does not rise.

Note : * is any of the

numbers 0 ~ 9

HL.E is shown on the set temp. display of

the panel.
NO

YES
Connector for air mix M/A is disconnected or in
poor contact.
Air mix M/A is failed.
Main harness shows poor continuity.

"HL.*" is shown on the set temp. display

of the panel.
NO

YES

Inner air sensor or harness is disconnected or

shorted
Inner air sensor connector is disconnected or in
poor contact.

Inspect and correct or replace parts.

See section monitor mode.

NO
YES
Inspect and correct or replace parts.

NO
YES
Blowout temp. rises at blowout
mode if temp. is set at HOT MAX
32.0 C (64.4 F)
NO
Air mix damper is in
HOT MAX

NO

YES
Warm air is flowing into
inner air sensor.

YES

If M/A action is at stop,

eliminate cause, correct and
measure operating force.
(less than 14.7N: OK)

NO

YES

Inspect warm water piping.

Controller or inner
air sensor is out of
order.

Inspect and replace.

NO
Inspect, correct or replace M/A lever
link.
Clean lever link and apply grease.

YES
M/A failed or controller
is out of order.
Replace.

T3-8-29

Inspect duct or
eliminate causes
for warm air entry.

E175B-E195B

AIR CONDITIONER SYSTEM

Blower motor does not run.

Note 1)

At air flow HI, battery voltage acts across

both terminals (+) and (-) of blower motor.
NO

YES
Blower motor fails.

Battery voltage acts across red

(+) and body of blower motor.
NO
Note 2)

YES

Inspect blower motor relay. Blower

motor rotates if white / red wire and
red wire of blower motor relay are
direct connected.

Replace.
Approx. 10V acts across light green wire
and grounding of blower amplifier.

NO
NO

YES

YES

Controller is out of order.

Replace.

Wire harness is faulty.

Inspect and correct or
replace.

NO
Eliminate
cause
and replace blower
amplifier.

Battery voltage acts across white / red

wire and body of blower motor relay.
NO
Inspect and repair
harness or replace.

Remove blower amplifier and check

for continuity across light green wire
and black wires; you get continuity.
YES
Inspect
and
repair harness.

YES
Blower turns if orange wire of blower motor relay
is connected with ground.
NO
Replace relay.

YES
Inspect and correct harness or
replace controller.

Note 1) Measure with connector set.

Note 2) Always turn off air-conditioner, starter key switch and light switch before work.

T3-8-30

AIR CONDITIONER SYSTEM

E175B-E195B

Blower motor speed does not change.

CASE (1)
"HL.*" is shown on the set temp. display of
the panel.
NO
Replace blower
controller.

amplifier

Note) * is any of the

numbers 0 ~ 9.

YES
Inner air sensor or harness is disconnected or
shorted.
Inner air sensor connector is disconnected or in
poor contact.
See section monitor mode.

Inspect and correct or replace parts.

CASE (2)
Does not blower motor speed change
because the setting mode is other face
NO
Is door or front window open?
NO
The limiting or control operation
is actuated by door switch or
front window switch

YES
See CASE (1).

T3-8-31

YES
See CASE (1).

E175B-E195B

AIR CONDITIONER SYSTEM

Magnet clutch does not engage.

Snow mark ( ) lights if A/C

switch is pressed.
NO

YES
Voltage acts upon clutch.

Snow mark ( ) flickers and

E is shown on panel display.

NO

To A On page T8-3-28.

Voltage is applied to pressure switch

harness.
NO

Pressure switch is faulty or refrigerant

gas is under charged or overcharged.
Refer to troubleshooting for
refrigeration cycle.

YES

Inspect clutch fuses.

Clutch faulty.

YES

Voltage acts across white / green wire

and Ground (Black) connector
connected to excavator.
NO

YES

Inspect air-conditioner
harness. No fault.
NO

YES

Replace harness.

Replace controller.

Inner air and outer air do not change

Inner / outer air mode display on

operation panel is flickering.
NO

YES

M/A lever includes foreign

matter or is broken.
NO
M/A failed

Connector of inner/outer air M/A is

disconnected or in poor contact. Or
M/A failed or main harness failed.

YES
Remove foreign matter
and replace parts.

Replace

T3-8-32

Inspect or replace.

AIR CONDITIONER SYSTEM

E175B-E195B

Modes do not change.

Mode display (Mark of person) on

operating panel is flickering.
NO

YES

M/A rod does not disengage.

NO

Mode M/A connector is disconnected

or in poor contact or M/A failed or
main harness is faulty.

YES

Repair.

Each damper lever does not

disengage.
NO
Repair.

Inspect or replace.

YES
When rod is removed and cam is operated
by hand, it is heavy. (more than 19.6N.).
NO

M/A or controller is out of order.

Replace.

YES
Cam or damper shaft includes foreign
matter or is broken
Erroneous motion occurs due to dirty
grease.
Remove foreign matter or replace parts.
Clean cam and apply new grease.

T3-8-33

E175B-E195B

AIR CONDITIONER SYSTEM

Trouble with refrigeration cycle.

Both high and low pressures are lower.

Air bubbles are seen in sight glass.
NO

YES

Cooling does not work if run at high speed.

NO

Oil comes out from piping and parts.

YES

NO

YES

Expansion valve is
clogged or maladjusted.

Expansion valve is frozen

or intruded by water.

Natural leak from hose.

Adjust
or
replace
expansion valve.

After making vacuum,

refill
refrigerant
and
replace receiver.

Charge gas.

Gas leaks from pipe

joints and parts.
Retighten
parts.

or

replace

Low pressure is higher.

NO

YES

Air bubbles are seen in sight glass.

High pressure is lower.

Compressor cylinder does not get hot.

Compressor cylinder gets very hot.

Expansion valve is maladjusted. (too much open)

Compressor does not discharge well.

Replace expansion valve.

Replace compressor

High pressure is lower.

Air bubbles are seen in sight glass.

NO
High pressure gets lower slowly.

YES
Condenser is fouled or clogged.
YES

High pressure circuit before receiver is

clogged up.

Remove
clogging
replace parts.

Clean condenser.

or

NO
Air bubbles are hard to go out even if
water is poured on condenser.

Air is mixed. Make vacuum

and refill refrigerant.

T3-8-34

AIR CONDITIONER SYSTEM

E175B-E195B

SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL

The failure of motor actuator and each sensor can be identified on the display of panel.
POSITION OF INDICATION FOR FAILURE.

SM0055

The error is indicated on 3 digits segment.

EXPLANATION OF INDICATION FOR FAILURE.
Failure of Motor Actuator
1.

HL.E is indicated on 3 digits segment.

Check harness or connector to motor actuator for the air

mix damper for disconnection.

SM0056

2.

MODE

is flickering.

Check harness or connector to motor actuator for the air

outlet damper for disconnection.

SM0057

3.

R/F

is flickering.

SM0058

Check harness or connector to motor actuator for the

inner and outer air damper for disconnection.
Note: The above indication and flickering does not
function if the harness and connector were
disconnected under the condition the panel ON/
OFF switch is ON.
After the failure was occured, if the panel ON/
OFF switch is turned ON, it functions.
After correction of failure, if the starter switch is
not switched from OFF to ON the error indication
and flickering are not released.

T3-8-35

E175B-E195B

AIR CONDITIONER SYSTEM

Failures of sensors
1.

HL.* is indicated on 3 digits segment.

Check the inner air sensor or the harness for

disconnection and short circuit, and also connectors for
disconnection.

SM0059

(* is any of the numbers 0 to 9.)

2.

**E and

mark are flickering.

(** is displayed leaving the present set temperature value.)

Check evaporator sensor or the harness for

disconnection and short circuit, and also connectors for
disconnection.

SM0060

Note: The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the condition
the panel ON/OFF switch is ON.
And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is
released.

Communication error of control amplifier and panel

1.

E is indicated on the only use segment of display.

Check the harness of control amplifier and panel for

disconnection, and connectors for poor connection.

SM0061

T3-8-36

AIR CONDITIONER SYSTEM

E175B-E195B

EXPLANATION OF MONITOR MODE

When error failure of sensors is displayed, the monitor mode is available to identify the sensor condition
(disconnection, short circuit).
1.

Position of monitor mode indication

SM0062

3 DIGITS SEGMENT

2.

SEGMENT FOR ONLY

MONITOR INDICATION

Operation of monitor mode

SM0063

1. Press inner and outer air flow select switch (A) and ON/OFF switch (D) simultaneously for 1 second.
2. Press AUTO switch (E).
(After all segments are lit on for 1 second, the mode is switched into monitor mode.)
3. Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit
and 2nd digit of segment in three digits. The 1st digit is indicated by "H".
4. Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by
pressing UP or DOWN of blower switch (B) or (C), and the required sensor is selected from the list
below.
SEGMENT ASSIGNMENT LIST
0

INNER AIR SENSOR

EVAPORATOR SENSOR

SOLAR RADIATION SENSOR

SM0064

(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)

5.

The monitor display is terminated by pressing the inner and outer air flow select switch (A) and ON/OFF
switch (D) for 1 second again, or turning off the main switch of excavator.

Notes:
- The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.
- Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch (D) again, and the error display is disappeared.

T3-8-37

E175B-E195B
3.

AIR CONDITIONER SYSTEM

Contents of monitor mode display

Refer to the list of segment display exclusively used for monitor and the list of segments in three digits.
1. Example 1
When the segment exclusively used for monitor
indicates 0 (displays the inner air sensor condition),
since the segment indicates 3F, the sensor is in normal
operating condition according to the list of 3 segments.
--> The inner air sensor is in normal operating condition.
SM0065

2. Example 2
When the segment exclusively used for monitor
indicates 1 (displays the evaporator sensor condition),
since the segment indicates 00, the sensor is in
disconnection condition according to the list of 3
segments.
--> The evaporator sensor is in disconnection condition.
SM0066

3. Example 3

SM0067

4.

When the segment exclusively used for monitor

indicates 2 (displays the solar radiation sensor
condition), since the segment indicates FF,the sensor is
in short-circuiting condition according to the list of 3
segments.
-->The solar radiation sensor is in short-circuiting
condition.

List of 3 segments
SECOND SEGMENT
INNER AIR SENSOR DISCONNECTION
EVAPORATOR SENSOR DISCONNECTION

THIRD SEGMENT

SOLAR RADIATION SENSOR SHORT-CIRCUITING

EACH SENSOR IS NORMAL

SOLAR RADIATION SENSOR 5V SIDE SHORT-CIRCUITING

INNER AIR SENSOR SHORT-CIRCUITING
EVAPORATOR SENSOR SHORT-CIRCUITING
SM0068

T3-8-38

OPERATIONAL PERFORMANCE TEST

M0103

OPERATIONAL PERFORMANCE TEST

E175B-E195B

SECTION AND GROUP CONTENTS

Section 4

OPERATIONAL PERFORMANCE TEST

Group 1
Group 2
Group 3
Group 4

Introduction
Standard Performances
Test Procedures
Mechatro Controller

SECTION 4

OPERATIONAL PERFORMANCE
TEST

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

Group 2 - Standard Performances

Performance Inspection Standard
Table E175B ...................................... T4-2-1
Performance Inspection Standard
Table E195B ...................................... T4-2-3

Group 3 - Test Procedures

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

Group 4 - Mechatro Controller

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

E175B-E195B

INTRODUCTION

E175B-E195B

HOW TO USE THE MAINTENANCE

STANDARD AND CAUTIONS TO BE
EXERCISED
Application

Cautions to be Exercised at Judgment

WHEN THE MACHINE IS NEW

EVALUATION OF MEASURED DATA

Confirm that the performances are in accordance

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

Disagreement of measuring conditions, variations of

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

Use the data for the criterion, for the purpose of

correction, adjustment and replacement.

DETERMINING CORRECTION, ADJUSTMENT

OR REPLACEMENT

WHEN PERFORMANCES ARE DETERIORATED

Machine performances deteriorate with time as

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

Determine whether it is caused by a fault or end of

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

Other Cautions to be Exercised

Terminology

PARTS LIABLE TO DEGRADE

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

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

T4-1-1

E175B-E195B

INTRODUCTION

PREPARATION FOR PERFORMANCE

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

Repair any defects and damage found, such as

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

Test area
1.

Select a hard and flat surface.

2.

Secure enough space to allow the machine to

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

3.

SM1231

If required, rope off the test area and provide

signboards to keep unauthorized personnel
away.

Precautions
1.

Before starting to test, agree upon the signals

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

2.

Operate the machine carefully and always give

first priority to safety.

3.

While testing, always take care to avoid

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

4.

Avoid polluting the machine and the ground

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

Make precise measurement

1.

Accurately calibrate test instruments

advance to obtain correct data.

in

2.

Carry out tests under the exact test conditions

prescribed for each test item.

3.

Repeat the same test and confirm that the test

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

T4-1-2

SM1232

STANDARD PERFORMANCES

E175B

PERFORMANCE INSPECTION STANDARD TABLE (E175B)

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

Measuring Position

Inspection Item

Standard
Value

Unit

Adjusting
Point

Hydraulic oil in tank

NAS 9
or less

Class

Sampling

Tank surface

50 5

Radiator surface

75 15

Atmospheric
temp
50 C ~ -10 C

Position

Cleanliness of hydraulic oil

Hydraulic oil temperature
Water temperature

Size

Port

Engine speed

H mode Lo idle
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

Main relief
valve pressure

Full throttle (Hi Idle)

1050 50
2200 50

2000 50

ATT Travel

Power
boost

a5

P1

a1

P2

a2

P1

a1

P2

a2

H
a1
R

R
H
Arm

Main pump

H
Bucket

a1

HI idle

34.3 +0.7
-0.5

MR1

Boom up

37.8 +1.0
-0.5

MR1

39.7 +0
-5.9

OR3

Boom up

37.7 +0
-4.0

OR4

Boom down

39.7 +0
-5.9

OR1

Bucket digging

OR2

Bucket dump

37.7 +0

OR7

Arm in

39.7 +0
-5.9

OR8

Arm out

OR5

Swing LH

OR6

Swing RH

-4.0

LH
Swing

a2
RH

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

PR1

-4.0

a2

min-1

0.5
5.0 +-0

37.7+0

PF 1/4

28.0 +6.0
+0

MPa

Forward
RH

a1
Reverse

Travel

Over load relief valve pressure

2200 50

S mode Hi idle

Boom

High pressure circuit

Low throttle

2200 50

G pump

1000 50

A mode Hi idle

Pilot primary pressure circuit

Measuring
Condition

34.4+0.7

-0.5

Forward
LH

a2
Reverse

T4-2-1

34.4+0.7
-0.5

Simultaneous
Operation of travel RH
and LH

E175B

STANDARD PERFORMANCES

Inspection Item
Sprocket revolution
(RH, LH)

Standard value

1st speed

28~24

2nd speed

46~41

Operating speeds

Arm
Operating time
of cylinder

Positioner
Swing speed
Travel speed
Amount of travel
deviation

Prestazioni

Bucket

In

3.4~4.0

Out

2.4~3.0

Digging

3.5~4.1

Dumping

2.1~2.7

Up

4.0~4.6

Down

6.5~7.1

RH - LH

4.9~5.9

1st speed

Iron shoe

28.2~31.2

2nd speed

Iron shoe

16.8~18.6

2nd speed

(At no load)

s / 1 rev
s / 3 rev

mm / 5 min

55~75

degree
mm

15 Gradient
Neutral position after
180 full speed swing

Swing parking brake

drift

15 Gradient

Tip of the bucket tooth

90

Boom cylinder

3
4.2

mm / 20 m

Performance of Swing
brake

Arm cylinder

min-1

0~240

Parking brake drift

ATT amount of drift

Measuring
condition

Unit

mm / 5 min

(A vuoto)

Amount of horizontal play at the bucket tooth

30~50

mm

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

correspond to the following operations.
1.

Bucket digging

5.

Swing left

2.

Bucket dump

6.

Swing right

3.

Boom up

7.

Arm in

4.

Boom down

8.

Arm out

T4-2-2

(8)
(5)

(4)
(6) (1)

(7)

(2)
(3)

STANDARD PERFORMANCES

E195B

PERFORMANCE INSPECTION STANDARD TABLE (E195B)

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

Measuring Position

Inspection Item

Standard
Value

Unit

Adjusting
Point

Hydraulic oil in tank

NAS 9
or less

Class

Sampling

Tank surface

50 5

Radiator surface

75 15

Atmospheric
temp
50 C ~ -10 C

Position

Cleanliness of hydraulic oil

Hydraulic oil temperature
Water temperature

Size

Port

Engine speed

H mode Lo idle
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

Main relief
valve pressure

Full throttle (Hi Idle)

1050 50
2200 50

2000 50

ATT Travel

Power
boost

a5

P1

a1

P2

a2

P1

a1

P2

a2

H
a1
R

R
H
Arm

Main pump

H
Bucket

a1

a2

HI idle

34.3 +0.7
-0.5

MR1

Boom up

37.8 +1.0

MR1

-0.5

39.7 +0
-5.9

OR3

Boom up

37.7 +0
-4.0

OR4

Boom down

39.7 +0

OR1

Bucket digging

OR2

Bucket dump

37.7 +0
-4.0

OR7

Arm in

39.7 +0

OR8

Arm out

OR5

Swing LH

OR6

Swing RH

-5.9

-5.9

a2
RH

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

PR1

LH
Swing

min-1

5.0 +-00.5

37.7+0
-4.0

PF 1/4

30.0 +4.0
+0

MPa

Forward
RH

a1
Reverse

Travel

Over load relief valve pressure

2200 50

S mode Hi idle

Boom

High pressure circuit

Low throttle

2200 50

G pump

1000 50

A mode Hi idle

Pilot primary pressure circuit

Measuring
Condition

34.4+0.7
-0.5

Forward
LH

a2
Reverse

T4-2-3

34.4+0.7
-0.5

Simultaneous
Operation of travel RH
and LH

E195B

STANDARD PERFORMANCES

Inspection Item
Sprocket revolution
(RH, LH)

Standard value

1st speed

26~22

2nd speed

40~35

Operating speeds

Arm
Operating time
of cylinder

Positioner
Swing speed
Travel speed
Amount of travel
deviation

Prestazioni

Bucket

In

2.9~3.5

Out

2.6~3.2

Digging

3.2~3.8

Dumping

2.1~2.7

Up

3.0~3.6

Down

4.9~5.5

RH - LH

4.3~5.3

1st speed

Iron shoe

32.5~35.5

2nd speed

Iron shoe

20.5~22.3

2nd speed

(At no load)

s / 1 rev
s / 3 rev
mm / 20 m

mm / 5 min

55~75

degree
mm

15 Gradient

Performance of Swing
brake

Neutral position after

180 full speed swing

Swing parking brake

drift

15 Gradient

Tip of the bucket tooth

90

Boom cylinder

Arm cylinder

10

min-1

0~240

Parking brake drift

ATT amount of drift

Measuring
condition

Unit

mm / 5 min

(A vuoto)

Amount of horizontal play at the bucket tooth

30~50

mm

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

correspond to the following operations.
1.

Bucket digging

5.

Swing left

2.

Bucket dump

6.

Swing right

3.

Boom up

7.

Arm in

4.

Boom down

8.

Arm out

T4-2-4

(8)
(5)

(4)
(6) (1)

(7)

(2)
(3)

TEST PROCEDURES

E175B-E195B

MEASUREMENT OF ENGINE SPEED

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

Engine speed measured value through service

diagnosis
1.

Turn "ON" the starter switch with the buzzer

stop switch pressed.

2.

A program No. and an actual engine revolution

are displayed as the No.2 Item.

3.

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

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

4.

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

time the "Washer switch" is pushed.

5.

The display does not disappear unless the

starter switch is turned to"OFF".

GAUGE CLUSTER

BUZZER STOP
SWITCH
WASHER
SWITCH

WIPER
SWITCH
SCREEN CHANGE SWITCH

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

SM0851

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

T4-3-1

E175B-E195B

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

E175B

a3

Psv2

Psv1

MEASURING CLEANLINESS OF HYDRAULIC OIL

A3
Dr1

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.

a5

B1

Dr3
B3

(a1)

Dr1

PH2

E195B

Place to install pressure gauge

Dr2

(a2)

SM1281

Psv1
(Psv2)

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

A3

a5

PILOT CIRCUIT
Replace pilot gauge plug (a5) with plug PF1/4 for
pressure measurement, and attach pressure gauge
6.9 MPa (1000 psi).

T4-3-2

B3
a2
(a1)

A2
(A1)

SM1282

TEST PROCEDURES

E175B-E195B

Pressure adjustment position

MAIN CONTROL VALVE
Relief valve position on main control valve.

PLUG FOR
OPTIONAL RELIEF

ARM (H)
OR7

FRONT
MACHINE

MAIN RELIEF
(ATT & TRAVEL)

BOOM (H)
OR3

BUCKET (R)
OR2

View from the top of the machine

BOOM (R)
OR4

SM1283

BUCKET (H)
OR1

MACHINE
FRONT

ARM (R)
OR8
View from the bottom of the machine

T4-3-3

PLUG FOR
OPTIONAL RELIEF
SM1284

E175B-E195B

TEST PROCEDURES

PILOT RELIEF VALVE

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

A3

a5

Dr3

B3
PR1

SWING OVER LOAD RELIEF

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

SM1285

SWING RIGHT
OVERLOAD RELIEF
OR6

SWING LEFT
OVERLOAD RELIEF
OR5

(A)

(B)

PB

PA

SM1286

E175B

a3

Psv2

E195B

Psv1
(Psv2)

Psv1

A3
Dr1

A3
Dr2
a5

B1

Dr3
B3

B3
(a1)

a5

Dr1

PH2

(a2)

a2
(a1)

SM1281

T4-3-4

A2
(A1)

SM1282

TEST PROCEDURES

E175B-E195B

Procedure for adjusting relief valve

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

Pressure change MPa

(psi)

1 turn

Approx. 2.1 (305)

LOCK NUT HEX24

2-STAGE MAIN RELIEF VALVE

311

(Commom for travel and ATT sections)

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

SM1287

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

4 3

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

SM0859

: 19 mm Adjust screw
: 6 mm

No. of turns of adjust

screw

Pressure change MPa

(psi)

Boosting side 1 turn

Approx. 17.6 (2560)

STD side 1 turn

Approx. 17.6 (2560)

OVER LOAD RELIEF VALVE

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

Pressure change MPa

(psi)

1 turn

Approx. 17.7 (2560)

1
SM0860

T4-3-5

E175B-E195B

TEST PROCEDURES

OVER LOAD RELIEF VALVE (SWING)

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

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

No. of turns of adjust

screw

Pressure change MPa

(psi)

1 turn

Approx. 10 (1450)

SM0861

OVER LOAD RELIEF VALVE (TRAVEL)

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

: 17 mm
: 6 mm
2
SM0862

T4-3-6

TEST PROCEDURES

E175B-E195B

MEASURING TRAVEL PERFORMANCES

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

SM0863

REFLECTION
PANEL

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

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

SM0864

E175B
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

22~19.5

17.3 or
less

46~41

35.9~32

29.1 or
less

E195B
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

26~22

20.2~17.3

15.3 or
less

40~35

30~27

25.1 or
less

T4-3-7

E175B-E195B

TEST PROCEDURES

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

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

Approx. 30~40 cm

PREPARATION

SM0865

1.

Straight course more than 30m (108ft).

2.

Travel position in which the bottom of the

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

MEASUREMENT
1.

2.

Measure the max. deviation distance of the

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

Travel deviation

A
20m

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

Measuring
position

Standard
value

Reference value
for remedy

Service
limit

240 (9.45)
or less

480 (18.9)

720 (28.4)

SM0866

T4-3-8

TEST PROCEDURES

E175B-E195B

Performances of parking brake

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

BOOM FOOT PIN

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

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

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

15 degree slope

SM0867

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

Units: mm (in)/5 min

Measuring
position

Standard
value

Reference value
for remedy

Service
limit

1 (0.04)

2 (0.08)
GUIDE FRAME

ANGLE METER

SM0868

T4-3-9

E175B-E195B

TEST PROCEDURES

Drain rate of travel motor

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

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

PREPARATION
1.

Place a stopper under the RH and LH travel

sprockets.

2.

Stop the engine and release pressure from the

hydraulic circuit.

3.

Connect a hose with the drain port of the travel

motor and take drain in a container.

MEASUREMENT AT TRAVEL LOCK

90 o 10
(3.54") (0.394")

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

40
(1.57")
150
(5.91")

STOPPER
"B"

ROTARY DIRECTION

o 80
(3.15")
SM0869

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

Start the engine and relieve pressure at the full

stroke of the travel lever.

2.

Measure the drain rate for 30 seconds of

relieving.

Drain rate of travel motor

E175B
Unit: (gal)
L/30 s

Drain rate of travel motor

Measuring
position

Standard
value

Reference value
for remedy

Service limit

Drain rate

5 (1.3)

13 (3.4)

15 (4.0)

E195B
Unit: (gal)
L/30 s

Drain rate of travel motor

Measuring
position

Standard
value

Reference value
for remedy

Service limit

Drain rate

7 (1.6)

14 (3.5)

21 (4.6)

T4-3-10

SM0870

TEST PROCEDURES

E175B-E195B

MEASURING SWING PERFORMANCES

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

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

PREPARATION
Put the bucket empty and extend the boom, arm and
bucket cylinder fully.
And the machine becomes a position of minimum
reach.
MEASUREMENT AT TRAVEL LOCK
Swing the machine by bringing the swing lever to its
full stroke. Measure the time required to make two
turns after one turn of preliminary run and calculate
the time required for one turn.
E175B
Swing speed

Unit : sec/rev

Measuring
position

Standard
value

Reference value
for remedy

Service limit

Swing speed
at min. reach

4.9~5.9

6.2~7.5

7.8~

Measuring
position

Standard
value

Reference value
for remedy

Service limit

Swing speed
at min. reach

4.3~5.3

5.4~6.8

7.0~

E195B
Swing speed

Unit : sec/rev

T4-3-11

SM0871

E175B-E195B

TEST PROCEDURES

Performance of swing brake

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

ARM TOP
PIN

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

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

PREPARATION
1.

Put the bucket empty, retract the arm cylinder

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

2.

Put a matching mark on the outer

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

MEASUREMENT AT TRAVEL LOCK

1.

2.

When operating in regular swing speed, by

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

Swing
angle ()

drift

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

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

Swing brake performance

x 360

MEASURING THE LENGTH OF THE ARC OVER

THE OUTER CIRCUMFERENCE OF OUTER RACE
MATCHING MARKS ON
OUTER RACE

MATCHING MARKS
ON INNER RACE
SM0873

Unit : degree

Measuring
position

Standard
value

Reference value
for remedy

Service limit

Swing 180

75

85

90

T4-3-12

TEST PROCEDURES

E175B-E195B

Performance of swing parking brake

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

SM0874

Put the angle meter on the shoe plate and make

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

MEASUREING THE LENGTH OF THE ARC OVER

THE OUTER CIRCUMFERENCE OF OUTER RACE
MATCHING MARKS ON
OUTER RACE

MEASUREMENT AT TRAVEL LOCK

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

Performance of swing
parking brake

Unit : mm(in)/5min

Measuring
position

Standard
value

Reference value
for remedy

Service limit

1 (0.04)

2 (0.08)

T4-3-13

MATCHING MARKS
ON INNER RACE
SM0875

E175B-E195B

TEST PROCEDURES

Drain rate of swing motor

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

45~55C
(113~131F)

Firm, level ground

Engine revolution:

Hi idle

PREPARATION
1.

Stop the engine.

2.

Release pressure from inside the hydraulic

circuit.

3.

Disconnect the swing motor drain hose from its

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

4.

Put a plug to the tank side.

MEASUREMENT AT SWING LOCK

1.

Start the engine and put the side faces of

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

2.

Relieve the swing motor at full stroke of the

swing motion.

3.

Collect the amount of drained oil in a container

for 30 seconds.

Drain rate of swing motor

Unit : L(gal)/30sec

Measuring
position

Standard
value

Reference value
for remedy

Service limit

Drain rate

2.1 (0.55)

5.2 (1.4)

6.2 (1.6)

T4-3-14

SM0876

TEST PROCEDURES

E175B-E195B

MEASURING ATTACHMENT OPERATING

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

45~55C
(113~131F)
Engine revolution:
Hi idle
Operating time excluding the cushion stroke.
PREPARATION
Firm level ground with the bucket empty.
MEASUREMENT
Arm in and out, positioning in and out, bucket
digging and dump
In a position in which the tooth of the bucket rises to
a level of about 30cm (1ft) above ground, measure
the full stroke operating time required with the arm,
the positioning and bucket operating levers at full
stroke.

30 cm (1 ft)

E175B
Cylinder Operating time

Unit : sec

Measuring
position

Standard
value

Reference value
for remedy

Service limit

3.5~4.1

4.4~5.2

5.4~

2.1~2.7

2.7~3.4

3.5~

3.4~4.0

4.2~5.0

5.4~

2.4~3.0

3.0~3.8

4.0~

4.0~4.6

5.0~5.7

5.9~

10

6.5~7.1

8.2~9.0

9.4~

30 cm (1 ft)

E195B
Cylinder Operating time

Unit : sec

Measuring
position

Standard
value

Reference value
for remedy

Service limit

3.2~3.8

4.0~4.8

5.0~

2.1~2.7

2.7~3.4

3.5~

2.9~3.5

3.8~4.5

4.9~

2.6~3.2

2.9~4.0

4.2~

3.0~3.6

3.8~4.5

4.7~

10

4.9~5.5

6.1~7.0

7.3~

10

30 cm (1 ft)
SM0877

T4-3-15

E175B-E195B

TEST PROCEDURES

Oil tightness of cylinders

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

Hydraulic oil temperature:

45~55C
(113~131F)

Firm, level ground

After cylinders are replaced, bleed off air from the
cylinders, before checking for oil tightness.
Retract the arm cylinder rod 50mm (2in) from stroke
end so that the piston does not match a same range
of the cushioning mechanism.
PREPARATION
Put the bucket empty. Extend the arm cylinder rod
50mm (2in) from the most retracted position. And
extend the bucket cylinders fully. Then hold the
boom so that the arm top pin is positioned at same
height with boom foot pin.
MEASUREMENT
Measure the items five minutes after the engine is
turned off.
E175B
Oil tightness of cylinder
Standard
value

Unit: mm(in)/5min
Reference value
for remedy

Service limit

3 (0.12)

5 (0.2)

7 (0.28)

4.2 (0.17)

7 (0.28)

10.5 (0.41)

90 (3.54)

150 (5.9)

225 (8.86)

E195B
Oil tightness of cylinder
Measuring
position

BOOM FOOT PIN

CONDITIONS

Measuring
position

Standard
value

Unit: mm(in)/5min
Reference value
for remedy

Service limit

6 (0.24)

8 (0.31)

10 (0.39)

10 (0.39)

13 (0.51)

18 (0.71)

90 (3.54)

150 (5.9)

225 (8.86)

T4-3-16

D
ARM TOP PIN

SM0878

TEST PROCEDURES

E175B-E195B

MEASURING PERFORMANCES OF SWING

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

Install a dial indicator to the magnetic base and

fix it to the lower frame.

2.

Direct the upper swing body and the lower

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

LOCATION OF BEARING
MOUNTING BOLTS

SWING BEARING
A

DIAL INDICATOR
LOWER FLAME

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

SM0879

Unit: mm (in)

Measuring
position

Standard
value

Reference value
for remedy

Service limit

0.8~1.8
(0.03~0.07)

2.3~3.3
(0.09~0.13)

3.6 (0.14)

90 ~100

30cm

SM0880

Position 1

BOOM FOOT
PIN

ARM TOP
PIN

SM0872

Position 2

T4-3-17

E175B-E195B

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

E175B-E195B

ENGINE CONTROL INPUT/OUTPUT

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

E-1:
FUSE&RELAY
BOX

ENGINE SPEED
SENSOR

STARTER
SWITCH

C-1:
MECHATRO CONTROLLER

ACCEL
POTENTIO METER

ENGINE

PUMP
PROPORTIONAL
VALVE

SM0881

T4-4-1

E175B-E195B

MECHATRO CONTROLLER

ENGINE CONTROL
Engine control assy

2
Section B-B

10

HIGH
HIGH

3
1

LOW

LOW

2
4

11
3
5
3

12
3

Section A-A

Detail aa
9
7

Section C-C

1 - Governor motor
2 - Lever assy
3 - Sems-Bolt M8x25 (Q.ty 6) 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 M6x20 (Q.ty 2) 4.4 Nm (3.25 lbf x ft)
11 - Sems-Bolt M6x20 9.6 Nm (7.08 lbf x ft)
12 - Bracket

T4-4-2

SM1280

MECHATRO CONTROLLER

E175B-E195B

ENGINE CONTROL EQUIPMENT

Governor motor and C1 controller
1.

By operating accel dial, the input voltage

change issensed by CN1028 pin of C1
controller.

2.

The C1 controller computes the input voltage,

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

3.

The limit switch in the governor motor is the

starting point of the governor motor.

OIL SEAL
OUTPUT
SHAFT

REDUCTION GEAR SECTION

MOTOR SECTION

CAM
LIMIT
SWITCH

SM0883

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

CN-136F

SM0884

Work mode select switch

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

WORK MODE
SELECT SWITCH

SM0885

T4-4-3

E175B-E195B

MECHATRO CONTROLLER

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

Adjustment of engine ("A" adjustment)

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

2.

Adjustment of pump ("B" adjustment)

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

3.

Adjustment of unloading valve ("C" adjustment)

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

In cases where the adjustment of mechatro

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

Mechatro controller

2.

Engine

3.

Hydraulic pump or hydraulic pump proportional

valve

4.

Unloading proportional
unloading valve.

valve,

spool

of

Preparation
1.

Raise the oil temperature to about 50C

(122F) to warm up the engine.

2.

Turn the air-con OFF.

3.

Turn the starter key switch OFF to stop the

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

As the error codes other than those shown above

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

T4-4-4

MECHATRO CONTROLLER

E175B-E195B

Adjusting procedure

MULTI DISPLAY

WORK MODE SELECT SWITCH

BUZZER STOP SWITCH

WASHER SWITCH
WIPER SWITCH

SELECT SWITCH

SM0886

ADJUSTMENT OF ENGINE ("A" ADJUSTMENT)

PROCEDURE
1.

Turn starter key switch ON keeping the work

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

2.

Keep buzzer stop switch on gauge cluster

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

3.

Press selector switch on gauge cluster to

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

T4-4-5

SM0887

E175B-E195B
4.

5.

MECHATRO CONTROLLER

After starting engine, press selector switch on

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

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

2.0M

SM0888

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

The adjustment automatically shifts from

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

2.

After detection of the engine rated speed, the

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

T4-4-6

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

35.0M
300mA

SM0889

MECHATRO CONTROLLER

E175B-E195B

ADJUSTMENT OF UNLOADING VALVE (C

ADJUSTMENT)
PROCEDURE
1.

2.

The adjustment shifts from pump to unloading,

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

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

When the unloading valve operates to the

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

Stop the engine. (The adjusted data is automatically

stored.).
SM0890

CORRECTIVE ACTION TAKEN WHEN THE

ADJUSTMENT CAN BE NOT PERFORMED
1.

In cases where the adjustment of engine can

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

T4-4-7

E175B-E195B
2.

MECHATRO CONTROLLER

In cases where the adjustment of pump can not

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

SM0891

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

In cases where unloading valve can not be

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

T4-4-8

SM0892

MECHATRO CONTROLLER

E175B-E195B

OTHER PRECAUTIONS
1.

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

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

2.

In the condition where large load is constantly

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

WHEN THE ADJUSTMENT OF UNLOADING

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

Turn starter switch ON keeping the work mode

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

2.

Keep buzzer stop switch on gauge cluster

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

3.

Change the adjusting items with washer switch

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

4.

Press selector switch on gauge cluster to

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

T4-4-9

MULTI DISPLAY
(EXAMPLE)

SM0893

E175B-E195B
5.

6.

MECHATRO CONTROLLER

After starting engine, press selector switch on

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

Stop the engine. (The adjusted data is automatically

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

T4-4-10

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

SM0894

TROUBLESHOOTING

M0103

TROUBLESHOOTING

E175B-E195B

SECTION AND GROUP CONTENTS

Section 5

TROUBLESHOOTING

Group 1
Group 2
Group 3

Troubleshooting (by Error Codes)

Troubleshooting (by trouble)
Troubleshooting (Trouble diagnosis mode)

SECTION 5

TROUBLESHOOTING

CONTENTS
Group 1 - Troubleshooting (by Error
Codes)
1. Judgment of actual thing at site ......... T5-1-1
2. Classification on failure and
troubleshooting .................................. T5-1-2
3. The blown fuse of Mechatro
Controller ........................................... T5-1-2
4. Troubleshooting by Error Codes ........ T5-1-2

Group 2 - Troubleshooting (by trouble)

1. Hydraulic system ............................... T5-2-1
2. Electric systems ................................. T5-2-30
2.1 Wiring checking procedure ......... T5-1-30
2.2 Trouble ....................................... T5-1-33

Group 3 - Troubleshooting (Trouble

diagnosis mode)
1. Trouble diagnosis mode .................... T5-3-1

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

OUTLINE
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred.
This manual describes how to solve the specific
phenomenon systematically as early as possible.
For troubleshooting concerning the inside of
equipment, refer to troubleshooting for each manual
of equipment.

1. JUDGMENT OF ACTUAL THING AT SITE

SM0100

GET TO THE SITE AS QUICKLY AS POSSIBLE

Attending the field to verify actual thing

Verify model, serial number, situation of trouble and

field, and notify person of arrival time.
VERIFY BACKGROUND
OF TROUBLE OCCURRED
1. Model name and serial number
2. Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3. Operating time by hour-meter
4. History of trouble occurred and additional works.
5. Recurrence of past trouble, or problems on the
additional works.

SM0101

Verifying background of trouble occurred

HOW TO DIAGNOSE TROUBLE

1. Verify defective part
2. Make the condition of trouble again
3. Where defective parts can not be verified,
surmise causes systematically.
4. Verify reasons for surmise
5. Report methods, procedure, and period for
repairing to user.
SM0102

EXPLANATION OF THE CAUSE OF TROUBLE

1. Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
flaws on the piston rod. And the method of using
the machines should be explained so that the
same kind of trouble does not reoccur.

Confirm the symptoms of the trouble

2. Treatment of damaged parts

The damaged parts to be claimed and returned
are evidence so they should be handled with
care. Protect them from entry of water, soils, etc.
into port of hydraulic unit, etc. and return them.
And also use care not to flaw and damage those
surfaces.

SM0103

Diagnosing fail by means troubleshooting

T5-1-1

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

2. CLASSIFICATION OF FAILURE AND TROUBLESHOOTING

Classify failures into the following 3 types and carry out the troubleshooting.
No.

Classes of failure

Troubleshooting

When error code after self-diagnosis is displayed Carry out troubleshooting according to the error
on gauge cluster
code.

When no failure is detected currently but error When it is hard to recreate the failure situation,
code after self diagnosis is remained in trouble cancel the data in the history and reproduce the
history
failed situation or suppose the cause according to
the troubleshooting by error code, and then repair
it.

When error code after self diagnosis is not Carry out troubleshooting according to
displayed or is not remained in the history
instructions
in
Chapter
T5-2
"TROUBLESHOOTING BY TROUBLE".
Carry out troubleshooting according to
instructions in Chapter T5-3 "TROUBLE
DIAGNOSIS MODE".

3. THE BLOWN FUSE OF MECHATRO CONTROLLER

If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
(1)

The blown fuse of mechatro controller

a. Blown fuse 5A of mechatro controller :
"DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the
controller program is not executed.
b. Blown fuse 20A of mechatro controller
The controller functions normally but the power supply applied when the controller drives the
solenoid, etc. stops.
Many error codes are displayed on the gauge cluster.
D013, D023, D033, D063,
E013, E023, F021

4. TROUBLESHOOTING BY ERROR CODE

When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out
the troubleshooting referring to applicable page in the contents of error codes.

Error
Code

Trouble

Described
page

A015

Engine adjustment (A adjustment) is not adjusted yet or is failed.

T5-1-5

A025

Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed.

T5-1-5

A035

Unload valve adjustment (C adjustment) is not adjusted yet or is failed.

T5-1-6

A215

Written data of ROM adjustment data is incorrect.

T5-1-6

A225

Writing of ROM adjustment data is incorrect.

T5-1-7

A235

Written data of ROM hour meter data is incorrect.

T5-1-7

A245

Writing of ROM hour meter data is incorrect.

T5-1-8

A255

Writing of proportional valve adjustment data is incorrect.

T5-1-8

B012

Incorrect output of boom up pressure sensor

T5-1-9

B013

Disconnection of boom up pressure sensor

T5-1-9

B014

Short-circuit of boom up pressure sensor

T5-1-10

B022

Incorrect output of boom down pressure sensor

T5-1-10

T5-1-2

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Error
Code

Trouble

B023

Disconnection of boom down pressure sensor

T5-1-11

B024

Short-circuit of boom down pressure sensor

T5-1-11

B032

Incorrect output of arm out pressure sensor

T5-1-12

B033

Disconnection of arm out pressure sensor

T5-1-12

B034

Short-circuit of arm out pressure sensor

T5-1-13

B042

Incorrect output of arm in pressure sensor

T5-1-13

B043

Disconnection of arm in pressure sensor

T5-1-14

B044

Short-circuit of arm in pressure sensor

T5-1-15

B052

Incorrect output of bucket digging pressure sensor

T5-1-16

B053

Disconnection of bucket digging pressure sensor

T5-1-16

B054

Short-circuit of bucket digging pressure sensor

T5-1-17

B062

Incorrect output of bucket dump pressure sensor

T5-1-17

B063

Disconnection of bucket dump pressure sensor

T5-1-18

B064

Short-circuit of bucket dump pressure sensor

T5-1-18

B072

Incorrect output of swing pressure sensor

T5-1-19

B073

Disconnection of swing pressure sensor

T5-1-19

B074

Short-circuit of swing pressure sensor

T5-1-20

B092

Incorrect output of travel right pressure sensor

T5-1-20

B093

Disconnection of travel right pressure sensor

T5-1-21

B094

Short-circuit of travel right pressure sensor

T5-1-22

B102

Incorrect output of travel left pressure sensor

T5-1-23

B103

Disconnection of travel left pressure sensor

T5-1-23

B104

Short-circuit of travel left pressure sensor

T5-1-24

B113

Disconnection of pressure sensor of optional selector positioning

T5-1-25

B114

Short-circuit of pressure sensor of optional selector positioning

T5-1-26

B162

Incorrect output of P1 optional side pressure sensor

T5-1-26

B163

Disconnection of P1 side optional pressure sensor

T5-1-27

B164

Short-circuit of P1 side optional pressure sensor

T5-1-28

B172

Incorrect output of P2 optional side pressure sensor

T5-1-28

B173

Disconnection of P2 side optional pressure sensor

T5-1-29

B174

Short-circuit of P2 side optional pressure sensor

T5-1-29

C012

Incorrect output of P1 pump pressure sensor

T5-1-30

C013

Disconnection of P1 pump pressure sensor

T5-1-30

C014

Short-circuit of P1 pump pressure sensor

T5-1-31

C022

Incorrect output of P2 pump pressure sensor

T5-1-31

C023

Disconnection of P2 pump pressure sensor

T5-1-32

C024

Short-circuit of P2 pump pressure sensor

T5-1-32

C033

Disconnection of boom head pressure sensor

T5-1-33

C034

Short-circuit of boom head pressure sensor

T5-1-33

D012

Failure of output transistor ON at P1 unload proportional valve

T5-1-34

D013

Disconnection of P1 unload proportional valve

T5-1-34

D022

Failure of output transistor ON at P2 unload proportional valve

T5-1-35

D023

Disconnection of P2 unload proportional valve

T5-1-36

D032

Failure of output transistor ON at travel straight proportional valve

T5-1-36

D033

Disconnection of travel straight proportional valve

T5-1-37

D062

Failure of output transistor ON at arm in high speed proportional valve

T5-1-38

T5-1-3

Described
page

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Error
Code

Trouble

Described
page

D063

Disconnection of arm in high speed proportional valve

T5-1-39

D152

Failure of output transistor ON at short-circuit valve

T5-1-39

D153

Disconnection of short-circuit valve

T5-1-40

E012

Failure of output transistor ON at P1 pump proportional valve

T5-1-40

E013

Disconnection of P1pump proportional valve

T5-1-41

E022

Failure of output transistor ON at P2 pump proportional valve

T5-1-42

E023

Disconnection of P2 pump proportional valve

T5-1-42

F011

Failure of output transistor OFF and GND short of attachment boost SOL valve

T5-1-43

F013

Failure of output transistor ON and disconnection of attachment boost SOL valve

T5-1-4

F021

Failure of output transistor OFF and GND short of swing parking SOL valve

T5-1-45

F023

Failure of output transistor ON and disconnection of swing parking SOL valve

T5-1-45

F031

Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve

T5-1-46

F033

Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve

T5-1-47

F041

Failure of output transistor OFF and GND short of optional selector SOL valve

T5-1-47

F043

Failure of output transistor ON and disconnection of optional selector SOL valve

T5-1-48

G011

Failure of output transistor ON at governor motor

T5-1-48

G013

Disconnection of governor motor

T5-1-49

G023

Starting point indexing is impossible

T5-1-49

G032

Overrun of speed sensor of direct input Mechatro-controller

T5-1-50

G033

Disconnection of speed sensor of direct input Mechatro-controller

T5-1-50

H013

Disconnection of acceleration potentio

T5-1-51

H014

Power short-circuit of acceleration potentio

T5-1-51

H023

Disconnection of boom angle potentio

T5-1-52

H024

Power short-circuit of boom angle potentio

T5-1-53

H033

Disconnection of arm angle potentio

T5-1-54

H034

Power short-circuit of arm angle potentio

T5-1-55

H091

Failure of GND short-circuit of fuel sensor

T5-1-56

H093

Disconnection of fuel sensor

T5-1-56

I313

Received error of cluster communication (time-out error)

T5-1-57

K014

Adhesion of battery relay terminal

T5-1-58

R014

Failure of arc prevention relay of wiper motor

T5-1-59

R024

Failure of normal rotation relay of wiper motor

T5-1-60

R034

Failure of reverse rotation relay of wiper motor

T5-1-61

R044

Failure of washer motor relay

T5-1-62

R134

Failure of swing flasher relay

T5-1-63

R144

Failure of swing flasher relay

T5-1-64

R154

Failure of travel alarm relay

T5-1-65

R164

Failure of auto idling stop relay 2

T5-1-66

R174

Failure of engine forcible stop relay

T5-1-67

R184

Failure of lever lock relay

T5-1-68

R214

Failure of safety relay

T5-1-69

T5-1-4

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 1
Error code

A015

Trouble

Not yet adjusted engine or failed adjustment of engine (A adjustment)

Judging condition

Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting range.

Symptom

Deviated from the reqired value, but no problem in normal operations.

Control in the
Rotate with the default engine.
event of failure
Returned
in
The engine adjustment is completed normally.
normal condition
Screen No.

Service diagnosis
Screen No.
checking screen

G-3 SPEED SET

Screen No.

Checking object

Checking contents and remedy

Checking

Carry out engine adjustment (A adjustment). When "ERROR ENG" was

displayed during adjustment, refer to the section "Adjustment procedure Measures to be taken with the adjustment failed"

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 2
Error code

A025

Trouble

Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)

Judging condition

Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within the
adjusting range.

Symptom

Deviated from the rated output, but no problem in normal operation.

Control in the
Workable with the default proportional valve output.
event of failure
Returned
in
The pump proportional valve adjustment is completed normally.
normal condition
Screen No.

Service diagnosis
Screen No.
checking screen

E-1 P1 PUMP

E-2 P2 PUMP

Screen No.

Checking object

Checking contents and remedy

Checking

Carry out pump adjustment (B adjustment).

When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-5

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 3
Error code

A035

Trouble

Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)

Judging condition

The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting
range.

Symptom

It is not normal output, but no problem in normal operation.

Control in the
Work with the aid of output by default proportional valve.
event of failure
Returned
in
The adjustment of unload valve is completed normally.
normal condition
Screen
No.

D-1 P1 UN-LOAD (BP-CUT)

Service diagnosis Screen

checking screen
No.

D-2 P2 UN-LOAD (BP-CUT)

Screen
No.
Checking object

Checking contents and remedy

Checking

Carry out adjustment of unload valve (C adjustment).

When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 4
Error code

A215

Trouble

The data of ROM adjustment is written incorrectly.

Judging condition

Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)

Symptom

No affect.

Control in the
Control at side of correct memory data.
event of failure
Returned
in
It does not regain. Replace controller.
normal condition
Screen
No.
Service diagnosis Screen
checking screen
No.
Screen
No.
Checking object
1

Mechatro controller

Checking contents and remedy

Check that the error is corrected after replacement of controller.

2
3

T5-1-6

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 5
Error code

A225

Trouble

The data of ROM adjustment is written incorrectly.

Judging condition

Check adjustment data, and judge the data is correct or not.

Symptom

It is not normal output, but no problem in normal operation.

Control in the
Control can be done by default value.
event of failure
Returned
in
It does not regain. Replace controller.
normal condition
Screen
No.
Service diagnosis Screen
checking screen
No.
Screen
No.
Checking object
1

Mechatro controller

Checking contents and remedy

Check that the error is corrected after replacement of controller.

2
3

Table 6
Error code

A235

Trouble

The data of ROM adjustment is written incorrectly.

Judging condition

Check hourmeter memory, and judge the data is correct or not. (Trouble history only)

Symptom

No affect.

Control in the
Control at side of correct memory data.
event of failure
Returned
in
It does not regain. Replace controller.
normal condition
Screen
No.
Service diagnosis Screen
checking screen
No.
Screen
No.
Checking object
1

Mechatro controller

Checking contents and remedy

Check that the error is corrected after replacement of controller.

2
3

T5-1-7

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 7
Error code

A245

Trouble

The data of ROM hourmeter is written incorrectly.

Judging condition

Check hourmeter memory, and judge the data is incorrect.

Symptom

The hourmeter data which was judged as error is taken as 0 Hr. No problem in normal operation.

Control in the
Normal control is available.
event of failure
Returned
in
It does not regain. Replace controller.
normal condition
Screen
No.
Service diagnosis Screen
checking screen
No.
Screen
No.
Checking object
1

Mechatro controller

Checking contents and remedy

Check that the error is corrected after replacement of controller.

2
3

Table 8
Error code

A255

Trouble

The data of proportional valve adjustment is written incorrectly.

Judging condition

Check proportional valve adjustment data, and judge the data is incorrect.

Symptom

It is not normal output, but no problem in normal operation.

Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned
in
It does not regain. Replace controller.
normal condition
Screen
No.
Service diagnosis Screen
checking screen
No.
Screen
No.
Checking object
1

Mechatro controller

Checking contents and remedy

Check that the error is corrected after replacement of controller.

2
3

T5-1-8

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 9
Error code

B012

Trouble

Boom up pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the sensor after
starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The boom up operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

B-1 BOOM RAISE

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Boom up pressure sensor SE-3 When B012 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between boom up

pressure sensor and controller
CN-126F
CN-101F

When B012 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 10
Error code

B013

Trouble

Boom up pressure sensors wiring disconnects.

Judging condition

The input voltage from boom up pressure sensor is less than 0.1 V.

Symptom

The boom up speed slows down.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-1 BOOM RAISE

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Boom up pressure sensor SE-3 When B013 is cancelled and other error occurs after exchanging the connector
with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between boom up

When B013 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller
Check wiring for possible failure according to the wiring checking procedure
CN-126F
and repair it if necessary.
CN-101F

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-9

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 11
Error code

B014

Trouble

Boom up pressure sensors power source is shortcut.

Judging condition

The input voltage from boom up pressure sensor is 4.7 V or more.

Symptom

The boom up speed slows down.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-1 BOOM RAISE

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Boom up pressure sensor SE-3 When B014 is cancelled and other error occurs after exchanging the connector
with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between boom up

When B014 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller
Check wiring for possible failure according to the wiring checking procedure
CN-126F
and repair it if necessary.
CN-101F

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 12
Error code

B022

Trouble

Boom down pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the sensor after
starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The boom down operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

B-2 BOOM LOWER

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
SE-4
Check sensor unit for possible failure. If failure found, replace it.

Wiring between boom down

pressure sensor and controller
CN-127F
CN-101F

When B022 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-10

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 13
Error code

B023

Trouble

Boom down pressure sensors wiring is disconnecting.

Judging condition

The input voltage from boom down pressure sensor is 0.1 V or less.

Symptom

The boom down operability becomes poor.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-2 BOOM LOWER

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the connector
with other sensor.
SE-4
Check sensor unit for possible failure. If failure found, replace it.

Wiring between boom down

When B023 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller
Check wiring for possible failure according to the wiring checking procedure
CN-127F
and repair it if necessary.
CN-101F

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 14
Error code

B024

Trouble

Boom down pressure sensors power source is shortcut.

Judging condition

The input voltage from boom down pressure sensor is 4.7 V or more.

Symptom

The boom down operability becomes poor.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-2 BOOM LOWER

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
SE-4
Check sensor unit for possible failure. If failure found, replace it.

Wiring between boom down

pressure sensor and controller
CN-127F
CN-101F

When B024 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-11

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 15
Error code

B032

Trouble

Arm-in pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the sensor after
starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The arm-out operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

B-3 ARM OUT

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Arm-out pressure sensor SE-8

When B032 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between arm-out pressure

sensor and controller
CN-131F
CN-101F

When B032 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 16
Error code

B033

Trouble

Arm-out pressure sensors wiring is disconnecting.

Judging condition

The input voltage from arm-out pressure sensor is 0.1 V or less.

Symptom

Shock at stopping of arm-out is great.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-3 ARM OUT

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Arm-out pressure sensor SE-8

When B033 is cancelled and other error occurs after exchanging the connector
with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between arm-out pressure

When B033 is displayed after the connector is exchanged with other sensor.
sensor and controller
Check wiring for possible failure according to the wiring checking procedure
CN-131F
and repair it if necessary.
CN-101F

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-12

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 17
Error code

B034

Trouble

Arm-out pressure sensors power source is shortcut.

Judging condition

The input voltage from arm-out pressure sensor is 4.7 V or more.

Symptom

Shock at stopping of arm-out is great.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1, P2 unload proportional valves to 0 mA. (Valve emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-3 ARM OUT

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Arm-out pressure sensor SE-8

When B034 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring
between
arm-out
pressure sensor and controller
CN-131F
CN-101F

When B034 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 18
Error code

B042

Trouble

Arm-in pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the arm-in pressure
sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The arm-in operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

B-4 ARM IN

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Arm-in pressure sensor

SE-7

Checking contents and remedy

When B042 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between arm-in pressure

sensor and controller
CN-130F
CN-101F

When B042 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-13

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 19
Error code

B043

Trouble

Arm-in pressure sensors wiring is disconnecting.

Judging condition

The input voltage from arm-in pressure sensor is 0.1 V or less.

Symptom

Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but
if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket
bottom put on the ground.

Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1 and P2 unload proportional valve to 0 mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200 mA.
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-4 ARM IN

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Arm-in pressure sensor

SE-7

When B043 is cancelled and other error occurs after exchanging the connector
with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between arm-in pressure

When B043 is displayed after the connector is exchanged with other sensor.
sensor and controller
Check wiring for possible failure according to the wiring checking procedure
CN-130F
and repair it if necessary..
CN-101F

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-14

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 20
Error code

B044

Trouble

Arm-in pressure sensors power source is shortcut.

Judging condition

The input voltage from arm-in pressure sensor is 4.7 V or more.

Symptom

Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if
attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket
bottom put on the ground.

Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1, P2 unload proportional valves to 0 mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200 mA.
Returned
in
It returns automatically in normal condition.
normal condition
Screen No.
Service diagnosis
Screen No.
checking screen
Screen No.

B-4 ARM IN

Checking object

Checking contents and remedy

Arm-in pressure sensor

SE-7

When B044 is cancelled and other error occurs by turning starter switch on
after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between arm-in pressure When B044 is displayed after turning the starter switch on after the connector
sensor and controller
is exchanged with other sensor.
CN-130F
Check wiring for possible failure according to the wiring checking procedure
CN-101F
and repair it if necessary..

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-15

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 21
Error code

B052

Trouble

Bucket digging pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the bucket digging
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The bucket digging operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

B-5 BUCKET DIG

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
SE-1
Check sensor unit for possible failure. If failure found, replace it.

Wiring between bucket digging

pressure sensor and controller
CN-124F
CN-101F

When B052 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 22
Error code

B053

Trouble

Bucket digging pressure sensors wiring is disconnected.

Judging condition

The input voltage from bucket digging pressure sensor is 0.1 V or less.

Symptom

The bucket digging speed slows down a little.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-5 BUCKET DIG

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
SE-1
Check sensor unit for possible failure. If failure found, replace it.

Wiring between bucket digging

pressure sensor and controller
CN-124F
CN-101F

When B053 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-16

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 23
Error code

B054

Trouble

Bucket digging pressure sensors power source is shortcut.

Judging condition

The input voltage from bucket digging pressure sensor is 4.7 V or more.

Symptom

The bucket digging speed slows down a little.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-5 BUCKET DIG

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
SE-1
Check sensor unit for possible failure. If failure found, replace it.

Wiring between bucket digging

pressure sensor and controller
CN-124F
CN-101F

When B054 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 24
Error code

B062

Trouble

Bucket dump pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The bucket dump operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

B-6 BUCKET DUMP

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Bucket digging pressure sensor When B062 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
SE-2
Check sensor unit for possible failure. If failure found, replace it.

Wiring between bucket digging

pressure sensor and controller
CN-125F
CN-101F

When B062 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-17

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 25
Error code

B063

Trouble

Bucket dump pressure sensors wiring is disconnected.

Judging condition

The input voltage from bucket dump pressure sensor is 0.1 V or less.

Symptom

The bucket dump speed slows down a little.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-6 BUCKET DUMP

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Bucket digging pressure sensor When B063 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
SE-2
Check sensor unit for possible failure. If failure found, replace it.

Wiring between bucket digging

pressure sensor and controller
CN-125F
CN-101F

When B063 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 26
Error code

B064

Trouble

Bucket dump pressure sensors power source is shortcut.

Judging condition

The input voltage from bucket dump pressure sensor is 4.7 V or more.

Symptom

The bucket dump speed slows down a little.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-6 BUCKET DUMP

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Bucket digging pressure sensor When B064 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
SE-2
Check sensor unit for possible failure. If failure found, replace it.

Wiring between bucket digging

pressure sensor and controller
CN-125F
CN-101F

When B064 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-18

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 27
Error code

B072

Trouble

Swing pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the swing pressure
sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The swing operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

B-7 SWING

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Checking contents and remedy

Swing pressure sensor

When B072 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

SE-5
2

Wiring between swing pressure When B072 is displayed after turning the starter switch on after the connector
sensor and controller
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
CN-169F
and repair it if necessary.
CN-103F

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 28
Error code

B073

Trouble

Swing pressure sensors wiring is disconnected.

Judging condition

The input voltage from swing pressure sensor is 0.1 V or less.

Symptom

The swing operability becomes poor.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-7 SWING

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Swing pressure sensor

SE-5

Checking contents and remedy

When B073 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between swing pressure When B073 is displayed after turning the starter switch on after the connector
sensor and controller
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
CN-169F
and repair it if necessary.
CN-103F

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-19

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 29
Error code

B074

Trouble

Swing pressure sensors power source is shortcut.

Judging condition

The input voltage from swing pressure sensor is 4.7 V or more.

Symptom

The swing operability becomes poor.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-7 SWING

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Checking contents and remedy

Swing pressure sensor

When B074 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

SE-5
2

Wiring between swing pressure When B074 is displayed after turning the starter switch on after the connector
sensor and controller
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
CN-169F
and repair it if necessary.
CN-103F

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 30
Error code

B092

Trouble

Travel right pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the travel right
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The travel right operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

B-9 TRAVEL (R)

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Travel right pressure sensor

SE-9

Checking contents and remedy

When B092 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between travel right

pressure sensor and controller
CN-301F
CN-102F

When B092 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-20

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 31
Error code

B093

Trouble

Travel right pressure sensors wiring is disconnected.

Judging condition

The input voltage from Travel right pressure sensor is 0.1 V or less.

Symptom

The Travel right operability becomes poor.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-9 TRAVEL (R)

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Travel right pressure sensor

SE-9

Checking contents and remedy

When B093 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between travel right

pressure sensor and controller
CN-301F
CN-102F

When B093 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-21

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 32
Error code

B094

Trouble

Travel right pressure sensors power source is shortcut.

Judging condition

The input voltage from Travel right pressure sensor is 4.7 V or more.

Symptom

The Travel right operability becomes poor.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-9 TRAVEL (R)

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Travel right pressure sensor

SE-9

Checking contents and remedy

When B094 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between travel right

pressure sensor and controller
CN-301F
CN-102F

When B094 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-22

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 33
Error code

B102

Trouble

Travel left pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the travel left
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The travel left operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

B-10 TRAVEL (L)

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

Travel left pressure sensor

When B102 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

SE-10
2

Wiring between travel left

pressure sensor and controller
CN-302F
CN-102F

When B102 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 34
Error code

B103

Trouble

Travel left pressure sensors wiring is disconnected.

Judging condition

The input voltage from Travel left pressure sensor is 0.1 V or less.

Symptom

The Travel left operability becomes poor.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-10 TRAVEL (L)

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

Travel left pressure sensor

When B103 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

SE-10
2

Wiring between travel left

pressure sensor and controller
CN-302F
CN-102F

When B103 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-23

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 35
Error code

B104

Trouble

Travel left pressure sensors power source is shortcut.

Judging condition

The input voltage from Travel left pressure sensor is 4.7 V or more.

Symptom

The Travel left operability becomes poor.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-10 TRAVEL (L)

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

Travel left pressure sensor

When B104 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

SE-10
2

Wiring between travel left

pressure sensor and controller
CN-302F
CN-102F

When B104 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-24

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 36
Error code

B113

Trouble

Option selector position detect pressure sensors wiring is disconnected.

Judging condition

The input voltage from option selector position detect pressure sensor is 0.1 V or less.

Symptom

When B mode is selected, option selector valve error is indicated.

Control in the
Normal control.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

16

B-11

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Option selector position detect When B113 is cancelled and other error occurs by turning starter switch on after
pressure sensor
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
SE-29

Wiring between option selector

position detect pressure sensor
and controller
CN-162F
CN-104F

When B113 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-25

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 37
Error code

B114

Trouble

Option selector position detect pressure sensors wiring is disconnected.

Judging condition

The input voltage from selector position detect pressure sensor is 4.7 V or more.

Symptom

When B mode is selected, option selector valve error is indicated.

Control in the
Normal control.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

16

B-11

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Option selector position detect When B114 is cancelled and other error occurs by turning starter switch on after
pressure sensor
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
SE-29

Wiring between option selector

position detect pressure sensor
and controller
CN-162F
CN-104F

When B114 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 38
Error code

B162

Trouble

P1 side option pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the P1 side option
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The P1 side option operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

B-16 P1 OPT.

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

P1 side option pressure sensor

SE-20

Checking contents and remedy

When B162 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between P1 side option

pressure sensor and controller
CN-304F
CN-102F

When B162 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-26

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 39
Error code

B163

Trouble

P1 side option pressure sensors wiring is disconnected.

Judging condition

The input voltage from P1 side option pressure sensor is 0.1 V or less.

Symptom

The P1 side option does not work.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the (Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-16 P1 OPT.

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

P1 side option pressure sensor

SE-20

Checking contents and remedy

When B163 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between P1 side option

pressure sensor and controller
CN-304F
CN-102F

When B163 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-27

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 40
Error code

B164

Trouble

P1 side option pressure sensors wiring is disconnected.

Judging condition

The input voltage from P1 side option pressure sensor is 4.7 or more.

Symptom

The P1 side option does not work.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the (Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-16 P1 OPT.

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Checking contents and remedy

P1 side option pressure sensor

SE-20

When B164 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between P1 side option

pressure sensor and controller
CN-304F
CN-102F

When B164 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 41
Error code

B172

Trouble

P2 side option pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the P2 side option
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The P2 side option operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

B-17 P2 OPT.

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

P2 side option pressure sensor

SE-11

Checking contents and remedy

When B172 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between P2 side option

pressure sensor and controller
CN-304F
CN-102F

When B172 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-28

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 42
Error code

B173

Trouble

P2 side option pressure sensors wiring is disconnected.

Judging condition

The input voltage from P2 side option pressure sensor is 0.1 V or less.

Symptom

The selection of conflux does not work.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-17 P2 OPT.

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Checking contents and remedy

P2 side option pressure sensor

SE-11

When B173 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between P2 side option

pressure sensor and controller
CN-303F
CN-102F

When B173 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 43
Error code

B174

Trouble

P2 side option pressure sensors wiring is disconnected.

Judging condition

The input voltage from P2 side option pressure sensor is 4.7 V or more.

Symptom

The selection of conflux does not work.

Set proportional valve output rate of P1 and P2 pumps to 0 mA.

Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

B-17 P2 OPT.

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

P2 side option pressure sensor

SE-11

Checking contents and remedy

When B174 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between P2 side option

pressure sensor and controller
CN-303F
CN-102F

When B174 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-29

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 44
Error code

C012

Trouble

P1 pump pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The P1 pump operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

C-1 PUMP P1

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

P1 pump pressure sensor

When C012 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

SE-22
2

Wiring between P1 pump

pressure sensor and controller
CN-139F
CN-103F

When C012 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 45
Error code

C013

Trouble

P1 pump pressure sensors wiring is disconnected.

Judging condition

The input voltage from P1 pump pressure sensor is 0.1 V or less.

Symptom

The delicate operability of P1 pump related attachment becomes poor.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure
(Hydraulic pump emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

C-1 PUMP P1

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

P1 pump pressure sensor

When C013 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

SE-22
2

Wiring between P1 pump

pressure sensor and controller
CN-139F
CN-103F

When C013 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-30

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 46
Error code

C014

Trouble

P1 pump pressure sensors power source is shortcut.

Judging condition

The input voltage from P1 pump pressure sensor is 4.7 V or more.

Symptom

The delicate operability of P1 pump related attachment becomes poor.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure
(Hydraulic pump emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

C-1 PUMP P1

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

P1 pump pressure sensor

When C014 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

SE-22
2

Wiring between P1 pump

pressure sensor and controller
CN-139F
CN-103F

When C014 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 47
Error code

C022

Trouble

P2 pump pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The P2 pump operability becomes poor.

Control in the
Normal control.
event of failure
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

C-2 PUMP P2

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

P2 pump pressure sensor

When C022 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

SE-23
2

Wiring between P2 pump

pressure sensor and controller
CN-140F
CN-103F

When C022 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-31

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 48
Error code

C023

Trouble

P2 pump pressure sensors wiring is disconnected.

Judging condition

The input voltage from P2 pump pressure sensor is 0.1 V or less.

Symptom

The delicate operability of P2 pump related attachment becomes poor.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure
(Hydraulic pump emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

C-2 PUMP P2

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

P2 pump pressure sensor

When C023 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

SE-23
2

Wiring between P2 pump

pressure sensor and controller
CN-140F
CN-103F

When C023 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 49
Error code

C024

Trouble

P2 pump pressure sensors power source is shortcut.

Judging condition

The input voltage from P2 pump pressure sensor is 4.7 V or more.

Symptom

The delicate operability of P2 pump related attachment becomes poor.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure
(Hydraulic pump emergency mode)
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

C-2 PUMP P2

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

P2 pump pressure sensor

When C024 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

SE-23
2

Wiring between P2 pump

pressure sensor and controller
CN-140F
CN-103F

When C024 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-32

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 50
Error code

C033

Trouble

Boom head pressure sensors wiring is disconnected.

Judging condition

The input voltage from boom head pressure sensor is 0.1 V or less.

Symptom

Overload detection is not available.

Control in the
Normal control.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

C-3 BOOM-HEAD

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Checking contents and remedy

Boom head pressure sensor

SE-24

When C033 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between boom head

pressure sensor and controller
CN-140F
CN-103F

When C033 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 51
Error code

C034

Trouble

Boom head pressure sensors power source is shortcut.

Judging condition

The input voltage from boom head pressure sensor is 4.7 V or more.

Symptom

Then overload detection switch is ON, overload alarm sounds constantly.

Control in the
Normal control.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

C-3 BOOM-HEAD

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Boom head pressure sensor

SE-24

Checking contents and remedy

When C034 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between boom head

pressure sensor and controller
CN-706F
CN-104F

When C034 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-33

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 52
Error code

D012

Trouble

P1 unload proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more.

Symptom

Option conflux can not be done.

Control in the
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

D-1 P1 UN-LOAD (BP-CUT)

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Checking contents and remedy

P1 unload proportional valve

PSV-D

When D012 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between P1 unload

proportional valve and controller
CN-120F
CN-105F

When D012 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 53
Error code

D013

Trouble

P1 unload proportional valves wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less.

(If output is 100 mA or less, judging is not done.)

Symptom

Option conflux can not be done.

Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode).
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

D-1 P1 UN-LOAD (BP-CUT)

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

P1 unload proportional valve

PSV-D

Checking contents and remedy

When D013 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between P1 unload

proportional valve and controller
CN-120F
CN-105F

When D013 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-34

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 54
Error code

D022

Trouble

P2 unload proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more.

Symptom

Independent operations of boom up and of bucket digging/dump become slow.

Control in the
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

D-2 P2 UN-LOAD (BP-CUT)

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

P2 unload proportional valve

PSV-B

Checking contents and remedy

When D022 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between P2 unload

proportional valve and controller
CN-118F
CN-105F

When D022 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-35

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 55
Error code

D023

Trouble

P2 unload proportional valves wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less.

(If output is 100 mA or less, judging is not done.)

Symptom

Independent operations of boom up and of bucket digging/dump become slow.

Control in the
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

D-2 P2 UN-LOAD (BP-CUT)

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Checking contents and remedy

P2 unload proportional valve

PSV-B

When D023 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

Wiring between P2 unload

proportional valve and controller
CN-118F
CN-105F

When D023 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 56
Error code

D032

Trouble

Travel straight proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more

Symptom

Travel deviation occurs by combined operation of travel and attachment.

Control in the
Set Travel straight proportional valve output to 0 mA
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

D-3 S-TRAVEL

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
straight

Checking contents and remedy

Travel
valve

Wiring between Travel straight

proportional valve and controller
CN-119F
CN-105F

When D032 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

PSV-C

proportional When D032 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

T5-1-36

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 57
Error code

D033

Trouble

Travel straight proportional valves wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less.

(If output is 100 mA or less, judging is not done.)

Symptom

Travel deviation occurs by combined operation of travel and attachment.

Control in the
Set Travel straight proportional valve output to 0 mA.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

D-3 S-TRAVEL

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
straight

Checking contents and remedy

Travel
valve

Wiring between Travel straight

proportional valve and controller
CN-119F
CN-105F

When D033 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

PSV-C

proportional When D033 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.

T5-1-37

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 58
Error code

D062

Trouble

Arm-in spool 2 proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more

Symptom

Operability of combined operation with arm-in becomes poor.

Control in the
Set Arm-in spool 2 proportional valve output to 0 mA.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

D-4 ARM IN-2-SPEED

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Arm-in spool 2 proportional When D062 is cancelled and other error occurs by turning starter switch on after
valve
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
PSV-A

Wiring between Arm-in spool 2

proportional valve and controller
CN-121F
CN-105F

When D062 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-38

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 59
Error code

D063

Trouble

Arm-in spool 2 proportional valves wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less.

(If output is 100 mA or less, judging is not done.)

Symptom

Operability of combined operation with arm-in becomes poor.

Control in the
Set Arm-in spool 2 proportional valve output to 0 mA.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

D-4 ARM IN-2-SPEED

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Arm-in spool 2 proportional When D063 is cancelled and other error occurs by turning starter switch on after
valve
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
PSV-A

Wiring between Arm-in spool 2

proportional valve and controller
CN-121F
CN-105F

When D063 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 60
Error code

D152

Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
Service diagnosis Screen
checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

1
2
3

T5-1-39

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 61
Error code

D153

Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
Service diagnosis Screen
checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

1
2
3

Table 62
Error code

E012

Trouble

P1 pump proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more.

Symptom

The delicate operability of P2 pump related attachment becomes poor.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure
(Hydraulic pump emergency mode)
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

E-1 PUMP P1

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

P1 pump proportional valve

When E012 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.

PSV-P1

Wiring between P1 pump

proportional valve and controller
CN-141F
CN-105F

When E012 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
When replacing of connector is executed, turn off power source once.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-40

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 63
Error code

E013

Trouble

P1 pump proportional valves wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less.

(If output is 100mA or less, judging is not done.)

Symptom

The delicate operability of P2 pump related attachment becomes poor.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure
(Hydraulic pump emergency mode)
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

E-1 PUMP P1

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

P1 pump proportional valve

When E013 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.

PSV-P1

Wiring between P1 pump

proportional valve and controller
CN-141F
CN-105F

When E013 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
When replacing of connector is executed, turn off power source once.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-41

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 64
Error code

E022

Trouble

P2 pump proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more.

Symptom

The delicate operability of P2 pump related attachment becomes poor.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure
(Hydraulic pump emergency mode)
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

E-2 PUMP P2

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

P2 pump proportional valve

When E022 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.

PSV-P2

Wiring between P2 pump

proportional valve and controller
CN-142F
CN-105F

When E022 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
When replacing of connector is executed, turn off power source once.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 65
Error code

E023

Trouble

P2 pump proportional valves wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less.

(If output is 100 mA or less, judging is not done.)

Symptom

The delicate operability of P2 pump related attachment becomes poor.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure
(Hydraulic pump emergency mode)
Returned
in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
No.

E-2 PUMP P2

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

P2 pump proportional valve

When E023 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.

PSV-P2

Wiring between P2 pump

proportional valve and controller
CN-142F
CN-105F

When E023 is displayed after turning the starter switch on after the connector
is exchanged with other sensor.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
When replacing of connector is executed, turn off power source once.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-42

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 66
Error code

F011

Trouble

ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.

Judging condition

The feed-back signal is grounding level while exciting command is output.

Symptom

ATT boost is not available.

Control in the
Normal control.
event of failure
Returned
in
The feed-back signal is 24V level while exciting command is output.
normal condition
Screen
No.

F-1 POWER BOOST

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

ATT boost solenoid valve

When F011 is cancelled and other error occurs by exchanging the connector for
other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.

SV-2
2

Wiring between ATT boost

solenoid valve and controller
CN-117F
CN-105F

When F011 is displayed after the connector is exchanged with other solenoid
valve.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-43

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 67
Error code

F013

Trouble

ATT boost solenoid valve and output transistor ON are failure, and disconnection.

Judging condition

The feed-back signal is 24 V level while exciting command is not output.

Symptom

ATT boost is not available or is leaving available.

Control in the
Normal control.
event of failure
Returned
in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Screen
No.

F-1 POWER BOOST

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

ATT boost solenoid valve

When F013 is cancelled and other error occurs by exchanging the connector
for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.

SV-2
2

Wiring between ATT boost

solenoid valve and controller
CN-117F
CN-105F

When F013 is displayed after the connector is exchanged with other solenoid
valve.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-44

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 68
Error code

F021

Trouble

Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.

Judging condition

The feed-back signal is grounding level while exciting command is output.

Symptom

Swing parking is not available.

Control in the
Normal control.
event of failure
Returned
in
The feed-back signal is 24 V level while exciting command is output.
normal condition
Screen
No.

F-2 SWING-BRAKE

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Checking contents and remedy

Swing parking solenoid valve

SV-1

When F021 is cancelled and other error occurs by exchanging the connector
for other solenoid valve. Check solenoid valve unit for possible failure. If failure
found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.

Wiring between swing parking

solenoid valve and controller
CN-123F
CN-105F

When F021 is displayed after the connector is exchanged with other solenoid
valve.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 69
Error code

F023

Trouble

Swing parking solenoid valve and output transistor ON are failure, and disconnection.

Judging condition

The feed-back signal is 24 V level while exciting command is not output.

Symptom

Swing parking is not available or is leaving available.

Control in the
Normal control.
event of failure
Returned
in
The feed-back signal is grounding level while exciting command is output.
normal condition
Screen
No.

F-1 POWER BOOST

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Swing parking solenoid valve

SV-1

Checking contents and remedy

When F023 is cancelled and other error occurs by exchanging the connector
for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.

Wiring between swing parking

solenoid valve and controller
CN-123F
CN-105F

When F023 is displayed after the connector is exchanged with other solenoid
valve.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-45

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 70
Error code

F031

Trouble

Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-circuit.

Judging condition

The feed-back signal is grounding level while exciting command is output.

Symptom

Travel 2 speed is not obtainable.

Control in the
Normal control.
event of failure
Returned
in
The feed-back signal is 24 V level while exciting command is output.
normal condition
Screen
No.

F-3 1/2-TRAVEL

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Travel 1, 2 speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
for other solenoid valve.
SV-3
Check solenoid valve unit for possible failure. If failure found, replace it.

Wiring between travel 1, 2

speed solenoid valve and
controller
CN-123F
CN-105F

When F031 is displayed after the connector is exchanged with other solenoid
valve.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-46

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 71
Error code

F033

Trouble

Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.

Judging condition

The feed-back signal is 24 V level while exciting command is not output.

Symptom

Travel 2 speed is not obtainable or is keeping 1 speed.

Control in the
Normal control.
event of failure
Returned
in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Screen
No.

F-3 1/2-TRAVEL

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Travel 1, 2 speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
for other solenoid valve.
SV-3
Check solenoid valve unit for possible failure. If failure found, replace it.

Wiring between travel 1, 2

speed solenoid valve and
controller
CN-122F
CN-105F

When F033 is displayed after the connector is exchanged with other solenoid
valve.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary..

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 72
Error code

F041

Trouble

Option selector solenoid valve and output transistor OFF are failure, and grounding is short-circuit.

Judging condition

The feed-back signal is grounding level while exciting command is output.

Symptom

Option selector valve does not change to breaker side.

Control in the
Normal control.
event of failure
Returned
in
The feed-back signal is ground level while exciting command is output.
normal condition
Screen
No.

11

F-4 OPT SELECT

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Option selector solenoid valve

SV-13

Checking contents and remedy

When F041 is cancelled and other error occurs by exchanging the connector
for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.

Wiring between option selector

solenoid valve and controller
CN-251F
CN-105F

When F041 is displayed after the connector is exchanged with other solenoid
valve.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-47

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 73
Error code

F043

Trouble

Option selector solenoid valve and output transistor ON are failure, and disconnection.

Judging condition

The feed-back signal is 24 V level while exciting command is not output.

Symptom

Option selector valve does not change to breaker side or it does not change from breaker to nibbler.

Control in the
Normal control.
event of failure
Returned
in
The feed-back signal is ground level while exciting command is not output.
normal condition
Screen
No.

11

F-4 OPT SELECT

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Option selector solenoid valve

SV-13

Checking contents and remedy

When F043 is cancelled and other error occurs by exchanging the connector
for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.

Wiring between option selector

solenoid valve and controller
CN-251F
CN-105F

When F043 is displayed after the connector is exchanged with other solenoid
valve.
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 74
Error code

G011

Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
Service diagnosis Screen
checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

1
2
3

T5-1-48

TROUBLESHOOTING (BY ERROR CODES)

Table 75
Error code

G013

Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
Service diagnosis Screen
checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

1
2
3

Table 76
Error code

G023

Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
Service diagnosis Screen
checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

1
2
3

T5-1-49

E175B-E195B

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 77
Error code

G032

Trouble

Mechatro controller direct input speed sensor is overrun.

Judging condition

Engine rpm input is 3000 rpm or more. (Only trouble history).

Symptom

Operate without problem.

Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

G-3 MEAS 1 (for mechatro controller)

Service diagnosis Screen

checking screen
No.

G-3 MEAS 2 (receive from engine controller)

Screen
No.
Checking object

Checking contents and remedy

Engine speed sensor

Measure the resistance between terminals of speed sensor.

Wiring between option selector

Check wiring for possible failure according to the wiring checking
solenoid valve and controller
procedure and repair it if necessary.
CN-251F
Especially check wiring for false disconnection and noise included.
CN-105F

Mechatro controller

SV-13

Normal value: 1.6~2.0k

Check that the error is corrected after replacement of controller.

Table 78
Error code

G033

Trouble

Mechatro controller direct input speed sensor, Disconnection.

Judging condition

Voltage of alternator is 12 V or more, and speed sensor indicates excess low engine rpm.

Symptom

Operate without problem.

Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

G-3 MEAS 1 (for mechatro controller)

Service diagnosis Screen

checking screen
No.

G-3 MEAS 2 (receive from engine controller)

Screen
No.
Checking object
1

Engine speed sensor

SE-13

Checking contents and remedy

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

Wiring between engine speed

sensor and controller
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
CN-136F
CN-106F

Mechatro controller

Check that the error is corrected after replacement of controller.

(Controller is broken by only applying power to grounding of signal.).

T5-1-50

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 79
Error code

H013

Trouble

Accel potentiometer is disconnected.

Judging condition

The input voltage from accel potentiometer is 0.1 V or less.

Symptom

LOW idling is fixed.

Control in the
LOW idling is fixed.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

H-1 ACCEL VOLT.

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Checking contents and remedy

Accel potentiometer

Measure the resistance between terminals of speed sensor. 1.6~2.4k

Turn the potentiometer and measure resistance between signal and GND.

SE-16
2

Wiring
between
accel
potentiometer and controller
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
CN-402F
CN-102F

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 80
Error code

H014

Trouble

Accel potentiometers power source is shortcut.

Judging condition

The input voltage from accel potentiometer is 4.7 V or more.

Symptom

LOW idling is fixed.

Control in the
LOW idling is fixed.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

H-1 ACCEL VOLT.

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Accel potentiometer
SE-16

Checking contents and remedy

Measure the resistance between terminals of accel potentiometer.
1.6~2.0k .
Turn the potentiometer and measure resistance between signal and GND.

Wiring
between
accel
potentiometer and controller
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
CN-402F
CN-102F

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-51

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 81
Error code

H023

Trouble

Boom angle potentiometers wiring is disconnected.

Judging condition

The input voltage from boom angle potentiometer is 0.1 V or less.

Symptom

Indications of rating load and working radius of High-reach crane become abnormal.

Control in the
Normal control.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

12

H-2 BOOM

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Boom angle potentiometer

SE-17

Checking contents and remedy

Measure the resistance between terminals of boom angle potentiometer.
4.0~6.0k .
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k

Wiring between boom angle

potentiometer and controller
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
CN-702F
CN-103F

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-52

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 82
Error code

H024

Trouble

Boom angle potentiometers power source is shortcut.

Judging condition

The input voltage from boom angle potentiometer is 0.1 V or less.

Symptom

Indications of rating load and working radius of High-reach crane become abnormal.

Control in the
Normal control.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

12

H-2 BOOM

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Boom angle potentiometer

SE-17

Checking contents and remedy

Measure the resistance between terminals of boom angle potentiometer.
4.0~6.0k .
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k

Wiring between boom angle

potentiometer and controller
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
CN-702F
CN-103F

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-53

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 83
Error code

H033

Trouble

Arm angle potentiometers wiring is disconnected.

Judging condition

The input voltage from arm angle potentiometer is 0.1 V or less.

Symptom

Indications of rating load and working radius of High-reach crane become abnormal.

Control in the
Normal control.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

12

H-3 ARM

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Arm angle potentiometer

SE-18

Checking contents and remedy

Measure the resistance between terminals of arm angle potentiometer.
4.0~6.0k .
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k

Wiring between arm angle

potentiometer and controller
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
CN-703F
CN-103F

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-54

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 84
Error code

H034

Trouble

Arm angle potentiometers power source is shortcut.

Judging condition

The input voltage from arm angle potentiometer is 0.1 V or less.

Symptom

Indications of rating load and working radius of High-reach crane become abnormal.

Control in the
Normal control.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

12

H-3 ARM

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Arm angle potentiometer

SE-18

Checking contents and remedy

Measure the resistance between terminals of arm angle potentiometer.
4.0~6.0k .
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k

Wiring between arm angle

potentiometer and controller
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
CN-703F
CN-103F

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-55

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 85
Error code

H091

Trouble

Fuel sensor grounding is short-circuited.

Judging condition

The input voltage from fuel sensor is 0.1 V or less.

Symptom

Warning for low fuel level is indicated.

Control in the
Fuel level becomes 0%.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

10

H-9 FUEL LEVEL

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

Fuel sensor potentiometer

Move fuel sensor and measure the resistance between terminals of fuel sensor.

SE-15

EMPTY 95

.~ FULL 5

Wiring between fuel sensor and

controller
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
CN-152F
CN-104F

Mechatro controller

Check that the error is corrected after replacement of controller.

Table 86
Error code

H093

Trouble

Fuel sensors wiring is disconnection.

Judging condition

The input voltage from fuel sensor is 4.7 V or more.

Symptom

Warning for low fuel level is indicated.

Control in the
Fuel level becomes 0%.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.

10

H-9 FUEL LEVEL

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

Fuel sensor potentiometer

Move fuel sensor and measure the resistance between terminals of fuel sensor.

SE-15

EMPTY 95

.~ FULL 5

Wiring between fuel sensor and

controller
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
CN-152F
CN-104F

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-56

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 87
Error code

I313

Trouble

Reception of cluster communication is abnormal. (Time-out error)

Judging condition

Reception from gauge cluster can not receive correctly.

Symptom

Switch operation of gauge cluster can not be done.

Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned
in
It returns automatically in normal condition.
normal condition
Screen
No.
Service diagnosis Screen
checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Wiring between gauge cluster

and controller
Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
CN-600F
CN-101F

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-57

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 88
Error code

K014

Trouble

Battery relay contact welded.

Judging condition

The power 24 V is continuously supplied to controller for 40 seconds or more while the key switch ON
signal turned OFF.

Symptom

The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF.

Control in the
Normal control with key switch OFF.
event of failure
Returned
in Turn key switch ON.
normal condition Or when the power supply 24 V to mechatro controller is stopped.
Screen
No.

K-1 AIS RELAY 2

Service diagnosis Screen

checking screen
No.

K-3 KEY SWITCH OFF

Screen
No.
Checking object

Checking contents and remedy

Battery relay
R-1
CN-256F

Turn key switch off and disconnect the connector (CN-256F) on the battery
relay coil. If 24 V power lives on battery relay secondary side, check on battery
relay for failure and replace it if failed.

Auto idle stop relay 2

R-24
Alternator relay

Turn off the key switch, and remove the connector (CN-256F) on the battery
relay coil side. If power of battery relay on secondary side falls, remove either
auto idling stop relay 2 or alternator relay.
The failure may be occurred in case where the power falls after the relay was
removed, and therefore check on the relay unit and replace it with new one if
failed.

R-28
3

Wiring between auto idle stop

relay/alternator
relay
and When K014 is left displayed with the relay removed.
Check that no power 24 V is produced on relay (-) line according to the wiring
controller
checking procedure and replace it if necessary.
CN-109F, CN2-1
When no failure found after checking on wiring and K014 is left displayed
Fuse& relay box
Replace fuse/relay box.
E-1

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-58

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 89
Error code

R014

Trouble

Wiper motor arc prevention relay error.

Judging condition

The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
power source.

Symptom

Wiper does not move.

Control in the
Relay output is stopped.
event of failure
Returned
in
When the power is OFF.
normal condition
Screen
No.

25

PREVENT ARC

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Wiper motor arc prevention When error is cancelled after removing wiper motor arc prevention relay, check
relay unit for failure, replace it with new one if failed.
relay
R-31
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

Wiring between wiper motor arc

prevention relay and controller
CN-109F, CN2-1
Fuse& relay box
E-1

Mechatro controller

When R014 is left displayed with the relay removed.

Check that no power 24 V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R014 is left displayed.
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

T5-1-59

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 90
Error code

R024

Trouble

Wiper motor forward rotation relay error.

Judging condition

The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
power source.

Symptom

Wiper does not move.

Control in the
Relay output is stopped.
event of failure
Returned
in
When the power is OFF.
normal condition
Screen
No.

25

CW MOTOR RLY

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay,
check relay unit for failure, replace it with new one if failed.
relay
R-29
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

Wiring between wiper motor

forward rotation relay and When R024 is left displayed with the relay removed.
Check that no power 24 V is produced on relay (-) line according to the wiring
controller
checking procedure and replace it if necessary.
CN-109F, CN2-1
When no failure found after checking on wiring and R024 is left displayed.
Fuse& relay box
Replace fuse/relay box.
E-1

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-60

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 91
Error code

R034

Trouble

Wiper motor reverse rotation relay error.

Judging condition

The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
power source.

Symptom

Wiper does not move after forward rotation.

Control in the
Relay output is stopped.
event of failure
Returned
in
When the power is OFF.
normal condition
Screen
No.

25

CCW MOTOR RLY

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object

Checking contents and remedy

Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
check relay unit for failure, replace it with new one if failed.
relay
R-30
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

Wiring between wiper motor

forward rotation relay and When R034 is left displayed with the relay removed
Check that no power 24 V is produced on relay (-) line according to the wiring
controller
checking procedure and replace it if necessary.
CN-109F, CN2-1
When no failure found after checking on wiring and R034 is left displayed
Fuse& relay box
Replace fuse/relay box.
E-1

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-61

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 92
Error code

R044

Trouble

Washer motor relay error.

Judging condition

The mechatro controller output line to washer motor relay is short-circuited with the power source.

Symptom

Washer motor does not move.

Control in the
Relay output is stopped.
event of failure
Returned
in
When the power is OFF.
normal condition
Screen
No.

25

MOTOR RELAY

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Washer motor relay

R-32

Checking contents and remedy

When error is cancelled after removing washer motor relay, check relay unit for
failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0

, it is in abnormal condition.

Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller
Check that no power 24 V is produced on relay (-) line according to the wiring
CN-112F, CN2-1
checking procedure and replace it if necessary.
Fuse& relay box
When no failure found after checking on wiring and R044 is left displayed
Replace fuse/relay box.
E-1

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-62

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 93
Error code

R134

Trouble

Swing flasher relay error.

Judging condition

The mechatro controller output line to swing flasher relay is short-circuited with the power source.

Symptom

Right swing flasher does not light.

Control in the
Relay output is stopped.
event of failure
Returned
in
When the power is OFF.
normal condition
Screen
No.

22

D13

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Swing flasher relay

R-19

Checking contents and remedy

When error is cancelled after removing connector (CN-74F) of swing flasher
relay, check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0
condition.

, it is in abnormal

Wiring between swing flasher

When R134 is left displayed with the relay removed
relay and controller
Check that no power 24 V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F
figure C) according to the wiring checking procedure and replace it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-63

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 94
Error code

R144

Trouble

Swing flasher relay error.

Judging condition

The mechatro controller output line to swing flasher relay is short-circuited with the power source.

Symptom

Left swing flasher does not light.

Control in the
Relay output is stopped.
event of failure
Returned
in
When the power is OFF.
normal condition
Screen
No.

22

D14

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Swing flasher relay

R-19

Checking contents and remedy

When error is cancelled after removing connector (CN-74F) of swing flasher
relay, check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0
condition.

, it is in abnormal

Wiring between swing flasher

When R144 is left displayed with the relay removed
relay and controller
Check that no power 24 V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F
figure B) according to the wiring checking procedure and replace it if necessary.

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-64

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 95
Error code

R154

Trouble

Travel alarm relay error.

Judging condition

The mechatro controller output line to travel alarm relay is short-circuited with the power source.

Symptom

Travel alarm does not actuate.

Control in the
Relay output is stopped.
event of failure
Returned
in
When the power is OFF.
normal condition
Screen
No.

23

D15

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Travel alarm relay

R-8

Checking contents and remedy

When error is cancelled after removing of travel alarm relay, check relay unit for
failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0

, it is in abnormal condition.

Wiring between travel alarm When R154 is left displayed with the relay removed
relay and controller
Check that no power 24 V is produced on relay (-) line according to the wiring
CN-109F, CN2-2
checking procedure and replace it if necessary.
Fuse & relay box
When no failure found after checking on wiring and R154 is left displayed.
Replace fuse/relay box.
E-1

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-65

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 96
Error code

R164

Trouble

Auto idle stop relay 2 relay error.

Judging condition

The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.

Symptom

Power source for mechatro controller often turns off.

Auto idle stop relay 2 does not actuate.

Control in the
Relay output is stopped.
event of failure
Returned
in
When the power is OFF.
normal condition
Screen
No.

K-1 AIS RELAY 2

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

Auto idle stop relay 2 relay

R-24

When error is cancelled after removing of auto idle stop relay 2, check relay unit
for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0

, it is in abnormal condition.

Wiring between auto idle stop When R164 is left displayed with the relay removed
relay 2 and controller
Check that no power 24 V is produced on relay (-) line according to the wiring
CN-109F, CN2-2
checking procedure and replace it if necessary.
Fuse & relay box
When no failure found after checking on wiring and R164 is left displayed.
Replace fuse/relay box.
E-1

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-66

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 97
Error code

R174

Trouble

Engine forcibly stop relay error.

Judging condition

The mechatro controller output line to engine forcibly stop is short-circuited with the power source.

Symptom

When key switch is turned off but engine does not stop.
Engine auto idle stop function does not actuate..

Control in the
Relay output is stopped.
event of failure
Returned
in
When the power is OFF.
normal condition
Screen
No.

K-3 ENG STOP

Service diagnosis Screen

checking screen
No.
Screen
No.
1

Checking object

Checking contents and remedy

Engine forcibly stop relay

R-25

When error is cancelled after removing of engine forcibly stop relay, check relay
unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0

, it is in abnormal condition.

Wiring between engine forcibly When R174 is left displayed with the relay removed
stop relay and controller
Check that no power 24 V is produced on relay (-) line according to the wiring
CN-109F, CN2-2
checking procedure and replace it if necessary.
Fuse & relay box
When no failure found after checking on wiring and R174 is left displayed.
Replace fuse/relay box.
E-1

Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-67

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

Table 98
Error code

R184

Trouble

Safety lock lever relay error.

Judging condition

The mechatro controller output line to safety lock lever relay is short-circuited with the power source.

Symptom

Safety lock lever timer does not actuate.

Control in the
Relay output is stopped.
event of failure
Returned
in
When the power is OFF.
normal condition
Screen
No.

K-4 LOCK LEVER

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Safety lock lever relay

R-26

Checking contents and remedy

When error R184 is cancelled after removing of safety lock lever relay, check
relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is

Wiring between safety lock lever

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

Mechatro controller

, it is in abnormal condition.

When R184 is left displayed with the relay removed

Check that no power 24 V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R184 is left displayed.
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

T5-1-68

TROUBLESHOOTING (BY ERROR CODES)

E175B-E195B

Table 99
Error code

R214

Trouble

Safety relay error.

Judging condition

The mechatro controller output line to safety relay is short-circuited with the power source.

Symptom

Safety relay does not actuate.

Control in the
Relay output is stopped.
event of failure
Returned
in
When the power is OFF.
normal condition
Screen
No.

K-2 SAFETY RLY

Service diagnosis Screen

checking screen
No.
Screen
No.
Checking object
1

Safety lock lever relay

R-26

Checking contents and remedy

When error R214 is cancelled after removing of safety relay, check relay unit for
failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0

Wiring between safety lock lever

relay and controller
CN-109F, CN2-2
Fuse & relay box

Mechatro controller

E-1

, it is in abnormal condition.

When R214 is left displayed with the relay removed

Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R214 is left displayed.
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

T5-1-69

E175B-E195B

TROUBLESHOOTING (BY ERROR CODES)

[MEMO]

T5-1-70

TROUBLESHOOTING (BY TROUBLE)

E175B-E195B

TROUBLESHOOTING BY TROUBLE
1. HYDRAULIC SYSTEM
Preface:
The troubleshooting for the failures shown below is explained here.
Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.
1.

All controls do not function/slow

2.

Engine down/stalled

3.

Move at lever neutral position

4.

Poor fine operability

5.

Slow boom up, insufficient power

6.

Slow boom down, insufficient power for lifting up body

7.

Slow arm in, insufficient power

8.

Slow independent arm out (in the air)

9.

Slow bucket digging

10. Slow bucket dumping

11. Swing operation not functioned/slow
12. Noise during swing operation
13. Swing on a slope drifts when control lever is in neutral position
14. Swing drifts when swing operation is stopped
15. Slow travel speed/weak
16. Travel deviation
17. Travel 1st/2nd speed not changed
18. Travel parking on a slope is not held
19. Travel does not run straightly when both crawlers and attachment operated simultaneously.
20. Slow breaker (crusher) operation, weak power
21. Option selector valve malfunction: not switched to breaker circuit
22. Option selector valve malfunction: not switched to nibbler circuit

T5-2-1

E175B-E195B
1.

TROUBLESHOOTING (BY TROUBLE)

All controls do not function/slow

No.

Sections

Contents/normal value

Corrective action, others

Fuse

Check fuse No.4

(10 A)

If the fuse is blown out, check

on the short-circuited section.

Safety lever lock

switch

Carry out service

diagnosis

No.4 K-4 switch:

Check action of switch by
Push down the lever and it turns on, push tester, or check that the power
up and it turns off.
voltage is lowered by pushing
the lever down.

Safety lever lock

switching

Check that the

Measure both terminals of solenoid
solenoid is switched connector. 24 V by pushing the lever
correctly
down, 0 V by pushing it up

Safety lever lock

relay

Carry out service

diagnosis

Pilot pressure sensor

Solenoid valve for

safety lock lever

Check solenoid unit for

possible failure.
Check harness for possible
failure.

No.4 K-4 lock lever:

Check action of relay by tester
Push down the lever and it turns off, push
up and it turns on.
Stop engine stop and key is on
position.
All pilot low pressure sensors are 0
MPa to 0.1 MPa.

Check 5 V power for controller

Measure pressure
of solenoid A1 port

About 0 MPa by pushing the lever up,

and 4 MPa or more by push it down.

Replace solenoid valve

Pilot line filter

Disassemble and
check it visually

Check filter for clogging

Clean filter

Pilot gear pump

Measure pilot
Check that it is 4 MPa or more in high
primary pressure at idling
gear pump

Multi control valve (in Change position

case that travel is
operable)

Since all are blocked due to poor

switching performance, check that the
lever select pattern is set to the proper
position.

10

Actual measuring
current value of P1/
P2 unload
proportional valve

No.8 D-1 P1 unload valve (cut valve)

D-1 P2 unload valve (cut valve)
See Service Diagnosis Data List
Operation No.3 Boom up full lever &
relief

11

Secondary pressure Measure the

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

12

Actual measuring
current value of P1/
P2 pump
proportional valve

Carry out service

diagnosis

Carry out service

diagnosis.

Check gear pump and the

relief valve for possible failure

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Check that P1/P2 unload secondary

Replace proportional valve
pressures are within the range of 0.5 to
1.2 MPa in boom up full lever and high
idling operation

No.9 E-1 P1 pump

E-2 P2 pump
See Service Diagnosis Data List
Operation No.18 Travel right full lever
& idling
Operation No.19 Travel left full lever &
idling

T5-2-2

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

E175B-E195B

Corrective action, others

13

Secondary pressure Measure the pump

of pump proportional proportional valve
valve
secondary pressure
directly in idling
operation. (Ports a3,
a4)

Check that pump proportional valve

Replace proportional valve
secondary pressure is 2.7 MPa or more
in right (left) travel full lever and high
idling operation
Right travel: P1 pump proportional valve
Left travel: P2 pump proportional valve

14

Main relief pressure Carry out service

diagnosis

See Service Diagnosis Data List

Measure the relief pressure
Operation No.3 Boom up full lever & relief actually

15

Check set pressure Check that P1 and P2 pump pressures

are 32 MPa in boom up full lever, high
idling and H mode operation.

Reset or replace

16

Pump regulator

Visual check

When removing, free from abnormal

Replace
resistance against sliding.
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage, etc.

17

Pump

Visual check

When removing, inside parts (cylinder

Replace
block, piston, valve plate, shaft, etc.) are
free from abnormal resistance against
sliding, abnormal damage, etc.

2.

Engine down/stalled

No.

Sections

Actual measuring
current value of P1/
P2 pump
proportional valve

Contents/normal value
Carry out service
diagnosis

Corrective action, others

No.9 E-1 P1 pump

E-2 P2 pump
See Service Diagnosis Data List
Operation No. 1 Operation is nil

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Secondary pressure Measure the pump

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

Check that P1/P2 pump proportional

valve pressures are within the range of
0.5 to 1.0 MPa in control lever neutral
and high idling operation.

Replace proportional valve

Pressure sensor of
P1, P2 pump

Check pressure

See Service Diagnosis Data List

Operation No. 1 Operation is nil
Operation No.3 Boom up full lever &
relief

Check pressure sensor and

replace it if necessary

Pump regulator

Visual check

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on outside
surface
Spring free from breakage, damage, etc.

Replace

Pump

Visual check

Replace
When removing, inside parts (cylinder
block, piston, valve plate, shaft, etc.) are
free from abnormal resistance against
sliding, abnormal damage, etc.

T5-2-3

E175B-E195B
3.

TROUBLESHOOTING (BY TROUBLE)

Move at lever neutral position

No. Sections

Contents/normal value

Corrective action, others

Pilot pressure
sensor

Carry out service

diagnosis

Check that targeted pilot pressure of

sensor is 0MPa in high idling

Check remote control valve

Remote control
valve

Check targeted
remote control
valve

Check that spool is free from abnormal

damage and spring is free from
breakage

Replace

Main spool

Check targeted
spool visually

Check that spool is free from abnormal

damage and spring is free from
breakage

Replace

Over load relief

valve

Check targeted
spool visually

Free from dust entered in port relief

valve. Seat is free from abnormality

Replace

Lock valve poppet

Check targeted
(in case of boom and poppet visually
arm)

Seat is free from abnormality

Replace

Lock valve selector Exchange lock

(in case of boom and valve selector of
arm)
boom/arm and
boom/arm

Check that the trouble is reversed

Replace

Holding valve spool

for boom
(in case of boom)

Check that smooth

sliding of spool in
sleeve

Free from abnormal resistance against

sliding

Replace
Do not pull spool out of sleeve
forcibly.

Holding valve relief

valve for boom
(in case of boom)

Check targeted
spool visually

Filter free from abnormal contamination Replace

Cylinder

Check targeted
cylinder visually

Make sure of no problem of seals by

disassembling and investigation

4.

Replace cylinder or seals

Poor fine operability

No. Sections

Contents/normal value

Corrective action, others

Pressure sensor

Carry out service

diagnosis

See Service Diagnosis Data List

Replace pressure sensor
Operation No. 1 Operation is nil
All low pressure sensors are 0MPa to
0.1 MPa

Actual measuring
current value of P1/
P2 unload
proportional valve

Carry out service

diagnosis

No.8 D-1 P1 unload valve (cut valve)

D-1 P2 unload valve (cut valve)
See Service Diagnosis Data List
Operation No. 1 Operation is nil

Secondary pressure Measure the

of unload
proportional valve
proportional valve
secondary pressure
directly at the ports
A7 and A8 of 8
sections solenoid
block

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Check that P1/P2 unloads secondary

Replace proportional valve
pressures is within the range of 2.7 MPa
or more in control lever neutral and high
idling operation

T5-2-4

TROUBLESHOOTING (BY TROUBLE)

No. Sections

E175B-E195B

Contents/normal value

Corrective action, others

Carry out service

diagnosis

No.9 E-1 P1 pump

E-2 P2 pump
See Service Diagnosis Data List
Operation No. 1 Operation is nil

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Actual measuring
current value of P1/
P2 pump
proportional valve

Secondary pressure Measure the pump

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

Check that P1/P2 pump proportional

valve pressures are within the range of
0.5 to 1.0 MPa in control lever neutral
and high idling operation

Replace proportional valve

Check regulator

Command current
Carry out service
value of short-circuit diagnosis.

No.15 D-15
See Service Diagnosis Data List
Operation No. 1 Operation is nil.

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Secondary pressure Measure the

Control lever is neutral, high idling and
of proportional valve secondary pressure secondary pressure is within the range
in short-circuit valve. of proportional
of 0.5 -1.0 MPa.
valve in short-circuit
valve directly. (G
Port)

Replace proportional valve.

Slow return check

Visual check
valve of pilot line
(in case of boom up
or arm out)

Check that slow return check valve

installed on pilot line is free from dust
entered

Clean and replace

Short-circuit valve
spool.

When removing, free from abnormal

resistance against free from abnormal
damage, etc on outside surface Spring
is free from breakage, damage, etc.

Replace (Check on the casing

site for damage).

5.

Visual check

Slow boom up, insufficient power

No. Sections

Contents/normal value

Corrective action, others

Boom up pressure
sensor

Carry out service

diagnosis

See Service Diagnosis Data List

Check and replace pressure
Operation No.3 boom up full lever and sensor
relief
Check remote control valve

Remote control
valve

Measure directly
remote control
pressure of boom
up

Check that pressure is 3.0 MPa or more Check remote control valve
in boom up full lever and high idling
When equipped with multi
operation
control valve, check it while
changing lever pattern

Pump pressure
sensor

Carry out service

See Service Diagnosis Data List
diagnosis for P1, P2
Operation No.4 boom up full lever and
pump pressures in
in operation
operation.

When there is difference

between P1 and P2 pump
pressures, check high
pressure sensor.

Actual measuring
current value of P1/
P2 unload
proportional valve

Carry out service

diagnosis

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

No.8 D-1 P1 unload valve (cut valve)

D-1 P2 unload valve (cut valve)
See Service Diagnosis Data List
Operation No.3 Boom up full lever &
relief

T5-2-5

E175B-E195B

No. Sections

TROUBLESHOOTING (BY TROUBLE)

Contents/normal value

Corrective action, others

Secondary pressure Measure the

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

Check that P1/P2 unload secondary

pressures are within the range of
0.5~1.2 MPa in boom up full lever and
high idling operation

Replace proportional valve

Actual measuring
current value of P1/
P2 pump
proportional valve

No.9 E-1 P1 pump

E-2 P2 pump
See Service Diagnosis Data List
Operation No.4 boom up full lever & in
operation

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Secondary pressure Measure the pump

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

Check that P1/P2 pump proportional

Replace proportional valve
valve pressures are within the range of
1.8 to 3.0 MPa in boom up full lever and
high idling operation

P2 by-pass cut valve Visual check

<Trouble>
Only P2 pressure is
low.

No problem for sliding ability of main

poppet and no contamination on orifice
No problem for sliding ability of internal
piston (Check it through PBp2 port.)

Clean and replace

Remote control
valve

Check targeted
remote control
valve

Check that spool is free from abnormal

damage and spring is free from
breakage

Replace

10

Lock valve poppet

<Trouble>
Both P1 and P2
pressures are low.

Visual check

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface

Replace
(Check on the casing side for
damage)

11

Conflux check valve Visual check

<Trouble>
Only P2 pressure is
high.

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface

Replace
(Check on the casing side for
damage)

12

Holding valve for

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

Visual check

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface

Replace
(Check on the casing side for
damage)

13

Boom spool
<Trouble>
Only P1 pressure is
high.

Visual check

When removing, free from abnormal

resistance against sliding
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

14

Check boom spool

and recirculation
<Trouble>
Only P1 pressure is
low.

Disassembly and
investigation

Free from abnormal resistance against

sliding
Spring is free from breakage.

Replace spool assembly

15

Conflux spool
<Trouble>
Only P2 pressure is
high.

Visual check

When removing, free from abnormal

resistance against sliding
Spring is free from breakage.
Free from abnormal damage, etc on
outside surface

Replace
(Check on the casing side for
damage)

Carry out service

diagnosis

T5-2-6

TROUBLESHOOTING (BY TROUBLE)

E175B-E195B

No. Sections

Contents/normal value

16

Main relief valve

<Trouble>
Relief pressure is
low.

Check set pressure See Service Diagnosis Data List

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

17

Over load relief

valve
<Trouble>
Relief pressure is
low.

Visual check (Head Pressure is 32 MPa or more in boom up When only relief pressure of
side)
full lever and high idling. Free from dust boom up is low, replace valve
entered in over load relief valve. Seat is
free from abnormality

6.

Corrective action, others

Slow boom down, insufficient power for lifting up body

No. Sections

Contents/normal value

Corrective action, others

Boom down
pressure sensor

Carry out service

diagnosis

Check and replace pressure

sensor.
Check remote control valve.

Remote control
valve

Measure remote
Check that pressure is 3.0 MPa or more Check remote control valve
control pressure of in boom down full lever and high idling When equipped with multi
boom down directly operation
control valve, check it while
changing lever pattern.

Actual measuring
current value of P1
unload proportional
valve

Carry out service

diagnosis

Secondary pressure Measure the

of P1 unload
proportional valve
proportional valve
secondary pressure
directly at the ports
A7 of 8 sections
solenoid block.

Check that P1 unload secondary

Replace proportional valve
pressures are within the range of 0.8 to
1.2 MPa in boom down full lever and
high idling operation

Actual measuring
current value of P1
pump proportional
valve

No.9 E-1 P1 pump

See Service Diagnosis Data List
Operation No.5 boom down full lever
& in operation

Secondary pressure Measure the pump

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

Check that P1 pump proportional valve Replace proportional valve

pressures are within the range of 2.0 to
2.5 MPa in boom down full lever and
high idling operation

Actual measuring
current value of
travel straight
proportional valve

Check that the value is not change

Check pressure sensor of
regardless of operation
travel
See Service Diagnosis Data List
In case where the reading is
Operation No. 1 Operation is nil
largely differed from the
Operation No.18 Travel right full lever
actually measured value,
& idling
check proportional valve
Operation No.19 Travel left full lever &
and controller for possible
idling
failure.

Carry out service

diagnosis

Carry out service

diagnosis

See Service Diagnosis Data List

Operation No.5 boom down full lever
& in operation

P1 unload valve (cut valve)

See Service Diagnosis Data List
Operation No.5 boom down full lever
& in operation

T5-2-7

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

E175B-E195B

No. Sections

TROUBLESHOOTING (BY TROUBLE)

Contents/normal value

Corrective action, others

Travel straight
Measure directly
proportional valve
the travel straight
secondary pressure proportional valve
secondary
pressure.

High idling pressure is 0.8 MPa or less

regardless neutral/operation

Actual measuring
current value of
short-circuit valve.

Check that the value is not change

Check pressure sensor of
regardless of operation No 15 D-15
travel.
See Service Diagnosis Data List
In case where the reading is
Operation No. 1 Operation is nil.
largely differed from the
Operation No.18 travel right full lever
actually measured value,
& idling. Operation No.19 travel left full
check proportional valve
lever & idling
and controller for possible
failure.

10

Secondary pressure Measure directly

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

High idling pressure is 0.8 MPa or less

regardless neutral/operation

Replace proportional valve

11

Remote control
valve

Check targeted
remote control
valve

Check that spool is free from abnormal

damage and spring is free from
breakage

Replace

12

Lock valve poppet

<Trouble>
Boom down is low.

Visual check

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface

Replace
(Check on the casing side for
damage)

13

Holding valve
Visual check
(poppet)
<Trouble>
Boom down is slow.

When removing, free from abnormal

resistance against sliding Free from
abnormal damage, etc on outside
surface

Replace
(Check on the casing side for
damage)

14

Boom spool
Visual check
<Trouble>
Boom down is slow.

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

15

Check boom spool

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

Disassembly and
investigation

Free from abnormal resistance against

sliding
Spring is free from breakage.

Replace spool assembly

16

short-circuit valve
spool.

Visual check.

When removing, free from abnormal

resistance against free from abnormal
damage, etc on outside surface Spring
is free from breakage.

Replace (Check on the casing

site for damage).

Carry out service

diagnosis

T5-2-8

Replace proportional valve

TROUBLESHOOTING (BY TROUBLE)

E175B-E195B

No. Sections

Contents/normal value

17

Main relief valve

<Trouble>
Relief pressure is
low.

Check set pressure See Service Diagnosis Data List

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

18

Over load relief

valve
<Trouble>
Machine can not be
lifted by supporting
with boom.

Visual check

7.
No.

Corrective action, others

Free from dust entered in port relief

valve.
Seat is free from abnormality

Replace

Slow arm in, insufficient power

Sections

Contents/normal value

Corrective action, others

Arm in pressure
sensor

Carry out service

diagnosis

See Service Diagnosis Data List

Operation No.6 arm in full lever and
relief

Remote control
valve pressure

Measure directly
remote control
pressure of arm in

Check that pressure is 3.0 MPa or more Check remote control valve
in arm in full lever and high idling
When equipped with multi
operation
control valve, check it while
changing lever pattern

Pump pressure
sensor

Carry out service

See Service Diagnosis Data List
diagnosis for P1, P2
Operation No.7 arm in full lever and in
pump pressures in
operation
operation.

When there is difference

between P1 and P2 pump
pressures, check high
pressure sensor

Actual measuring
current value of P1/
P2 unload
proportional valve

Carry out service

diagnosis

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Secondary pressure Measure the

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

Check that P1/P2 unload secondary

Replace proportional valve
pressures are within the range of 0.5 to
1.2 MPa in arm in full lever and high
idling operation.

Actual measuring
current value of P1/
P2 pump
proportional valve

No.9 E-1 P1 pump

E-2 P2 pump
See Service Diagnosis Data List
Operation No.7 Arm in full lever & in
operation

Carry out service

diagnosis

No.8 D-1 P1 unload valve (cut valve)

D-1 P2 unload valve (cut valve)
See Service Diagnosis Data List
Operation No.6 Arm in full lever &
relief

T5-2-9

Check and replace pressure

sensor
Check remote control valve

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

E175B-E195B

No.

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value

Corrective action, others

Secondary pressure Measure the pump

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

Check that P1/P2 pump proportional

Replace proportional valve
valve pressures are 2.0 MPa or more in
arm in full lever and high idling
operation. (Secondary pressure is
affected by oil temperature and
attachment weight)

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

See Service Diagnosis Data List

Operation No. 1 Operation is nil
Operation No.6 Arm in full lever &
relief
Operation No.7 Arm in full lever & in
operation

Secondary pressure Measure directly

of arm in spool 2
the proportional
proportional valve
valve secondary
pressure at the
ports A8 (arm 2
spool) of 8 sections
solenoid block.

Check that secondary pressure of

Replace proportional valve
proportional valve secondary pressures
are within the range of following
Lever neutral: 0 MPa
Motion in the air: 1.7 to 2.2 MPa
Arm in relief: 2.5 MPa or more

10

Actual measuring
current value of
travel straight
proportional valve

Check that the value is not change

Check pressure sensor of
regardless of operation
travel
See Service Diagnosis Data List
In case where the reading is
Operation No. 1 Operation is nil
largely differed from the
Operation No.18 Travel right full lever
actually measured value,
& idling
check proportional valve
Operation No.19 Travel left full lever &
and controller for possible
idling
failure.

11

Secondary pressure Measure directly

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

0.8 MPa or less in high idling operation

regardless of neutral/operation

Replace proportional valve

12

Remote control
valve

Check targeted
remote control
valve

Check that spool is free from abnormal

damage and spring is free from
breakage

Replace

13

Main relief valve

<Trouble>
Relief pressure is
low.

Check set pressure See Service Diagnosis Data List

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

14

Over load relief

valve
<Trouble>
P1, P2 pressure is
low.

When only relief pressure of

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

Carry out service

diagnosis

T5-2-10

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

E175B-E195B

Corrective action, others

15

Over load relief

valve
<Trouble>
P1, P2 pressure is
low.

Visual check (Rod

side)

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

and relief.
arm out is low, replace valve
Free from dust entered in over load relief
valve.
Seat is free from abnormality.

16

Arm 1 spool
<Trouble>
P1, P2 pressure is
high.

Visual check

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

17

Arm 2 spool
<Trouble>
P1, P2 pressure is
high or low.

Visual check

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

18

Check arm 2 spool

and recirculation
<Trouble>
Arm in power is
poor.

Disassembly and
investigation

Free from abnormal resistance against

sliding
Spring is free from breakage.

Replace spool assembly

19

Check lock valve

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

Visual check

Free from abnormal resistance against

sliding
Free from abnormal damage, etc on
outside surface

Replace
(Check on the casing side for
damage)

8.
No
.

Slow independent arm out (in the air)

Sections

Contents/normal value

Corrective action, others

Arm out pressure

sensor

Carry out service

diagnosis

See Service Diagnosis Data List

Check and replace pressure
Operation No.8 arm out full lever and sensor
relief
Check remote control valve

Remote control
valve

Measure directly
Check that pressure is 3.0 MPa or more Check remote control valve
remote control
in arm out full lever and high idling
When equipped with multi
pressure of arm out operation
control valve, check it while
changing lever pattern

Pump pressure
sensor

Carry out service

See Service Diagnosis Data List
diagnosis for P1, P2
Operation No.9 arm out full lever and
pump pressures in
in operation
operation.

When there is difference

between P1 and P2 pump
pressures, check high
pressure sensor

Actual measuring
current value of P1/
P2 unload
proportional valve

Carry out service

diagnosis

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

No.8 D-1 P1 unload valve (cut valve)

D-1 P2 unload valve (cut valve)
See Service Diagnosis Data List
Operation No.8 Arm out full lever &
relief

T5-2-11

E175B-E195B

No
.

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value

Corrective action, others

Secondary pressure Measure the

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

Check that P1/P2 unload secondary

Replace proportional valve
pressures are within the range of 0.5 to
1.2 MPa in arm out full lever and high
idling operation

Actual measuring
current value of P1/
P2 pump
proportional valve

No.9 E-1 P1 pump

E-2 P2 pump
See Service Diagnosis Data List
Operation No.9 Arm out full lever & in
operation

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Secondary pressure Measure the pump

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

Check that P1/P2 pump proportional

valve pressures are within the range of
1.5 to 2.7 MPa in arm out full lever and
high idling operation
(Secondary pressure is affected by oil
temperature and attachment weight)

Replace proportional valve

Actual measuring
current value of
travel straight
proportional valve

Check that the value is not change

Check pressure sensor of
regardless of operation
travel
See Service Diagnosis Data List
In case where the reading is
Operation No. 1 Operation is nil
largely differed from the
Operation No.18 Travel right full lever
actually measured value,
& idling
check proportional valve
Operation No.19 Travel left full lever &
and controller for possible
idling
failure.

Secondary pressure Measure directly

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

0.8 MPa or less in high idling operation

regardless of neutral/operation

Replace proportional valve

10

Remote control
valve

Check targeted
remote control
valve

Check that spool is free from abnormal

damage and spring is free from
breakage

Replace

11

Main relief valve

<Trouble>
Relief pressure is
low.

Check set pressure See Service Diagnosis Data List

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

12

Over load relief

valve
<Trouble>
P1, P2 pressure is
low.

Visual check (Rod

side)

13

Visual check
Arm 1 spool
<Trouble>
P2 pressure is high.

Carry out service

diagnosis

Carry out service

diagnosis

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

and relief.
arm out is low, replace valve
Free from dust entered in over load relief
valve. Seat is free from abnormality

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

T5-2-12

Replace
(Check on the casing side for
damage)

TROUBLESHOOTING (BY TROUBLE)

No
.

Sections

Contents/normal value

E175B-E195B

Corrective action, others

14

Arm 2 spool
Visual check
<Trouble>
P1 pressure is high.

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

15

Check arm 2 spool

and recirculation
<Trouble>
Both P1, P2
pressures are low.

Disassembly and
investigation
(spring side)

Free from abnormal resistance against

sliding
Spring is free from breakage.

Replace spool assembly

16

Check lock valve

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

Visual check

Free from abnormal resistance against

sliding
Free from abnormal damage, etc on
outside surface

Replace
(Check on the casing side for
damage)

9.

Slow bucket digging

No. Sections

Contents/normal value

Corrective action, others

Bucket digging
pressure sensor

Carry out service

diagnosis

See Service Diagnosis Data List

Operation No.12 bucket digging full
lever and relief

Check and replace pressure

sensor
Check remote control valve

Remote control
valve

Measure directly
remote control
pressure of bucket
digging

Check that pressure is 3.0M Pa or more Check remote control valve

in bucket digging full lever and high
When equipped with multi
idling operation
control valve, check it while
changing lever pattern

Pump pressure
sensor

Carry out service

See Service Diagnosis Data List
diagnosis for P1, P2
Operation No.13 Bucket digging full
pump pressures in
lever and in operation
operation.

When there is difference

between P1 and P2 pump
pressures, check high
pressure sensor

Actual measuring
current value of P1/
P2 unload
proportional valve

Carry out service

diagnosis

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Secondary pressure Measure the

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

Check that P1/P2 unload secondary

Replace proportional valve
pressures are within the range of 0.5 to
1.2 MPa in bucket digging full lever and
high idling operation

Actual measuring
current value of P1/
P2 pump
proportional valve

No.9 E-1 P1 pump

E-2 P2 pump
See Service Diagnosis Data List
Operation No.13 Bucket digging full
lever & in operation

Secondary pressure Measure the pump

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

Carry out service

diagnosis

No.8 D-1 P1 unload valve (cut valve)

D-1 P2 unload valve (cut valve)
See Service Diagnosis Data List
Operation No.12 Bucket digging full
lever & relief

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Check that P1 pump proportional valve Replace proportional valve

pressures is 2.7 MPa or more and P2
pump proportional valve pressure is 1.6
to 2.2 MPa in bucket digging full lever
and high idling operation.

T5-2-13

E175B-E195B

TROUBLESHOOTING (BY TROUBLE)

No. Sections

Contents/normal value

Corrective action, others

Attachment boost
solenoid command

Carry out service

diagnosis

No.3 POWER BOOST

Check harness
Bucket digging COMP OFF, MEAS OFF Replace solenoid valve

Attachment boost
solenoid secondary
pressure

Measure switching
valve secondary
pressure

Check that pressure is 0 MPa in bucket Replace solenoid valve

digging full lever and high idling
operation

10

Actual measuring
current value of
travel straight
proportional valve

Carry out service

diagnosis

See Service Diagnosis Data List

Operation No.12 Bucket digging full
lever & relief

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

11

Secondary pressure Measure directly

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

Check that travel straight secondary

pressure is 2.7 MPa or more in bucket
digging full lever and high idling
operation

Replace proportional valve

12

P2 by-pass cut valve Visual check

<Trouble>
Only P2 pressure is
low.

No problem for sliding ability of main

poppet and no contamination on orifice
No problem for sliding ability of internal
piston (Check it through PBp2 port.)

Clean or replace

13

Check stroke limiter Visual check

<Trouble>
Both P1, P2
pressures are high.

When piston is removed from cover, it is Replace

free from abnormal resistance against
(Check on the casing side for
sliding
damage.)
Free from abnormal damage, etc on
outside surface

14

Remote control
valve

Check targeted
remote control
valve

Check that spool is free from abnormal

damage and spring is free from
breakage

15

Main relief valve

Check set pressure See Service Diagnosis Data List

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

16

Travel straight spool Visual check

<Trouble>
P2 pressure is high.

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

17

Bucket spool
<Trouble>
Both P1, P2
pressures are high.

Visual check

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

18

Over load relief

valve

Check targeted
spool visually

Free from dust entered in over load relief Replace

valve.
Seat is free from abnormality.

T5-2-14

Replace

TROUBLESHOOTING (BY TROUBLE)

E175B-E195B

10. Slow bucket dump

No.

Sections

Contents/normal value

Corrective action, others

Bucket dump
pressure sensor

Carry out service

diagnosis

See Service Diagnosis Data List

Operation No.14 Bucket dump full
lever and relief

Remote control
valve

Measure directly
remote control
pressure of bucket
dump

Check that pressure is 3.0 MPa or more Check remote control valve
in bucket dump full lever and high idling When equipped with multi
operation
control valve, check it while
changing lever pattern

Pump pressure
sensor

Carry out service

See Service Diagnosis Data List
diagnosis for P1, P2
Operation No.15 Bucket dump full
pump pressures in
lever and in operation
operation.

When there is difference

between P1 and P2 pump
pressures, check high
pressure sensor

Actual measuring
current value of P1/
P2 unload
proportional valve

Carry out service

diagnosis

No.8 D-1 P1 unload valve (cut valve)

D-1 P2 unload valve (cut valve)
See Service Diagnosis Data List
Operation No.14 Bucket dump full
lever & relief

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Secondary pressure Measure the

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

Check that P1/P2 unload secondary

pressures are within the range of
0.5~1.2 MPa in bucket dump full lever
and high idling operation. Replace
proportional valve

Replace proportional valve

Actual measuring
current value of P1/
P2 pump
proportional valve.

No.9 E-1 P1 pump

E-2 P2 pump
See Service Diagnosis Data List
Operation No.15 Bucket dump full
lever & in operation

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Secondary pressure Measure the pump

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

Check that P1 pump proportional valve Replace proportional valve

pressures is 2.7 MPa or more and P2
pump proportional valve pressure is 0.9
to 1.4 MPa in bucket dump full lever and
high idling operation.

Actual measuring
current value of
travel straight
proportional valve

See Service Diagnosis Data List

Operation No.14 Bucket dump full
lever & relief

Secondary pressure Measure directly

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

Carry out service

diagnosis

Carry out service

diagnosis

Check and replace pressure

sensor
Check remote control valve

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Check that travel straight secondary

Replace proportional valve
pressure is 2.7 MPa or more in bucket
dump full lever and high idling operation

T5-2-15

E175B-E195B

No.

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value

Corrective action, others

10

P2 by-pass cut valve Visual check

<Trouble>
Only P2 pressure is
low.

No problem for sliding ability of main

poppet and no contamination on orifice
No problem for sliding ability of internal
piston (Check it through PBP2 port.)

Clean and replace

11

Check stroke limiter Visual check

<Trouble>
Pilot pressure is low.

Free from abnormal damage and wear

on outside of piston inside cover

Replace
(Check on the casing side for
damage.)

12

Remote control
valve

Check targeted
remote control
valve

Check that spool is free from abnormal

damage and spring is free from
breakage

Replace

13

Main relief valve

<Trouble>
Relief pressure is
low.

Check set pressure See Service Diagnosis Data List

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

14

Travel straight spool Visual check

<Trouble>
P2 pressure is high.

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface

Replace
(Check on the casing side for
damage)

15

Bucket spool
<Trouble>
Both P1, P2
pressures are high.

Visual check

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

16

Over load relief

valve

Check targeted
spool visually

Free from dust entered in over load relief Replace

valve.
Seat is free from abnormality.

11. Swing operation not functioned/slow

No. Sections

Contents/normal value

Corrective action, others

Swing pressure
sensor

Carry out service

diagnosis

See Service Diagnosis Data List

Operation No.11 Swing full lever and
in operation

Check and replace pressure

sensor
Check remote control valve

Remote control
valve

Measure directly
remote control
pressure of swing

Check that pressure is 3.0 MPa or more Check remote control valve
in boom up full lever and high idling
When equipped with multi
operation
control valve, check it while
changing lever pattern

Swing parking brake Carry out service

solenoid
diagnosis

No.3 F-2 SWING-BRAKE

Lever neutral: COMP ON, MEAS ON
Swing: COMP OFF, MEAS OFF

Check swing pressure sensor

Check harness

Swing parking brake Measurement of

solenoid
solenoid valve A2
port

Lever neutral: 0 MPa

In operation: 4 MPa or more

Replace solenoid valve

T5-2-16

TROUBLESHOOTING (BY TROUBLE)

No. Sections

Contents/normal value

E175B-E195B

Corrective action, others

Shuttle valve
Visual check
<Trouble>
Pilot pressure is low.

No contamination on spool cover (short Clean or replace

side) and orifice
No damage on spool cover (long side)
and shuttle

Pump pressure
sensor

Carry out service

diagnosis for P2
pump pressures in
operation

See Service Diagnosis Data List

Operation No.11 Swing full lever and
in operation

Check high pressure sensor

Actual measuring
current value of P2
unload proportional
valve

Carry out service

diagnosis

No.8 D-2 P2 unload valve (cut valve)

See Service Diagnosis Data List
Operation No.11 Swing full lever & in
operation

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Secondary pressure Measure the

of P2 unload
proportional valve
proportional valve
secondary pressure
directly at the ports
A5 of 8 sections
solenoid block

Check that P2 unload secondary

Replace proportional valve
pressures are within the range of 0.5 to
1.2 MPa in swing full lever and high
idling operation

Actual measuring
current value of P2
pump proportional
valve

No.9 E-2 P2 pump

See Service Diagnosis Data List
Operation No.11 Swing full lever & in
operation

10

Secondary pressure Measure the pump Check that P2 pump proportional valve Replace proportional valve
of P2 pump
proportional valve
pressure is 2.7 MPa or more in swing full
proportional valve
secondary pressure lever and high idling operation
directly (Ports a3,
a4)

11

Actual measuring
current value of
travel straight
proportional valve
(Check this trouble
by only swing
operation)

Carry out service

diagnosis

Check that the value is not change

Check pressure sensor of
regardless of operation
travel
See Service Diagnosis Data List
In case where the reading is
Operation No. 1 Operation is nil
largely differed from the
Operation No.18 Travel right full lever
actually measured value,
& idling
check proportional valve
Operation No.19 Travel left full lever &
and controller for possible
idling
failure.

12

Secondary pressure
of travel straight
proportional valve
(Check this trouble
by only swing
operation)

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

0.8 MPa or less in high idling operation

regardless of neutral/operation

Carry out service

diagnosis

T5-2-17

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Replace proportional valve

E175B-E195B

No. Sections

TROUBLESHOOTING (BY TROUBLE)

Contents/normal value

Corrective action, others

13

Command current
Carry out service
value of short-circuit. diagnosis

Check that the value is not change

Check pressure sensor of
regardless of operation No 15 D-15
travel.
See Service Diagnosis Data List
In case where the reading is
Operation No. 1 Operation is nil.
largely differed from the
Operation No.18 travel right full lever
actually measured value,
& idling. Operation No.19 travel left full
check proportional valve
lever & idling
and controller for possible
failure.

14

Secondary pressure Measure directly

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

0.8 MPa or less in high idling operation

regardless of neutral/operation.

Replace proportional valve.

15

Remote control
valve

Check that spool is free from abnormal

damage and spring is free from
breakage

Replace

16

Travel straight spool Visual check

<Trouble>
P2 pressure is low.

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

17

Swing spool
Visual check
<Trouble>
P2 pressure is high.

When removing, free from abnormal

resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring is free from breakage.

Replace
(Check on the casing side for
damage)

18

Short-circuit valve
spool.

Visual check.

When removing, free from abnormal Replace (Check on the casing

resistance against free from abnormal site for damage).
damage, etc on outside surface
Spring is free from breakage.

19

Swing relief valve

<Trouble>
Relief pressure is
low.

Check set pressure See Service Diagnosis Data List

Operation No.10 Swing full lever and
relief

20

Swing motor

Visual check

21

Swing reduction
gear oil

Take sample oil

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

Disassemble and inspect

reduction gear

22

Swing reduction

Visual check

Replace

Check targeted
remote control
valve

Reset or replace

Inner parts (cylinder block, piston, valve Replace

brake etc) are to be free from abnormal
resistance against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)

Tooth surface is not worn abnormally

and is not chipped.

T5-2-18

TROUBLESHOOTING (BY TROUBLE)

E175B-E195B

12. Noise during swing operation

No. Sections

Contents/normal value

Corrective action, others

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

diagnosis
Lever neutral: COMP ON, MEAS
ON
Swing: COMP OFF, MEAS OFF

Check swing pressure

sensor
Check harness

Measurement of Lever neutral: 0 MPa

solenoid valve A2 In operation: 4 MPa or more
port

Replace solenoid valve

Swing parking
brake solenoid

Boost check valve Visual check

(Sound of
cavitation at
stopping)

When removing, free from abnormal Replace

resistance against sliding
Spring is free from breakage.

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

Visual check

When removing, free from abnormal Replace

resistance against sliding
Spring is free from breakage.

Swing motor
(Brake valve/
friction plate)

Visual check

Disassemble and inspect abnormal Replace

wear and scuffing

Swing motor
piston

Visual check

When removing, free from abnormal Replace

resistance against sliding
Spring is free from breakage.

Swing reduction
gear oil

Take sample oil

from swing
reduction gear
drain.

Sampling oil does not include a lot of Disassemble and inspect

metal powder.
reduction gear

Swing reduction

Visual check

Tooth surface has no abnormally

worn and chipped.

Replace

13. Swing on a slope drifts when control lever is in neutral position

No.

Sections

Contents/normal value

Swing
sensor

Remote
valve

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

solenoid
diagnosis
Lever neutral: COMP ON, MEAS ON
Swing: COMP OFF, MEAS OFF

Corrective action, others

pressure Carry out service Engine stop & starter key ON

Check and replace pressure
diagnosis
All pilot low pressure sensors are sensor
within range of 0 to 0.1 MPa.
control Check
remote
valve

targeted Check that spool is free from abnormal Replace

control damage and spring is free from
breakage

Measurement
of Lever neutral: 0 MPa
solenoid valve A2 In operation: 4 MPa or more
port

T5-2-19

Check swing pressure sensor

Check harness
Check parking brake release
switch
Replace solenoid valve

E175B-E195B

No.

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value

Corrective action, others

Swing motor
Visual check
(Brake valve/friction
plate)

Disassemble and inspect abnormal Replace

wear and scuffing

Parking brake

Piston and friction plate do not have Replace

abnormal resistance against sliding
Free from spring damage

Visual check

14. Swing drifts when swing operation is stopped

No
.

Sections

Contents/normal value

Visual check
Shuttle valve
<Trouble>
Pilot pressure is
low

Swing
sensor

Swing relief valve Check

pressure
<Trouble>
Relief pressure is
low.

Anti-reaction valve Visual check

Remote
valve

Swing motor

Corrective action, others

No contamination on spool cover Clean or replace

(short side) and orifice. No damage
on spool cover (long side) and
shuttle.

pressure Carry out service Engine stop & starter key ON

Replace pressure sensor
diagnosis
All pilot low pressure sensors are
within range of 0 to 0.1 MPa.

control Check
remote
valve

set See Service Diagnosis Data List Reset or replace

Operation No.10 Swing full lever
and relief
Clean or replace
Free from dirt entering
Sliding part should be free from
foreign matter entering, abnormal
damage and wear.

targeted Check that spool is free from Replace

control abnormal damage and spring is free
from breakage

Visual check

Inner parts (cylinder block, piston, Replace

valve brake etc) are to be free from
abnormal resistance against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)

15. Slow travel speed/weak

No.

Sections

Contents/normal value

Corrective action, others

Travel right and left Carry out service See Service Diagnosis Data List
Check and replace pressure
pressure sensor
diagnosis
Operation No.18 Travel right full lever sensor
and idling
Check remote control valve
Operation No.19 Travel left full lever
and idling

Remote
valve

control Measure
directly Check that pressure is 2.1 MPa or more Check remote control valve
remote
control in travel right (left), forward (reverse) full
pressure of travel lever and high idling operation
right and left

T5-2-20

TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

E175B-E195B

Corrective action, others

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

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Secondary pressure Measure

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

Actual
measuring Carry out service No.9 E-1 P1 pump
current value of P1/ diagnosis
E-2 P2 pump
P2
pump
See Service Diagnosis Data List
proportional valve
Operation No.18 Travel right full lever
& idling
Operation No.19 Travel left full lever &
idling

Secondary pressure Measure the pump

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

Actual
measuring Carry out service Check that the value is not change Check voltage of low
current value of diagnosis
regardless of operation
pressure sensor other than
travel
straight
See Service Diagnosis Data List
sensor for travel
proportional valve
Operation No. 1 Operation is nil
In case where the reading is
Operation No.18 Travel right full lever
largely differed from the
& idling
actually measured value,
Operation No.19 Travel left full lever &
check proportional valve
idling
and controller for possible
failure

Secondary pressure Measure

directly 0.8 MPa or less in high idling operation Replace proportional valve
of travel straight the
proportional regardless of neutral/operation
proportional valve
valve
secondary
pressure

Command current Carry out service Check that the value is not change Check pressure sensor of
value of short-circuit diagnosis
regardless of operation No 15 D-15
travel.
See Service Diagnosis Data List
In case where the reading is
Operation No. 1 Operation is nil.
largely differed from the
Operation No.18 travel right full lever
actually measured value,
& idling. Operation No.19 travel left full
check proportional valve
lever & idling
and controller for possible
failure.

Check that P1/P2 unload secondary Replace proportional valve

pressures are within the range of
followings in travel right (left), forward
(reverse) full lever and high idling
operation
Travel right (P1 unload): 0.5 to 1.0 MPa
Travel left (P2 unload): 0.5 to 1.0 MPa
In case where the reading is
largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Check that P1/P2 unload secondary Replace proportional valve

pressures are within the range of
followings in travel right (left), forward
(reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more

directly 0.8 MPa or less in high idling operation Replace proportional valve.
10 Secondary pressure Measure
secondary regardless of neutral/operation.
of proportional valve the
in short-circuit valve. pressure of the
proportional valve
in
short-circuit
valve. (G Port)

T5-2-21

E175B-E195B

No.

TROUBLESHOOTING (BY TROUBLE)

Sections

11 Remote
valve

Contents/normal value

control Check
remote
valve

targeted Check that spool is free from abnormal Replace

control damage and spring is free from
breakage
Check sealing ability of shuttle valve and
entry of dust in orifice

12 Travel straight spool Visual check

<Trouble>
P1 pressure is high.

13 Travel spool
Visual check
<Trouble>
targeted spool
Pump pressure is
high.

14 short-circuit
spool.

valve Visual check.

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

15 Travel motor relief Check set pressure Check P1 and P2 pump pressures are
valve
32 MPa or more in right and left travel
levers full lever (relief operation at
locked crawler belt) and high idling
16 Travel motor

17 Parking brake
travel motor

18 Travel
gear oil

Corrective action, others

If P1 is low, right travel

motorfs relief valve is failed.
If P2 is low, left travel
motorfs relief valve is failed.

Visual check

Inner parts (piston, cylinder block, valve Replace

plate, brake valve spool) are to be free
from abnormal resistance against
sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)

in Visual check

When removing, free from abnormal Replace

resistance against sliding
No sticking on friction plate and
separator plate

reduction Take sample oil Sampling oil does not include a lot of Disassemble and
from
travel metal powder.
reduction gear
reduction gear drain

19 Travel reduction

Visual check

Tooth surface is not worn abnormally Replace

and is not chipped.

T5-2-22

inspect

TROUBLESHOOTING (BY TROUBLE)

E175B-E195B

16. Travel deviation

No.

Sections

Contents/normal value

Corrective action, others

Travel right and left Carry out service See Service Diagnosis Data List
Check and replace pressure
pressure sensor
diagnosis
Operation No.18 Travel right full lever sensor
and idling
Check remote control valve
Operation No.19 Travel left full lever
and idling

Remote
valve

Actual
measuring Carry out service Check that the value is not change Check voltage of low
current value of diagnosis
regardless of operation
pressure sensor other than
travel
straight
See Service Diagnosis Data List
sensor for travel
proportional valve
Operation No. 1 Operation is nil
In case where the reading is
Operation No.18 Travel right full lever
largely differed from the
& idling
actually measured value,
Operation No.19 Travel left full lever &
check proportional valve
idling
and controller for possible
failure.

Secondary pressure Measure

directly 0.8 MPa or less in high idling operation Replace proportional valve
of travel straight the
proportional regardless of neutral/operation
proportional valve
valve
secondary
pressure

Actual
measuring Carry out service No.8 D-1 P1 unload valve (cut valve)
current value of P1/ diagnosis
D-1 P2 unload valve (cut valve)
P2
unload
See Service Diagnosis Data List
proportional valve
Operation No.18 Travel right full lever
& idling
Operation No.19 Travel left full lever &
idling

Secondary pressure Measure

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

Actual
measuring Carry out service No.9 E-1 P1 pump
current value of P1/ diagnosis
E-2 P2 pump
P2
pump
See Service Diagnosis Data List
proportional valve
Operation No.18 Travel right full lever
& idling
Operation No.19 Travel left full lever &
idling

Secondary pressure Measure the pump

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

control Measure
directly Check that pressure is 2.1 MPa or more Check remote control valve
remote
control in travel right (left), forward (reverse) full
pressure of travel lever and high idling operation
right and left

In case where the reading is

largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Check that P1/P2 unload secondary Replace proportional valve

pressures are within the range of
followings in travel right (left), forward
(reverse) full lever and high idling
operation
Travel right (P1 unload): 0.5 to 1.0 MPa
Travel left (P2 unload): 0.5 to 1.0 MPa
In case where the reading is
largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Check that P1/P2 unload secondary Replace proportional valve

pressures are within the range of
followings in travel right (left), forward
(reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more

T5-2-23

E175B-E195B

No.
9

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value

Exchange P1 for P2 Exchange delivery Check the direction of deviation

pipe of P1 for P2

10 Remote
valve

control Check
remote
valve

12 Travel spool
Visual check
<Trouble>
targeted spool
Pump pressure is
high.

When removing, free from abnormal Replace

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

13 Travel motor relief Check set pressure Check P1 and P2 pump pressures are
valve
32 MPa or more in right and left travel
levers full lever (relief operation at
locked crawler belt) and high idling

15 Travel
gear oil

If the direction is changed,

inspect a pump. If the
direction is not changed,
inspect a valve and travel unit.

targeted Check that spool is free from abnormal Replace

control damage and spring is free from
breakage
Check sealing ability of shuttle valve and
entry of dust in orifice

11 Travel straight spool Visual check

<Trouble>
P1 pressure is high.

14 Travel motor

Corrective action, others

Visual check

If P1 is low, right travel

motorfs relief valve is failed.
If P2 is low, left travel
motorfs relief valve is failed.
Replace as necessary

Inner parts (piston, cylinder block, valve Replace

plate, brake valve spool) are to be free
from abnormal resistance against
sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)

reduction Take sample oil Sampling oil does not include a lot of Disassemble and
from
travel metal powder.
reduction gear
reduction gear drain

16 Travel reduction

Visual check

Tooth surface is not worn abnormally Replace

and is not chipped.

17 Pump regulator

Visual check

When removing, free from abnormal Replace

resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage, etc.

18 Pump

Visual check

When removing, inside parts (cylinder Replace

block, piston, valve plate, shaft, etc.) are
free from abnormal resistance against
sliding, abnormal damage, etc.

T5-2-24

inspect

TROUBLESHOOTING (BY TROUBLE)

E175B-E195B

17. Travel 1st/2nd speed notchanged

(In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft
ground), the speed may sometimes does not change from 1st to 2nd because this machine equips the
function of automatic speed change.)
No.

Sections

Contents/normal value

Corrective action, others

Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed
switching solenoid
diagnosis
No.3 F-3 1/2-TRAVEL
Lever neutral COMP OFF, MEAS OFF
Travel operation COMP ON, MEAS ON

Check pressure sensor

Check harness
Check travel 1/2 speed switch
on gauge cluster

Travel 1/2 speed Measure A3 port Lever neutral: 0 MPa

switching solenoid
pressure
on In operation: 4 MPa or more
solenoid valve

Replace solenoid valve

1/2 speed switching Visual check

spool in travel motor

Check that spool is free from abnormal Replace

damage and spring is free from (Check on the casing side for
breakage
damage)

1/2 speed switching Visual check

orifice in travel motor

Free from entry of dust

Tilting
piston
travel motor

Free from abnormal wear on piston and Replace

seal
(Check on the casing side for
damage)

in Visual check

Remove dust or replace

18. Travel parking on a slope is not held

No.

Sections

Contents/normal value

Pilot
sensor

Remote
valve

Parking brake
travel motor

Orifice of passage Visual check

for parking brake in
travel motor

Corrective action, others

pressure Carry out service Engine stop & starter key switch is ON Check pressure sensor and
diagnosis
Targeted pilot low pressure sensor is replace as necessary
in range of 0 to 0.1 MPa
Check remote control valve
control Check
remote
valve

targeted Check that spool is free from abnormal Replace

control damage and spring is free from
breakage

in Visual check

When removing, free from abnormal Replace

resistance against sliding
Spring free from breakage, damage, etc.
Free from entry of dust

Remove dust or replace

19. Travel does not run straightly when both crawlers and attachment operated simultaneously .
No.
1

Sections

Contents/normal value

Corrective action, others

Actual
measuring Carry out service No. 8 D-3 S-TRAVEL is should be Check voltage of low
current value of diagnosis
COMP 557 mA and MEAS 55730 mA
pressure sensor other than
travel
straight
in both travel full lever and in boom-up
travel sensor
proportional valve
full lever at high idling (Command value In case where the reading is
is changed according to operation.
largely differed from the
Above mentioned values indicate while
actually measured value,
boom-up and full lever operation are
check proportional valve
performed).
and controller for possible
failure.

T5-2-25

E175B-E195B

No.

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value

Corrective action, others

Secondary pressure Measure

directly
of travel straight the
proportional
proportional valve
valve
secondary
pressure

Command current Carry out service No 15 D-15 is should be COMP 530 mA Check voltage of low
value
short-circuit diagnosis.
and MEAS 53030 mA in both travel full
pressure sensor other than
valve
lever and in boom-up full lever at high
travel sensor.
idling
In case where the reading is
largely differed from the
actually measured value,
check proportional valve
and controller for possible
failure.

Secondary pressure Measure

directly Check secondary pressure is within Replace proportional valve.
of proportional valve the
secondary range of 1.5 to 1.9 MPa in both travel full
in short-circuit valve. pressure of the lever and in boom-up full lever at high
proportional valve idling.
in
short-circuit
valve. (G Port)

Travel straight spool Visual check

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.

Short-circuit
spool.

When removing, free from abnormal Replace (Check on the casing

resistance against free from abnormal site for damage).
damage, etc on outside surface Spring
is free from breakage.

valve Visual check.

Check secondary pressure is within Replace proportional valve

range of 1.7 to 2.1 MPa in both travel full
lever and in boom-up full lever at high
idling. (Command value is changed
according
to
operation.
Above
mentioned values indicate while boomup and full lever operation are
performed).

20. Slow breaker (crusher) operation, weak power (In case of conflux, check p1 unload/pump and travel
straight)
No.

Sections

Contents/normal value

Corrective action, others

Pressure sensor for Carry out service See Service Diagnosis Data List
Check and replace pressure
optional attachment diagnosis
Operation No.16 P2 side OPT full sensor
lever and relief
Check remote control valve

Remote
valve

Actual
measuring Carry out service See Service Diagnosis Data List
In case where the reading is
current value of P1/ diagnosis
Operation No.16 P2 side OPT full largely differed from the
P2
unload
lever and relief
actually measured value,
proportional valve
check proportional valve and
controller for possible failure.

control Measure
directly Check that pressure is 2.1 MPa or more Check remote control valve
remote
control in optional attachment full lever and high
pressure of travel idling operation
right and left

T5-2-26

TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

E175B-E195B

Corrective action, others

Secondary pressure Measure

the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve
secondary pressure 1.2 MPa
directly at the ports
A7 and A5 of 8
sections solenoid
block

Actual
measuring Carry out service See Service Diagnosis Data List
Check voltage of low
current value of diagnosis
Operation No.16 P2 side OPT full
pressure sensor other than
travel
straight
lever & relief
sensor
for
optional
proportional valve
attachment
In case where the reading is
largely differed from the
actually measured value,
check proportional valve
and controller for possible
failure.

Secondary pressure Measure

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

Check that travel straight secondary Replace proportional valve

pressure is 2.7 MPa or more in optional
attachment full lever and high idling
operation

P1 by-pass cut valve Visual check

<Trouble>
Only P1 pressure is
low.

No problem for sliding ability of main Clean or replace

poppet and no contamination on orifice
No problem for sliding ability of internal
piston (Check it through PBp2 port.)

Relief pressure

Remote
valve

Check set pressure See Service Diagnosis Data List

Reset or replace
Operation No.16 P2 side OPT full
lever and relief
(Set value of factory shipment is 24.5
MPa.)

control Check
remote
valve

targeted Check sealing ability of shuttle valve and Replace

control entry of dust in orifice.

10 Travel straight spool Visual check

<Trouble>
P1 pressure is 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.

11 Spool for optional Visual check

attachment
<Trouble>
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

E175B-E195B

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

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

N&B
solenoid

selector Screw
emergency

N&B
solenoid

selector Carry out service No.11 F-4 Option selector is B mode

diagnosis
COMP ON, MEAS ON
Spool position BRK
Selector switch BRK

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

for Check that the error indication is Replace solenoid valve

disappeared by turning emergency
screw
Check solenoid valve
Check harness

22. Option selector valve malfunction: not switched to nibbler circuit.

(Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve")
No.

Sections

N&B selector spool

N&B
solenoid

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)

E175B-E195B

Table 1 - Action of optional selector solenoid valve

Safety
Engine lock lever
No.
SW's
condition
input

Running

ON

Safety
lock
lever
relay's
output

OFF

Work
mode

Optional
selector
valve
COMP.
MEAS.

OFF

Spool
position

Selector
valve
detecting
pressure
sensor

Warning display

Failure diagnosis
display

Nibbler

Normal

Running

ON

OFF

ON

Breaker

"SELECTOR
Normal
FAILURE"

Running

ON

OFF

OFF

Breaker

Normal

Running

ON

OFF

ON

Nibbler

Normal

[F042] displayed

Running

ON

OFF

ON

Breaker

Normal

Running

ON

OFF

OFF

Nibbler

Normal

"SELECTOR
FAILURE"

VALVE [F043] displayed

simultaneously

Running

ON

OFF

ON

N&B

Normal

"SELECTOR
FAILURE"

VALVE

Running

ON

OFF

OFF

Breaker

Normal

[F043] displayed

Running

ON

OFF

Failure

"SELECTOR
FAILURE"

VALVE [B113] displayed

10 Stopping

"SELECTOR
FAILURE"

VALVE [F042] displayed

simultaneously
VALVE

11

OFF

12

ON

T5-2-29

E175B-E195B

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.

E175B-E195B

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

E175B-E195B
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

E175B-E195B

E175B-E195B
1.

TROUBLESHOOTING (BY TROUBLE)

Engine does not stop.

No
.

Sections

Contents/normal value

Corrective action, others

Starter key switch Check signal of

starter key switch
ON by carrying
out
service
diagnosis.

Check continuity between

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

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

No.4 K-3 Key switch

Check on engine forcible
OFF at starter key switch OFF stop relay
position
ON at starter key switch ON position

Wiring

2.

Voltage between 0 V when starter switch is OFF

line No.62 among
starter
switch,
engine
forcible
stop
relay,
enginestop
solenoid and the
body grounding

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

"CPU DATA COMMUNICATION ERROR" is displayed on multi display.

No
.

Sections

Contents/normal value

Corrective action, others

Fuse

No.1 fuse (5 A)

Not blown fuse

Check harness
Replace fuse

Mechatro
controller

Accel control

Engine speed varies according to Check mechatro controller

and replace as necessary
accel potentiometer operation.
(Use remote control because the
auto accel function is working.)

Wiring

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

Gauge cluster

Gauge cluster

CHECKING Repair wiring

Replace gauge cluster

T5-2-34

TROUBLESHOOTING (BY TROUBLE)

3.
No
.

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

Contents/normal value

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

Gauge cluster

Low
sensor

4.
No
.

E175B-E195B

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

E175B-E195B
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

Fuse

Check fuse No.20

Replace fuse

SW-19:
Wiper interlock
switch

Service diagnosis No.19 D125

Check wiper interlock switch
Wiper switch display (D125) is OFF with front window closed. and repair it if necessary
Check according to "WIRING
CHECKING PROCEDURE"
and repair it if necessary

Rise up limit switch Service diagnosis No.25 Wiper system

built-in wiper motor
Reverse limit switch Switch action in operation

Check according to "WIRING

CHECKING PROCEDURE"

Normal condition

Rise up limit switch

ON

OFF

OFF

Reverse limit switch

ON

ON

OFF

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

T5-2-36

(STOP)

(STOP)

(REVERSE)

(FORWARD)

OFF

ON

ON

ON

OFF

OFF

OFF

OFF

OFF

OFF

ON

OFF

ON

ON

ON

OFF

OFF

Check that the relay is excited.

Check relay & fuse box and replace it
if necessary.

ON

TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

E175B-E195B

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

E175B-E195B

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)

E175B-E195B

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

E175B-E195B

TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

Table 1 - Failure diagnosis Mode-1/Diagnosis item

No.

Display

Contents of diagnosis

1 P1 UNLOAD

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

2 P1 UNLOAD

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

3 P1 UNLOAD

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

1 P2 UNLOAD

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

2 P2 UNLOAD

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

3 P2 UNLOAD

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

1 P1 PUMP

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

2 P1 PUMP

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

3 P1 PUMP

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)

E175B-E195B

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

E175B-E195B

TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

[MEMO:]

T5-3-6

REPAIR INSTRUCTIONS

M0103

REPAIR INSTRUCTIONS

E175B-E195B

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

E175B-E195B

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

E175B-E195B

PRECAUTIONS FOR DISASSEMBLY AND

ASSEMBLY
PREPARATIONS FOR DISASSEMBLY
- Thoroughly wash the machine before bringing it
into the shop. Bringing a dirty machine into the
shop may cause machine components to be
contaminated during disassembling/assembling,
resulting in damage to machine components, as
well as decreased efficiency in service work.
- Be sure to thoroughly understand all
disassembling/assembling
procedures
beforehand, to help avoid incorrect disassembling
of components as well as personal injury.
- Check and record the items listed below to
prevent problems from occurring in the future.
1. The machine model, machine serial
number, and hour meter reading.
2. Reason for disassembly (symptoms, failed
parts, and causes).
3. Clogging of filters and oil, water or air leaks,
if any.
4. Capacities and condition of lubricants.
5. Loose or damaged parts.
- Prepare the necessary tools to be used and the
area for disassembling work.
- Wear appropriate clothing, safety shoes, safety
helmet, goggles, and clothes with long sleeves.
- Confirm the position of first-aid kit and fire
extinguisher, and also where to make contact for
emergency measure and ambulance to prepare
for accidents and fire.
- Attach "Dont operate" tag to control lever, and
begin a meeting before starting the work.
DISASSEMBLING AND ASSEMBLING
HYDRAULIC EQUIPMENT
- Before removing pipes, release the pressure of
hydraulic oil tank, or open the cover on the return
side to tank, and take out the filter.
- Drain the oil in the removed pipes into pan to
prevent the oil from spilling on the ground.
- Pipes with plugs or caps to prevent oil leaking,
entry of dust, etc.

- If it is unavoidably necessary to disassemble and

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

- Clean the outside surface of equipment, etc.

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

E175B-E195B

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, dont move it to the
stroke end at beginning.
- Air in pilot circuit can be bleed out by only
operating digging, swing and travelling motions
thoroughly.
- Check hydraulic oil level.
Move attachments to hydraulic oil check position,
as indicated in the figure.
- Open the hydraulic pump compartment door, then
check the oil level on visual indicator (1) located
on the hydraulic oil reservoir. If the indicator is
within level marks, the oil quantity is acceptable.

W1-1-2

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

E175B-E195B

Floating Seal Precautions

1.

In general, replace the floating seal with a new

one. If the floating is to be reused, follow these
procedures:

1) Keep seal rings together as a matched set

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

If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to
prevent trouble.

SM0172

1) Clean the floating seal and seal mounting

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

RIGHT

WRONG

SM0173

RIGHT

WRONG
a

C
B

b
a=b

W1-1-3

ab

SM0174

E175B-E195B

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

29.5

M10

17

64

M12

19

10

108

M14

22

12

175

M16

24

14

265

M18

27

14

390

M20

30

17

540

M22

32

17

740

M24

36

19

930

M27

41

19

1370

M30

46

22

1910

M33

50

24

2550

M36

55

27

3140

W1-2-1

E175B-E195B

E175B-E195B

TIGHTENING TORQUE

IMPORTANT
1.

Apply lubricant (i. e. white zinc B dissolved into

spindle oil) to nuts and bolts to stabilize their
friction coefficients.

2.

Torque tolerance is 10%.

3.

Be sure to use bolts of correct length. Bolts that

are too long cannot be tightened, as the bolt tip
comes into contact with the bottom of the bolt
hole. Bolts that are too short cannot develop
sufficient tightening force.

4.

The torques given in the chart are for general

use only.
Do not use these torques if a different torque is
given for a specific application.

5.

Make sure that the nut and bolt threads are

clean before installing. Remove dirt or
corrosion, if any.

Bolt Tightening Order

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

Equally tighten upper

and lower alternately

Tighten diagonally
1

1.4

12

14

13

10

11

6
2.3

Tighten from center and diagonally

4
2

SM0176

W1-2-2

TIGHTENING TORQUE

E175B-E195B

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

E175B-E195B

TIGHTENING TORQUE

PIPING JOINT
Pipe Thread Connection / Union
Tightening Torque Specifications

Joint

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

SM0182

IMPORTANT
1.

2.

Do not over-tighten union nut (3). Excessive

force will be applied to metal sealing surfaces
(4) and (5), possibly cracking adaptor (1). Be
sure to tighten union nut (3) to specifications.

37
37

Scratches or other damage to sealing surfaces

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

Male Union Joint

Female Union Joint

SM0183

Type
37 Union Joint

Wrench Size

Tightening Torque

Union Nut

Joint Body

(Nm)

19

17

29

22

19

39

27

22

78.5

36

30, 32

157

41

36

205

50

46

323.6

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

W1-2-4

TIGHTENING TORQUE

E175B-E195B

O-Ring Seal Joint

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

IMPORTANT
1.

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

when reconnecting.

2.

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

3.

Take care not to damage O-Ring groove (8) or

sealing face (10). Damage to O-Ring (6) will
cause oil leakage.

4.

If union nut (9) is found to be loose, causing oil

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

Wrench Size

Tightening Torque

Union
Nut

Joint
Body

(Nm)

19

17

29.4

22

19

68.6

27

22

93

30

27

137.3

36

30

175

41

36

205

50

46

320

W1-2-5

10

Joint body
SM0184

E175B-E195B

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

E175B-E195B

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

E175B-E195B

TIGHTENING TORQUE

NOTE:

W1-2-8

SECTION 2

E175B-E195B

UPPERSTRUCTURE

CONTENTS
Group 1 - Upperstructure

Maintenance standard............................ W2-2-29

Removal and installation of

upperstructure....................................... W2-1-1
Preparation ....................................... W2-1-1
Removal of upperstructure ............... W2-1-1

Disassembly and assembly of regulator

(E195B) ................................................. W2-2-30
Disassembly ..................................... W2-2-31
Assembly ......................................... W2-2-34

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

Removal of the cab ........................... W2-1-2
Installation of the cab ........................ W2-1-3

Disassembly and assembly of pto gear

casing.................................................... W2-2-36
Disassembly...................................... W2-2-37
Assembly .......................................... W2-2-38

Removal and installation of

counterweight........................................ W2-1-4
Removal of counterweight ............... W2-1-4
Installation of counterweight ............ W2-1-5

Group 3 - Control valve

Disconnecting hoses of swivel joint

lower side.............................................. W2-1-6

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

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

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

Removal and installation of main frame. W2-1-8

Removal of main frame..................... W2-1-8
Installation of main frame.................. W2-1-9

Assembly and disassembly of control

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

Group 2 - Pump device

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 pump
device (E175B) ..................................... W2-2-2
Disassembly hydraulic pump device. W2-2-3
Assembly .......................................... W2-2-7
Maintenance standard ........................... W2-2-11
Disassembly and assembly of regulator
(E175B)................................................. W2-2-12
Disassembly of regulator .................. W2-2-14
Assembly ......................................... W2-2-18
Disassembly and assembly of pump
device (E195B) ..................................... W2-2-20
Disassembly .................................... W2-2-21
Assembly .......................................... W2-2-25

Group 4 - Swing device

Removal and installation of swing deviceW2-4-1
Preparation ....................................... W2-4-1
Removal............................................ W2-4-2
Installation......................................... W2-4-3
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 swing
reducer .................................................. W2-4-9
Preliminary operations ...................... W2-4-10
Disassembly...................................... W2-4-10
Assembly .......................................... W2-4-13
Maintenance standards.......................... W2-4-18
Swing reduction gear ........................ W2-4-19
Special tools...................................... W2-4-20

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

E175B-E195B

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 T2-1-47.

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

continuously while working.

the

vacuum

pump

W2-1-1

E175B-E195B

UPPERSTRUCTURE

REMOVAL AND INSTALLATION OF THE CAB

Removal of the cab
1.

Remove floor mat.

2.

Remove cover (1).

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

3.

Remove cover assy (2).

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

4.

Remove the harness connector (See section

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

5.

Remove the plastic tube for the window washer

from the rear left of cab.

6.

Remove the right panel of cab.

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

3
2

SM0259

Disassembly and assembly of cover (1)

and cover assy (2)

3
5

10
7

10

5
10
4

12

14

13

SM0260

Disassembly and assembly of right panels

(8), (9) and (14)

W2-1-2

UPPERSTRUCTURE
7.

E175B-E195B

Remove cab attaching bolt.

1) 5 capscrews (15) M12x65 and 1 capscrew

(16) M12x30
2) 2 nuts (17) M16
8.

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

11

SM0261

17

15

installation of the cab

Install it in reverse order of removing according to
the Tightening Torque Table.
Allen wrench
HEX

Tightening
torque
Nm (lbfft)

Nut M16 - (17)

24

191 (140)

Capscrew - (2), (9)

19

79.4 (60)

Sems bolt M6 (5), (6)

Torxdriver
T30

8.5 (6.3)

Sems bolt M6 (12), (13)

Plus driver

5.0 (3.7)

Tightening position

15

16
15
15
15

SM0262

Removing and installing cab mounting bolts.

18
18

SM0263

W2-1-3

E175B-E195B

UPPERSTRUCTURE

REMOVAL AND INSTALLATION OF

COUNTERWEIGHT

Removal of counterweight
1.

Remove plugs (1) from the counterweight and

attach two M36 eye bolts to the counterweight.

NOTE: approximate mass of counterweight:

- 3300 kg (7273 lbs) for E175B
- 3650 kg (8044 lbs) for E195B.
2.

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.).

SM1321

3.

Remove 4 bolts (4) M27.

Lift counterweight using a crane or hoist.

: 41 mm

4.

Remove shims (5), (6), (7) from the frame,

when present.

5.

5
6
7
SM1322

Lower the counterweight on proper stand.

SM1323

W2-1-4

UPPERSTRUCTURE

E175B-E195B

Installation of counterweight
NOTE: approximate mass of counterweight:
- 3300 kg (7273 lbs) for E175B
- 3650 kg (8044 lbs) for E195B.
2

1.

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

counterweight.
3

2.

Install shims (5), (6), (7) of the frame as they

were, when present.

3.

Lift counterweight and install it onto the frame.

4.

Install bolts M27 (4) and washers

counterweight and tighten temporarily.

5
6
7

to
4

SM1322

: 41 mm

5.

Remove wire rope.

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

: 41 mm
: 1150 150 Nm (851 111 lbfft)

6.

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

the counterweight.

4
SM1324

W2-1-5

E175B-E195B

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 (58.1 lbfft)

2.

Disconnect the hose (2) and (3).

(A and B Port: PF1)
: 36 mm
Tightening torque: 177 Nm (131 lbfft)

3.

Disconnect the hose (4) and (5).

(C and D Port: PF1)
: 36 mm
Tightening torque: 177 Nm (131 lbfft)

4.

Disconnect the two hose (6). (F Port: PF1/4)

: 19 mm
Tightening torque: 29.4 Nm (21.7 lbfft)

B
D

C
B
A

E
SM1325

W2-1-6

UPPERSTRUCTURE

E175B-E195B

SWIVEL JOINT LOWER SIDE HOSES

SM1326

W2-1-7

E175B-E195B

UPPERSTRUCTURE

REMOVAL AND INSTALLATION OF MAIN

FRAME
Removal of main frame
NOTE: approximate mass of main frame:
- 4000 kg (8816 lbs) for E175B
- 4000 kg (8816 lbs) for E195B.

1.

Insert two upper swing body lifting jigs (2) and

two counterweight fastening cap screws (M27)
(1) into the counterweight mounting holes from
above.

2.

Attach two chain blocks (4) to the boom foot

side.

3.

Attach wire ropes (3) like illustrated in the figure

beside.
Use chain blocks (4) for easy adjustment of
wire rope lengths and to level the frame.

3
4

IMPORTANT: make sure rear slings do not touch

engine.
Wire ropes:
D 16 mm (0.630") x 2.5 m (8 ft-2 in), 2 pcs
D 16 mm (0.630") x 1.5 m (4 ft-11 in), 2 pcs
Chain blocks:
for 2,000 kg (4408 lbs), 2 pcs
Special tool for lifting
P/n 38xxxxxxx, 2 pcs

4.

ST. No. 38xxxxxxx

Put matching marks (M) on swing bearing and

main frame.

SM0270

5
SM0271

W2-1-8

UPPERSTRUCTURE
5.

E175B-E195B

Remove the bolts (5) M20 (30 bolts for E175B,

32 bolts for E195B), the reamer bolt (6)
M20x105 and the relevant gaskets, from the
swing bearing.

: 30 mm

6.

7.

Lift main frame slightly from undercarriage.

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

Remove main frame.

SM1327

Installation of main frame

NOTE: approximate mass of main frame:
- 4000 kg (8816 lbs) for E175B
- 4000 kg (8816 lbs) for E195B.
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. SM1327).

3.

Slinging upper frame.

Match marks and install it with a reamer bolt (6)
and a washer temporarily.

SM0273

OUTER (S) ZONE POSITION

CAUTION
Confirm the reamer bolt position (X) referring to
fig SM1328 (E175B) or SM1329 (E195B).

X
4.

Apply Loctite # 262 onto thread of bolts (5)

then, install bolts.
: 30 mm
Tightening torque: 392 39 Nm
(290 28.8 lbfft)

(*)

SM1328

(*) Apply Loctite # 515 to the shared area

W2-1-9

E175B-E195B
5.

UPPERSTRUCTURE

Apply Loctite # 262 onto thread of reamer bolts

(6) then, install reamer bolt.

OUTER (S) ZONE POSITION

: 30 mm
Tightening torque: 392 39 Nm
(290 28.8 lbfft)

(*)

SM1329

(*) Apply Loctite # 515 to the shaded area

W2-1-10

PUMP DEVICE

E175B-E195B

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.
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

continuously while working.

vacuum

Removal

Installation

1.

Remove all protection panels and doors to give

access to the Hydraulic Pump Device.

1.

2.

Disconnect all electrical connectors.

3.

Remove all hoses and collector from hydraulic

pump device.

NOTE: hydraulic pump device weight:

- 88 kg (194 lbs) for E175B
- 89.5 kg (197 lbs) for E195B.
2.

: 19, 22, 30, 36 mm

: 8, 10 mm
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.
: 14 mm
: 235 Nm (174 lbfft)

Fasten the hydraulic pump device by means of

hoist and lifting ropes.
3.

NOTE: hydraulic pump device weight:

- 88 kg (194 lbs) for E175B
- 89.5 kg (197 lbs) for E195B.
5.

pump

Install all hoses and collector to the hydraulic

pump device.
: 19 mm
: 29.4 Nm (21.7 lbfft)
: 22 mm
: 39.2 Nm (29 lbfft)

Remove the fixing bolts of hydraulic pump

device and draw it from engine.

: 30 mm
: 137.2 Nm (101 lbfft)

: 14 mm

: 36 mm
: 156.9 Nm (111 lbfft)
: 8 mm
: 64 Nm (47 lbfft)
: 10 mm
: 108 Nm (80 lbfft)
4.

Connect all electrical connectors.

5.

Install all protection panels and doors.

W2-2-1

E175B

PUMP DEVICE

DISASSEMBLY AND ASSEMBLY OF PUMP DEVICE (E175B)

SM1330

NOTE: the number in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
01
02
03
04
05
06
111
113
116
123
124
127
141
151
153
156
157
211
212
251

Hydraulic Pump
Regulator
Regulator
Solenoid valve
Gear pump
PTO unit
Drive shaft (F)
Drive shaft (R)
Gear #1
Roller bearing (Q.ty 2)
Needle bearing (Q.ty 2)
Bearing spacer (Q.ty 2)
Cylinder block (Q.ty 2)
Piston (Q.ty 18)
Retainer plate (Q.ty 2)
Spherical bushing (Q.ty 2)
Cylinder spring (Q.ty 12)
Shoe plate (Q.ty 2)
Swash plate (Q.ty 2)
Swash plate support
(Q.ty 2)

255
256
261
263
271
272
312
313
314
401

402 406
415
468
490
531
532
533
534

Lock pin (Q.ty 2)

Set spring (Q.ty 2)
Seal cover (F)
Seal cover (R)
Pump casing (F)
Pump casing (R)
Valve block
Valve plate (R)
Valve plate (L)
Socket bolt; M16x150
(Q.ty 2)
Socket bolt; M16x190
(Q.ty 2)
Socket bolt; M6x16 (Q.ty 4)
Socket bolt; M8x20 (Q.ty 4)
Plug; G1/2 (Q.ty 4)
Plug; (Q.ty 9)
Tilting pin; (Q.ty 2)
Servo piston (Q.ty 2)
Plug (Q.ty 2)
Stopper (L) (Q.ty 2)

W2-2-2

535
702
710
711
717
723
724
727
732
733
734
774
789
792
806
808
824
886
901
953

Stopper (S) (Q.ty 2)

O-ring; 1B G30 (Q.ty 2)
O-ring; 1B G80
O-ring; G95
O-ring; 1B G125 (Q.ty 2)
O-ring; 1B P11 (Q.ty 4)
O-ring; 1B P8 (Q.ty 12)
O-ring; 1B P18 (Q.ty 4)
O-ring; 1B P14 (Q.ty 2)
O-ring; P28 (Q.ty 2)
O-ring; G85
Oil seal
Back up ring; P14 (Q.ty 2)
Back up ring; G30 (Q.ty 2)
Nut; M12 (Q.ty 2)
Nut; M16 (Q.ty 2)
Snap ring (Q.ty 2)
Spring pin (Q.ty 4)
Eye bolt M10 (Q.ty 2)
Set screw; M12x23 (Q.ty 2)

PUMP DEVICE

E175B

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
467

:19, 36 mm
311
312
466

1.

SM1331

Removing piloto pump.

Remove the socket bolts (435), then remove
pilot pump (4).
: 8 mm

2.

Removing PTO gear casing.

Remove the socket bolts (435), then remove
PTO gear casing (5).

435

: 8 mm
SM0278

3.

Removing regulator.
Remove the 4 socket bolts (415), then remove
regulator (2), (3).
: 6 mm

SM1332

W2-2-3

E175B
4.

PUMP DEVICE

Loosen socket bolts (401 and 402) that fasten

swash plate support (251), pump casing (271
and 272) and valve block (312).

402

: 14 mm

401

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

SM1333

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).

NOTE: use care so as not to score the sliding

surface of the cylinder, spherical bushing, shoe and
the swash plate.

271
141 (151) (157)
153
156

SM1334

W2-2-4

PUMP DEVICE
7.

E175B

Remove socket bolt (406) and seal cover (261).

406

: 5 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.

SM1335

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

SM1336

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)

SM1337

W2-2-5

E175B

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).

535
806

532

531

534
808
312

271

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.

W2-2-6

251

124

SM1338

PUMP DEVICE

E175B

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
SM1339

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.

W2-2-7

251
271 (531)

212

SM1340

E175B
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
SM1341

5.

nstall seal cover (261) to pump casing (271)

and fix it with socket bolts (406).

271

: 5 mm
: 12 Nm (8.9 lbfft)

261
406

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.

SM1342

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

SM1343

W2-2-8

PUMP DEVICE
7.

E175B

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 272) and fasten them together with socket
bolts (401 and 402).

402

: 14 mm
: 240 Nm (177 lbfft)
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 4 socket
bolt (415).

401

SM1333

: 6 mm
: 29 Nm (21.4 lbfft)
IMPORTANT: do not mistake the front regulator for
the rear regulator.

SM0295

W2-2-9

E175B

PUMP DEVICE

10. Install gear casing (5) and fasten it with socket

bolt (435).
: 8 mm
: 33.3 Nm (24.6 lbfft)

435

SM0278

11. Install pilot pump (4) and fasten it with socket

bolt (435).
: 8 mm
: 33.3 Nm (24.6 lbfft)

435

435
467

311
312
466

W2-2-10

SM1331

PUMP DEVICE

E175B

MAINTENANCE STANDARD:

Unit: mm (in)
Part name and inspection item

Standard
dimension

Recommended
value for
replacement

Clearance between piston and cylinder

bore (D-d)

0.039
(0.0015)

0.067
(0.0026)

Replace piston or cylinder.

0 ~ 0.1
(0 ~ 0.0039)

0.3
(0 ~ 0.0118)

Replace piston shoe assy.

4.9
(0.1930)

4.7
(0.1851)

Replace piston shoe assy.

41.1
(1.6193)

40.3
(1.5878)

Replace cylinder spring.

23.0
(0.9062)

22.0
(0.8668)

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).

Surface roughness requiring

correction.

Cylinder (sliding section).

Roughness of each surface.

Standard surface roughness

(correction value)

W2-2-11

3-Z
Less than 0.4 Z (lapping)

E175B

PUMP DEVICE

DISASSEMBLY AND ASSEMBLY OF REGULATOR (E175B)

651
418
079

496 (X9)

466

643

755
543
545
541
755

631
731

041

402

466
755

407

924

656

325
733

601

646
624

415

801

041

627

543
545
541
755
726

724
652

724

754

614

875
754
887

658

708

616

897
611

SM1344

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
325
402
407
415
418
466
496
541
543
545
601
611
614
616
624
627
631

643
646
651
652
656
658
708
724
726
731
733
754
755
801
875
887
897
924

Valve
Proportional Solenoid valve
Valve casing
Screw; M6x16 (Q.ty 4)
Screw; M6x30 (Q.ty 4)
Screw; M8x40 (Q.ty 4)
Screw; M5x12 (Q.ty 2)
Plug; G 1/4
Plug (Q.ty 9)
Seat (Q.ty 2)
Stopper 1 (Q.ty 2)
Steel ball (Q.ty 2)
Casing
Feedback lever
Center plug
Prevention plug
Spring seat
Adjusting stem
Sleeve

Tightening torque of bolt, plug and nut

No.

Thread size

Tightening torque
Nm (lbfft)

402, 407

M6

12 (8.9)

415

M8

29 (21)

418

M5

6.9 (5)

466

G 1/4

16 (12)

496

NPTF1/16

8.8 (6.5)

614

M14x1.5

27 (20)

801

M10

29 (21)

W2-2-13

E175B
Pilot piston
Pilot spring
Sleeve
Spool
Cover
Plug
O-Ring
O-Ring (Q.ty 5)
O-Ring
O-Ring
O-Ring
O-Ring (Q.ty 2)
O-Ring (Q.ty 3)
Nut; M10
Pin; 5x10L
Pin
Pin
Set screw; M10x20

E175B

PUMP DEVICE

Disassembly of regulator

415

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 (2 or 3) remove the 4 socket

bolts (415) and separate the regulator from the
pump body.

415

SM1345

: 6 mm
NOTE: be careful not to loose the O-rings and the
valve parts (541, 543 and 545).

4.

Remove the socket bolts (402) and separate

the port plate (656).

627
656

: 5 mm
5.

801

402

After removal of the plate (656) extract the

adjust stem (627) and the O-ring (733).
: 5 mm

733
924

SM1346

NOTE: the cover is equipped with lock nut (924),

hex nut (801) and set screw (924). Do not loosen
those parts. If they are loosened, preadjusted set
pressure and flow values change.

NOTE: adjust stem can be comes out easily if an

M4 bolt is used.
646

6.

Take out the pilot spring (646) and the sping

seat (624).
624

W2-2-14

SM1347

PUMP DEVICE
7.

E175B

Remove socket bolts (407) and pilot cover

(325) with O-ring (731).
: 5 mm

325

407

731

SM1348

8.

Take out prevention plug (616), fulcrum plug

(614) with O-ring (726) and draw out the pin
(875).

875

726

614 616

897
611
SM1349

9.

Remove the feedback lever (611) with pin

(897).

631
643
651
652

SM1350

10. Remove the sleeve (631), the pilot piston (643),

the spool (652) and the sleeve (651).

651
652

643
631

SM1351

W2-2-15

E175B

PUMP DEVICE

11. Remove plug (466), or plugs depending on the

regulator, with O-ring (755) in order to access
the internal area.
466
755

755
466

325
SM1352

W2-2-16

PUMP DEVICE

E175B

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.

Insert the spool (652) in the spool hole.

3.

Assemble on the spool (652) the feedback lever

(611) with the pin (496) put in it, operating on
the lever and the spool so that the pin enters
the hole in the spool.

652

601

897
611

SM1353

496

611

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.

4.

5.

652
SM1355

Place pin (875) in the hole of the feedback lever

and in the corresondin hole of the casing.
insert adjust plug (614) and O-ring (726) and
then the prevention plug (616).

616
875

726

614

: 22 mm
: 27 Nm (19.9 lbfft)

SM1354

W2-2-17

E175B
6.

PUMP DEVICE

Assemble the sleeve (651) on the spool (652).

NOTE: make sure that the spool and the sleeve

move smoothly in the casing.
Beware of the direction of the spool.
7.

Insert into the spool (652) the pilot piston (643)

and assemble on it the sleeve (631).

NOTE: before assembling of the sleeve, make sure

that the pilot piston moves smoothly.

651

631

643

SM1356

8.

Assemble on the pilot cover (325) the plug

(466) and the relevant O-ring; depending on the
regulator, 1 or 2 plugs are present.
: 19 mm

466

: 16 Nm (11.8 lbfft)

755

755
466

325
SM1352

9.

Assemble the pilot cover (325) and the relevant

O-ring (731) on casing (601) and fasten it with
4 socket bolts (407).

325

: 5 mm
: 12 Nm (8.85 lbfft)
407

731

SM1348

10. Put spring seat (624) and pilot spring (646) into
the pilot hole.

646

624

W2-2-18

SM1347

PUMP DEVICE

E175B

11. Put the adjust stem (627) with O-ring (733) on

the spring and fasten the port plate (656) by 4
socket bolts (402).
: 5 mm
: 12 Nm (8.85 lbfft)

627
656
801

NOTE: the cover is equipped with set screw (924)

and hex nut (801).

402

733
924

12. Assemble the regulator on the pump and fasten

it by 4 socket bolts (415).

SM1346

415
415

: 6 mm
: 29 Nm (21.4 lbfft)

SM1345

W2-2-19

E195B

PUMP DEVICE

DISASSEMBLY AND ASSEMBLY OF PUMP DEVICE

535
808
953

789

732

532

548
531

214

702 792
534
724

901

711

312

719

124

151 152 113

954

886
717
406

252
710

774
111
A

261
127
123
710
824
251
490

262
406
401
212

401
406
466
467
490
531
532
808

211

M16
M6
G 1/4
G 1/2
NPTF1/16
M20x1.5
M20x1.5
M16

153

156

157

313

434
725

116

Nm (lbf.ft)
240 (177)
12 (8.9)
36 (26.6)
110 (81)
8.8 (6.5)
240 (177)
240 (177)
130 (96)

885

314

981
983

141

436
728

271

04

05
A-A

SM1020

45111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 252 261 -

Gear pump
Pto unit
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.ty 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 (Front)
Swash plate support (Rear)
Seal cover (Front)

262 271 312 313 314 401 406 434 436 490 531 532 534 535 -

Seal Cover (Rear)

Pump casing (Q.ty 2)
Valve block
Valve plate (For CW Rotation)
Valve plate
(For CCW Rotation)
Socket bolt M16175 (Q.ty 8)
240 Nm
Socket bolt M616 (Q.ty 8)
12 Nm
VP plug G 1/4 (Q.ty 2) 36 Nm
VP plug G 1/2 (Q.ty 3) 110 Nm
Plug NPTF 1/16 (Q.ty 15)
8.8 Nm
Tilt Pin M2015 (Q.ty 2)
240 Nm
Servo piston M201.5
(Q.ty 2) 240 Nm
Stopper (Q.ty 2)
Stopper (Q.ty 2)

548 702 710 711 717 719 724 725 728 732 774 789 792 808 824 885 886 901 953 954 -

Feed back Pin (Q.ty 2)

O-Ring (Q.ty 2)
O-Ring (Q.ty 2)
O-Ring
O-Ring (Q.ty 2)
O-Ring (Q.ty 2)
O-Ring (Q.ty 18)
O-Ring (Q.ty 6)
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 4) 130 Nm
Snap ring (Q.ty 2)
Valve plate pin (Q.ty 2)
Spring pin (Q.ty 4)
Eye bolt M10 (Q.ty 2)
Set screw (Q.ty 2)
Set screw (Q.ty 2)

The codes in a rectangle represent adjust screws. Do not tamper whit the adjust screws as much possible.

W2-2-20

PUMP DEVICE

E195B

Disassembly
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

pump surface with wash oil.

3.

Drain out the oil in the pump casing by

removing drain port plugs.
: 19 mm, 36 mm

434
4.

436

SM1361

Disassembly of Gear pump (4).

a.
b.

Remove the flange socket (435) (Q. ty 2).

Remove the plug (466), the adapter (467),
and if necessary, the adjusting screw
(311) and the lock nut (312).

435

435

c.
d.

467

311
312
466

5.

SM1331

Remove regulator and PTO gear casing by

loosening the related socket bolts (415 and
435).
: 6 mm, 8 mm

NOTE: for disassembly and assembly of the

regulator and PTO gear casing, refer to the related
paragraphs.

SM1332

W2-2-21

E195B
6.

PUMP DEVICE

Loosen socket bolts (401) that fasten swash

plate support (251), pump casing (271) and
valve block (312).

271

312

401

: 14 mm

SM1362

7.

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.

SM1363

8.

Draw out the cylinder block (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.

SM1364

W2-2-22

PUMP DEVICE
9.

Remove socket bolt (406) and seal cover

(Front) (261).

E195B

406

: 5 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.
10. Remove socket bolt (406) and seal cover
(Rear) (262).
: 5 mm
SM1365

11. 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

SM1366

12. Draw out shoe plate (211) and swash plate

(212) from pump casing (271).

271

212
(211)

SM1367

13. 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)

SM1368

W2-2-23

E195B

PUMP DEVICE

14. Remove valve plate (313 and 314) from valve

block (312).

312

314 (313)

SM1369

15. 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).
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 (808) of valve block (312)
and swash plate support (251). A set flow rate
changes.

531

808

535

532

534

808
571

312

124

251

SM1370

W2-2-24

PUMP DEVICE

E195B

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
SM1371

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.

271 (531)

251

212

SM1372

W2-2-25

E195B
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
SM1373

5.

Install seal cover (Front) (261) to pump casing

(271) and fix it with socket bolts (406).
: 5 mm

271

: 12 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.
6.

406

Fit seal cover (Rear) (262) at the same way as

above.
SM1374

7.

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)

156
153

SM1375

W2-2-26

PUMP DEVICE
8.

E195B

Install valve plate (313 and 314) to valve block

(312) by aligning pin.

NOTE: do not mistake the suction and delivery

sides of the valve plate.

312

314 (313)

SM1376

9.

Install valve block (312) to pump casing (271)

and fasten them together with socket bolts
(401).
: 14 mm

312

271
401

: 240 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.

SM1377

10. Install regulator and PTO gear casing - pinch

feedback pin of tilting pin in feedback lever of
the regulator and PTO gear casing, install the
regulator and fasten socket bolt (415 and 435).
: 6 mm
: 29.4 Nm (21.7 lbfft)
: 8 mm
: 33.3 Nm (24.6 lbfft)

NOTE: do not mistake the front regulator for the rear

regulator.

W2-2-27

SM1378

E195B

PUMP DEVICE

11. Assembly of gear pump (4).

a.
b.
c.

Replace systematically every O-Rings

with new ones.
Install the plug (466), the adapter (467),
the adjusting screw (311) and the lock nut
(312).
Install the flange socket (435) (Q. ty 2).

NOTE: the setting of adjusting screw (311) must be

performed according to group T4-3, after installation
of pump device on the engine.

435

435
467

311
312
466

SM1331

12. Install drain port plugs (434 and 436).

: 19 mm, 36 mm
: 36 Nm (26.6 lbfft),
110 Nm (81.4 lbfft)
13. Refill with hydraulic oil the pump device till to
the maximum allowed level.

434

W2-2-28

436

SM1361

PUMP DEVICE

E195B

MAINTENANCE STANDARD:

Unit: mm (in.)
Part name and inspection item

Standard
dimension

Recommended
value for
replacement

Clearance between piston and cylinder

bore (D-d)

0.028
(0.0011)

0.056
(0.0022)

Replace piston or cylinder.

0 ~ 0.1
(0 ~ 0.0039)

0.3
(0.0118)

Replace piston shoe assy.

3.9
(0.1536)

3.7
(0.1457)

Replace piston shoe assy.

31.3
(1.2332)

30.2
(1.1899)

Replace cylinder spring.

10.5
(0.4137)

9.8
(0.3861)

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 roughness requiring

correction.
Standard surface roughness
(correction value)

W2-2-29

3-Z
Less than 0.4 Z (lapping)

E195B

PUMP DEVICE

DISASSEMBLY AND ASSEMBLY OF REGULATOR (E195B)

656 402
733
627
624

646

601

496

924

415
079

756

541

545

543

755
614

733
658

325

887
724
708

418

496

652

589

651

731

407

755

631

801

611

643

466
SM1379

079 - Solenoid proportional reducing valve

325 - Valve casing
402 - Socket bolt M6x16 (Q.ty 4) 11.8 Nm (8.7 lbfft)
407 - Socket bolt M6x30 (Q.ty 4) 11.8 Nm (8.7 lbfft)
415 - Socket bolt M8x50 (Q.ty 6) 29.4 Nm (21.7 lbfft)
418 - Socket bolt M5x12 (Q.ty 2) 6.9 Nm (5.1 lbfft)
466 - Vp plug G 1/4 15.7 Nm (11.6 lbfft)
496 - Plug (Q.ty 9) 8.8 Nm (6.5 lbfft)
541 - Seat (Q.ty 2)
543 - Stopper (Q.ty 2)
545 - Stell ball (Q.ty 2)
601 - Casing
611 - Feed back lever
614 - Fulcrum plug G 1/4 36.9 Nm (27.3 lbfft)
624 - Spring Seat
627 - Plunger
631 - Sleeve

643 - Pilot piston

646 - Pilot spring
651 - Sleeve
652 - Spool
656 - Cover
658 - Plug NPTF 1 /16 8.8 Nm (6.5 lbfft)
708 - O-Ring
724 - O-Ring (Q.ty 5)
731 - O-Ring
733 - O-Ring (Q.ty 2)
755 - O-Ring (Q.ty 2)
756 - O-Ring (Q.ty 2)
801 - Nut M8 15.7 Nm (11.6 lbfft)
887 - Pin
897 - Pin
924 - Set Screw M8x20

W2-2-30

PUMP DEVICE

E195B

Disassembly
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 (415)

and separate the regulator from the pump body.
: 6 mm

NOTE: exercise care so as not to lose O-Ring and

check valve sub (541, 543 and 545).

SM1380

4.

Remove socket bolts (407) and remove valve

casing (325) with solenoid proportional
reducing valve (079).
: 5 mm

325 (079)

407

SM1381

W2-2-31

E195B
5.

PUMP DEVICE

Remove socket bolt (402) and cover (656).

: 5 mm

NOTE: the cover is assembled with set screw (924)

and hex nut (801), but do not loosen them. If they
are loosened, the pressure setting change.

801

402 924

656
SM1382

6.

Draw out sleeve (631) and pilot piston (643)

from the regulator body.

631 (643)
SM1383

7.

Remove fulcrum plug (614) and feed back lever

(611).

611

: 6 mm
8.

Draw out spool (652) and sleeve (651) from the

sleeve hole of the regulator casing.

614
SM1384

9.

Draw out plunger (627). Then take out pilot

spring (646) and spring (624).

627 (624, 656)

NOTE: the plunger comes off easily if an M4 bolt is
used.

SM1385

W2-2-32

PUMP DEVICE
10. The disassembly is complete when the check
valve [seat (541), ball (545) and stopper (543)]
have been draw out.

NOTE: the check valves are placed on two places;

the mating surface of the pump casing (601) and on
the matching surface of the valve casing (325).

E195B

541

543 (545)

601
SM1386

W2-2-33

E195B

PUMP DEVICE

Assembly
1.

541

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.
- Do not fail to coat the moving parts with clean
hydraulic oil, before assembly.
- Replace seals such as O-Ring.

2.

601
SM1386

Fit the check valve to casing (601).

NOTE: assemble the check valve into the matching

surface of the pump casing (601) and the matching
of the valve casing (325).

3.

543 (545)

601

Place sleeve (651) and spool (652) into the

sleeve hole of casing.

NOTE: make sure that the spool and the sleeve

slide smoothly in the casing without interference.
Beware of the direction of the spool.

W2-2-34

651 (652)
SM1387

PUMP DEVICE
4.

Insert pin (897) of feedback lever (611) into the

pin hole of the sleeve and fix the feedback
lever with fulcrum plug (614).

E195B

611 (897)

: 6 mm
: 36.3 Nm (26.8 lbfft)
NOTE: operate the feedback lever and make sure
that it does not have much looseness and that it
operates without catching.

614
5.

SM1388

Place spring seat (624), pilot spring (646) and

plunger (627) into the hole in the sleeve.

646 (627)

SM1389

6.

Attach cover (656) to casing (601) and fasten

them together with socket bolts (402).
: 5 mm
: 11.8 Nm (8.7 lbfft)

NOTE: the cover is fitted with set screw (924) and

hex nut (801).
7.

Assemble sleeve (631) and pilot piston (643)

into casing (601).

NOTE: make sure that the pilot piston moves

smoothly.
8.

601
656

402

SM1390

Attach valve casing (325) fitted with solenoid

proportional reducing valve (079) to casing
(601) and fasten them together with socket
bolts (407).
: 5 mm
: 11.8 Nm (8.7 lbfft)

631
643

W2-2-35

SM1391

E195B

PUMP DEVICE

DISASSEMBLY AND ASSEMBLY OF PTO GEAR CASING

128

435

711

262

414

117
126

886

826
128
12
728

886
10

468
11

435

710
125
118
825

125

SM1357

10 - Idle shaft

414 - Socket bolt M1020 (Q.ty 2)

11 - Gear casing

435 - Flange socket M1020 (Q.ty 4)

12 - Spring pin

468 - VP plug PF3/4

117 - 2nd gear

710 - O-Ring

118 - 3rd gear

711 - O-Ring

125 - Ball bearing (Q.ty 2)

728 - O-Ring

126 - Roller bearing

825 - Snap ring

128 - Bearing spacer (Q.ty 2)

826 - Snap ring

262 - Cover

886 - Pin (Q.ty 2)

W2-2-36

PUMP DEVICE

E175B-E195B

Disassembly
1.

2.

Proceed with disassembly operations in a clean

place.
Spread rubber sheet or cloth on work bench to
protect parts from damaging.

414

Remove dust, rust, etc, on pump surface with

wash oil (468).

262

: 27 mm

468

: 73.5 Nm (53.4 lbfft)

SM0525

3.

Remove the socket bolts (414). Then remove

the cover (262).
10

: 8 mm
: 33.3 Nm (24.6 lbfft)
4.

Remove snap ring (12) and idle shaft (10).

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).
SM1358

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

W2-2-37

E175B-E195B

PUMP DEVICE

Assembly
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 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 1 mm, while the
area ratio is more than 5%) is seen on the gear tooth
surface of 2nd gear (117) and 3rd gear (118), replace
the gears. Replace the gears also in case they show
excessive damage.
Air pulling out point
1.

After the relief valve installation, start the

engine.

2.

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

(2) comes off, to allow the air flows out.

3.

Air pulling out operation is completed when, for

two seconds, only hydraulic oil flows out from
plug (1).

4.

Tighten the plug (1) to specified torque.

: 17
: 23 Nm (17 lbfft)

SM1251

W2-2-38

CONTROL VALVE

E175B-E195B

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 c
ontrol valve
1.

Remove the panel protecting the control valve,

removing the securing screws.
: 19 mm

2.

Disconnect all hoses, pipes and connectors

from the control valve (1).

NOTE: attach caps to hoses and pipes. Attach

labels or tags to hoses and pipes, to aid in
assembly.

2
3.

Remove the control valve securing screws (2).

: 19 mm
NOTE: control valve assembly mass: 155 kg (342
lbs).

4.

Remove the control valve.

W2-3-1

SM1277

E175B-E195B

CONTROL VALVE

Installation of control valve

1.

Install control valve (1) to frame and tighten the

bolts (2).
: 19 mm
: 110 Nm

1
2.

Connect all hoses, pipes and connectors to the

control valve.

2
2
2

SM1277

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

MU1, MU2, T3, Ar, Br, AL, BL, As, Bs, Aa,
Ba, Ac, Bc, Ab, Bb, Ao, Bo

3.

M10

P1, P2

M12

T1, T2

Name

ORS
Joint

Sems
bolt

Install the panel protecting the control valve

using the relevant securing screws.
: 19 mm
: 108 Nm

W2-3-2

Hose nut

Tightening
Tightening Remarks
Opposing
Opposing
torque
torque
flats
flats
Nm (lbfft)
Nm (lbfft)
19

36 (27)

19

29 (21)

22

74 (55)

22

49 (36)

36

162
(119)

36

118 (87)

14

57 (42)

17

96 (70)

CONTROL VALVE

E175B-E195B

CONTROL VALVE PORTS (1/2)

Ports

Functions

Ports on upper sides

LEFT

Ports

RIGHT PBp1 P1 bypass cut

P2 bypass cut PBp2

Option
Arm (H) relief valve

PAa2 Arm 2 in

PAo

MU1 Make-up line

-

PBs

Boom conflux

PB1

Travel left forward

PAL

Tank return

Bucket (R)relief valve

XAb Boom lowering valve

Arm 1 in PAa1
Swing (LH)

Functions

PBb Boom down

-

Boom (H) relief valve

PAr Travel right forward

-

T2

Main relief valve

PCb P1 unload
Ports on rear sides (on machine)

LEFT

RIGHT

P1

P1 pump

P2

P2 pump

Ports on right sides (on machine)

UPPER SIDE

LOWER SIDE

Bucket dump

Bc

Bucket dump

PBc

Bucket (H) stroke limit

PCc

Ac

Bucket digging

Ab

Bb

Boom down

Br

Travel right reverse

Boom up

Travel right forward

Ar

ATT power boost

PL
SM1278

W2-3-3

E175B-E195B

CONTROL VALVE

CONTROL VALVE PORTS (2/2)

Function

Option

Ports

Bo

Ports on left side (on machine)

LOWER
SIDE

Ports

UPPER
SIDE

Function

Ao

Option

Aa

Arm 1 out

Arm 2 in

Ba

Pss

Swing low pressure sensor

Swing left

Bs

As

Swing right

Travel left reverse

BL

Dr

Drain

AL

Travel left forward

T1

Tank return

Ports on lower side (on machine)

LEFT SIDE
Travel left reverse

PBL

P2 unload

PCa

Swing right

PAs

RIGHT SIDE

Arm 1 out PBa1

Arm out lock release PLc2
Arm (R) relief valve
Option

PTb

Travel priority

PBr

Travel right reverse

PAb

Boom up

Boom (R) relief valve

Bucket (H) relief valve

PAc

PBo

Bucket digging

PBa2 Arm 2 out

SM1279

W2-3-4

CONTROL VALVE

E175B-E195B

Control valve (1/6)

PAa2

PAo

275 x 4
274 x 4

213

(P3)

(P4)

212

PBa2

PBo

A
B
273 x 10

273 x 10
T2

P1 unload
(Travel priority)

PCb

PAL

PAr

PB1

PBb

PBs

PCc

PAa1

PAa2

PAo

Travel left

C
Travel right

Boom conflux
(P2 unload)

D
Boom

E
Bucket

PBc

J
C
D

Swing

Pss

Arm 1

F
Arm 2

MU1

PBp1

Option

PBp2

H
A

W2-3-5

SM1288

E175B-E195B

CONTROL VALVE

Control valve (2/6)

K
155

163

101
P2

T1

T2

CT2

K
PAL

PBL

PB1

PCa

PBs

PAs
Pss
PAa1

PBa1

PAo

PBo

PBp2

SECTION A-A
166

161

154

(P4)

161 155 163 164

567 155 163

(MU2)

(P6)

973

102

P1

973

CT1
PTb

PCb

973

973
PBr

PAr

PAb

PBb

973

973

PBc

PAc

PCc

973

973

PBa2

PAa2

973

PBp1

161

(P3)

164 163 155 161

W2-3-6

SECTION B-B
161
SM1289

CONTROL VALVE

E175B-E195B

Control valve (3/6)

202
333
331
336
328
325
601
331
261
309

P1 unload

201
333
331
339
327
325

Travel left

PCb

PAL

MR

331
261
306

PL

157
161
161
512
522
556
561
561
556
522
512

AL

CP2

CMR2

551
561
BL

CMR1

307
261
331
325
328
336
331
333
202

264
PBL

551
561
166
164
166

205
SECTION C-C

PTb

201
333
331
339
327
325
603
331
261
166
164
162
306
511
521

Travel priority

Travel right
Par

202
333
331
336
322
321

Travel left
PB1

AbR

331
261
305
Dr
Ar

CCb

511
521
551
561

CP1

551
561
Br

310

161
166
264

(T3)

PBr

205
SECTION D-D

PCa
SM1290

511
521

P2 unload

W2-3-7

567
154
261
331
325
328
336
331
333
202

E175B-E195B

CONTROL VALVE

Control valve (4/6)

203
333
331
339
320
319
279 x 3
211
331
216
261
266
266 x 4
160
301
561
556
524
514
551
561
521
511

Swing
PBs

Boom
PBb

204
333
331
336
322
321
266
331
261
166

Pss

XAb

303
161

CRb
Ab

As

LCb

LCs

511
524
556
561

Bs

Bb

161
264
264

602

PAb

205

SECTION E-E

266

160
221
561
218
209
333
331
339
320
319
602
331
261

206

PAs

BbR

Bucket
PCc

201
333
331
336
322
321

Arm 1
PAa1

PBc

BcR

602

AaR

331
261
161

304
Bc

511
521
551
561

Aa

LCc

LCa

Ac
CRa
Ba

PLc2

264
603
205
SM1291

PAc
AcR

SECTION F-F

W2-3-8

PBa1

511
521
551
561
161
561
556
524
514
156
167
160 x 2
302
264
211
205

CONTROL VALVE

E175B-E195B

Control valve (5/6)

201
333
331

Arm 2

Option

PAa2

201
333
331
337

PAo

339
326

330
329
604
331
261
311

325
331
261

AoR

161

MU1

308
162
515
521
551
561
561

Ao

511
LCAP2

521
LCo

551

LCAT2

561

551
521
511

Bo
Ba

162
162
162

264
PBa2

264

606
205

PBo

SECTION G-G

205

BaR

605

605
PBp1

PBp2

Bo

BoR

166
153

SECTION H-H

W2-3-9

604
SM1292

E175B-E195B

CONTROL VALVE

Control valve (6/6)

T2

P1

T1

511
521
CT1

551
561
511
P2

521

(MU2)

CT2

551
561

162
SECTION J-J

278 x 5
160
266
207
267

267

528
527
T1

T2

517

SECTION K-K

W2-3-10

518

SM1293

CONTROL VALVE

Tightening torque
Nm (lbfft)

25~29 (19~21)

No.

Parts Name

Q.ty

No.

Parts Name

Q.ty

101 Casing A

309 P1 unload spool

102 Casing B

310 P2 unload spool

153 Plug

311 Option spool

319 Spring

320 Spring

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

110~130 (81~96)

Tightening torque
Nm (lbfft)

E175B-E195B

155 Plug PF1/2

13~17 (9~12)

156 Plug PF 1/8

321 Spring

20~24 (15~18)

159 Plug PT1/4

322 Spring

7.8~9.8

160 Plug PT1/16

325 Spring

161 O-ring

13

326 Spring

162 O-ring

327 Spring

163 O-ring

328 Spring

164 O-ring

329 Spring

166 O-ring

330 Spring

167 O-ring

331 Spring seat

24

333 Spacer bolt

12

201 Cover

202 Cover

336 Stopper

203 Cover

337 Stopper

204 Cover

339 Stopper

205 Cover

511 Poppet

11

512 Poppet

514 Poppet

209 Cover

515 Poppet

211 Lock valve selector sub

517 Boost check valve

212 Plate

518 Poppet

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

16~18
Loctite #262

check

213 Plate

521 Spring

11

216 Boom lowering valve

522 Spring

218 Piston

524 Spring

221 Plug

527 Spring

261 O-ring

12

528 Spring

264 O-ring

130~150 (96~111)

551 Plug

12

266 O-ring

130~150 (96~111)

556 Plug

267 O-ring

561 O-ring

18

25~34 (18~25)

273 Socket bolt

40

98~120 (72~89)

274 Socket bolt

130~150 (96~111)

69~78 (51~58)

567 O-ring

601 Main relief valve

98~120 (72~89

275 Socket bolt

69~78 (51~58)

602 Over load relief valve

9.8~14 (7.2~13)

278 Socket bolt

69~78 (51~58)

603 Over load relief valve

9.8~14 (7.2~13)

279 Socket bolt

69~78 (51~58)

604

301 Boom spool sub

98~120 (72~89)

605 By-pass cut valve

302 Arm 1 spool

69~78 (51~58)

606 Over load relief valve

303 Swing spool

304 Bucket spool

305 Boom conflux spool

306 Travel spool

307 Travel priority spool

308 Arm 2 spool sub

Plug assy for relief valve

hole

140~180 (103~133) 973 Socket bolt

W2-3-11

E175B-E195B

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.

W2-3-12

SWING DEVICE

E175B-E195B

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 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

continuously while working.

the

vacuum

pump

W2-4-1

E175B-E195B

SWING DEVICE

Removal
1.

Remove hose (1) from the Tee in the makeup

port M.
: 36 mm
6

2.

Remove the hoses (2 and 3) from the Tee in the

drain port Dr.

: 27 mm
3.

Remove the hoses (4 and 5) from the elbows of

the A, B port.

2
3

: 36 mm

SM0701

4.

Remove the hose (6) from the elbow of the PG

port.
: 19 mm

5.

6.

Put in plugs into the opened ports on the swing

motor unit.

Remove the swing motor unit by loosing the

screws (7) (q.ty 13).
: 30 mm

7.

Remove the plastic cap (8) M12 at the top of the

swing motor and install the lifting eye bolt.
: 36 mm

8.

Sling and remove the swing unit.

NOTE: swing unit weight: about 202 kg (445 lbs).

W2-4-2

SM0702

SWING DEVICE

E175B-E195B

Installation
1.

Clean mating surfaces of swing motor unit and

upper frame.

2.

Apply Loctite #515 on entire mounting surface

of swing motor unit.

3.

Place the swing unit on the upper frame.

NOTE: swing unit weight: about 202 kg (445 lbs).

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).
Apply Loctite #262.
: 30 mm

SM0702

6
4

: 539 54 Nm (400 40 lbfft)

6.

Install the hoses (4 and 5) on the elbows of port

A and B.

: 36 mm
: 167 Nm (123 lbfft)
7.

SM0701

Install the hose (6) on the elbow of port PG.

: 19 mm
: 36 Nm (26.6 lbfft)

8.

Install the hoses (2 and 3) on the tee in the drain

port Dr.
: 27 mm
: 74 Nm (55 lbfft)

9.

Install the hose (1) on the make up port M.

: 36 mm
: 167 Nm (123 lbfft)

W2-4-3

E175B-E195B

SWING DEVICE

DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

33
27

44

20

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

16
A

43

29

42

12 30
32
37

35
36
4

41
25

26

24

6
40

8
9

A-A

45
18
11

28

34

10
SM0703

12345678910 11 12 13 14 15 -

Relief valve (q.ty 2)

O-Ring (q.ty 2)
Swing shockless valve
Shockless valve casing
Drive shaft
Cylinder
Spring
Piston (q.ty 9)
Shoe
Set plate
Shoe plate
Valve plate
Plug (q.ty 2)
O-Ring (q.ty 2)
O-Ring (q.ty 2)

16 17 18 19 20 21 24 25 26 27 28 29 30 31 32 -

O-Ring (q.ty 2)
Socket bolt (q.ty 4)
Swing motor casing
Valve casing
Plunger (q.ty 2)
Spring (q.ty 2)
Swing shockless valve (q.ty 2)
O-Ring (q.ty 2)
Backup ring (q.ty 2)
Socket bolt (q.ty 4)
Roller bearing
Plug (G 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.ty 3)
Separation plate (q.ty 4)
Plug (G 1/4)
Roller bearing
Plug (G 3/4) (q.ty 3)
Plug (PT 1/2)
Plug (PT 3/4)

SWING DEVICE

E175B-E195B

Preliminary operations
1.

Hydraulic components are precision products

and have small clearance. Therefore,
assemble and disassemble in a less dusty
clean place. Use clean tools and cleaning oil
and handle components with full care.

3.

Study the structural drawing before the work

begins and prepare necessary parts according
to your purpose and the scope of work. Seals
and O-Rings once removed can not be used
again.

2.

If a component is removed from the main body,

clean the area around the ports thoroughly and
plug them up so no dust and water do not enter.
When fitting them back to the body, do not
remove the plugs till piping is completed.

4.

The piston and the cylinder block are shop fitted

when new. If you intend to reuse them, put a
matching mark on the piston and the cylinder
block.

Disassembly
1.
2.

Remove the drain plug and drain hydraulic oil

from casing (18).

Fix the motor on a work bench so the drive shaft

(5) end comes down. On that occasion, put a
matching mark on the mating parts of casing
(18) and valve casing (19).

17

12
1

19
38

NOTE: choose a clean place, and lay with a rubber

sheet or a cloth on a work bench. Handle the valve
casing with care so parts do not have dents.
3.

18

Loosen relief valve (1) and separate it from

valve casing (19).
: 41 mm

4.

Loosen anti-reaction valve sub assy (3) and

remove from valve casing (17).
5

: 6 mm
5.

Separate plugs (31) from valve casing (19) and

draw out springs (21) and plungers (20).
: 17 mm

6.

SM0704

27

Loosen socket bolts (27) and separate valve

casing (19) from casing (18).
: 17 mm

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).

20
21

: 17 mm
31
SM0705

W2-4-5

E175B-E195B
8.

9.

SWING DEVICE

Draw out brake spring (38) from brake piston

(35).
Draw out the brake piston (35) with the special
tool (A) (xxxxxxxxx).

38

(A)

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.

11

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.
c. Separate the outer race of roller bearing (42)
from valve casing (19), using a slide hammer
bearing puller.
5

IMPORTANT: do not reuse the bearing.

10

39

40

6
SM0707

5
34
28
18
SM0708

W2-4-6

SWING DEVICE

E175B-E195B

Assembly
1.

Place casing (18) on a proper bench facing

upward.

The following operations are necessary only when

the roller bearings (28) and (42) are removed:
a. Shrinkage fit the inner race of roller bearing
(28) into drive shaft (5).
b. Shrinkage fit the inner race of roller bearing
(42) to drive shaft (5).
c. Fit oil seal (34) to casing (18).
d. Assemble the outer race of roller bearing (28)
into casing (18), by lightly tapping the steel
rod.
2.

Attach drive shaft (5) to casing (18).

3.

Insert shoe plate (11).

4.

Set the set plate (10) and spring (7), then set
piston sub (8, 9) assy.

34 28 18
SM0709

5.

Assemble piston sub assy (8, 9) fixed in

retainer plate (10) into cylinder (6), match it to
the spline of drive shaft (5) and insert it in place.

6.

Place casing (18) with oil seal facing downward

and assemble separator plate (40) and friction
plate (39) into casing (18).

11
10

5
SM0710

39

40

SM0711

W2-4-7

E175B-E195B

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

: 430 Nm (318 lbfft)

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 (274 lbfft)
14. Fit relief valve (1) to valve casing (19).
: 41 mm
5

:177 Nm (131 lbfft)

SM0713

15. Fit anti-reaction sub assy (3) to valve casing

(19).
27

: 6 mm
: 69 Nm (51 lbfft)

20
21

31
SM0705

W2-4-8

SWING DEVICE

E175B-E195B

DISASSEMBLY AND ASSEMBLY OF SWING REDUCER

19

28

16

6
20
3

10

15

12

18
17
5
9

23

22

31
32
25

26

13
24
27

21

11

30
SM0714

12345678910 -

Pinion shaft
#1 sun gear
#1 pinion (q.ty: 3)
#2 sun gear
#2 pinion (q.ty: 4)
Ring gear
#1 spider assy
#2 spider assy
Shaft (q.ty: 4)
Spherical bearing

11 12 13 15 16 17 18 19 20 21 -

Spherical bearing
Oil seal
Housing
Thrust washer (q.ty: 6)
Needle bearing (q.ty: 3)
Needle bearing (q.ty: 4)
Thrust washer (q.ty: 8)
Snap ring
Snap ring
Sleeve

W2-4-9

22 23 24 25 26 27 28 30 31 32 -

Spring pin (q.ty: 4)

Socket bolt (q.ty: 11)
Cap (q.ty: 2)
Tube
Elbow
Plug
Snap ring (q.ty: 3)
Oil seal
Grease fitting
Relief fitting

E175B-E195B

SWING DEVICE

Preliminary operations:
1.

Before disassembly, clean thoroughly the

swing reduction unit outer, checking for no
damage or scratches.

2.

Drain out the gear oil from reduction unit.

3.

Remove the draining pipe.

4.

In order to case the re-assembly, before

disassembly put a matching mark (X) on the
parts to be connected on the reduction casing.

23

x
x

27

SM0715

Disassembly
1.

Place the reduction unit assy on a stable work

bench as shown in figure, remove plug (27),
drain out oil put a matching mark on the
matching surface of the figure on the right side.

2.

Loosen all socket bolt (18) (M14). Attach eye

bolts (M10) in the lifting bolt holes in the top
surface of the swing motor and lift the assy by
crane.
If it is hard to remove the swing motor assy from
the reduction unit, float it by inserting a flatblade screwdriver in the groove of the flange.

SM0716

: 12 mm
3.

Remove #1 sun gear (2).

4.

The spider assy (7) [consisting of thrust

washers (15), #1 pinions (3), needle bearings
(16) and snap rings (28)] can be removed from
the spline easily if it is lifted up in that condition.

5.

6.

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.

6
13

SM0717

Draw out #2 sun gear (4) and remove the #2

spider assy (8).

SM0718

W2-4-10

SWING DEVICE

E175B-E195B

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 (B) (xxxxxxxxx).

SM0719

NOTE: spherical bearing (upper) (10) and oil seal

(12) are left in the housing.
9.

20

Pull oil seal (30), sleeve (21) and spherical

bearing (lower) (11) out by means of special
tools (C) (xxxxxxxxx) and (D) (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.

(B)

SM0720

(C)
21
30
11

(D)

SM0721

W2-4-11

E175B-E195B

SWING DEVICE

10. Set housing (13) as shown in the figure, insert

special tool (E) (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).

(E)
SM0722

NOTE: the shaft attached to spider assy (17) is

caulked. When replacing parts, replace the spider
assy as a set. Pinions (3) can not be replaced singly.
Replace them in a set of three.

15

16 28

13. Disassembling #2 spider assy performing the

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

9
18
5

24
18
22
SM0724

W2-4-12

SWING DEVICE

E175B-E195B

Assembly
1.

Sufficiently clean every part with wash oil and

dry it with compressed air.

2.

Check on every part for failure.

(F)
30

3.

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

special tool (F) (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 (G) (xxxxxxxxx).
Press force: 4~5 t

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

(G)

11

SM0727

W2-4-13

E175B-E195B

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 (H) (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

(H)

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 (L) (xxxxxxxxx).

E175B-E195B

(L)

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

16 28

15

15

SM0733

W2-4-15

E175B-E195B

SWING DEVICE

13. Assemble #2 Spider assy performing the

following operations.

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

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

14. Insert #2 spider assy (8) in spline axis of pinion

shaft.

6 - 7 mm

18
5

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

upward.

17

A
22
SM0734

SM0735

SM0736

W2-4-16

SWING DEVICE

E175B-E195B

16. Apply a thin film of sealant Loctite #515 to the

matching surface of housing (13) and ring gear
(6) and assemble them, aligning the gear teeth
and according to the matching marks given.

6
13

17. Mesh the #1 spider assy (7) with ring gear (6)
and set them in place.

18. Mesh #1 sun gear (2) with #1 pinions (3) and

set them in place.
19. Fit drain tube (25) and plug (27).

SM0737

: 12 mm
: 69.1 4.4 Nm (51.1 3.2 lbfft)

20. Fill in 3 L of gear oil (API GL-4).

21. Attach eye bolts (M10) in the tapped holes of
the swing motor and put a wire sling in them.
Coat the matching surface of ring gear (6) with
sealant Loctite #515.
Insert the spline joint of the swing motor and
match the matching marks. Coat socket bolts
(23) with sealant Three-Bond 1360K and fasten
them.

: 12 mm

SM0738

: 181 18 Nm (134 13 lbfft)

23

x
x

25
27

SM0739

W2-4-17

E175B-E195B

SWING DEVICE

MAINTENANCE STANDARDS
Swing motor

Unit: mm (in)
Item

Standard
dimension

Recommended
value for
replacement

0.027
(0.0010)

0.052
(0.0020)

Replace piston or cylinder.

0
(0)

0.3
(0.0118)

Replace piston and shoe assy.

5.5
(0.2167)

5.3
(0.2088)

Replace piston and shoe assy.

2.0
(0.0788)

1.8
(0.0709)

Replace.

Remedy

Clearance between piston and cylinder

bore (D-d)

D
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

Standard surface
roughness

Surface roughness
requiring correction

Shoe

0.8Z (Ra=0.2) (lapping)

3Z (Ra=0.8)

Shoe plate

0.4Z (Ra=0.1) (lapping)

3Z (Ra=0.8)

Cylinder

1.6Z (Ra=0.4) (lapping)

12.5Z (Ra=3.2)

Valve plate

0.8Z (Ra=0.2) (lapping)

6.3Z (Ra=1.6)

NOTE: lap each sliding surface to a standard roughness level or finer. If the spherical sliding surface of the
spring (7) and cylinder (6) are roughened, replace parts in pairs.

W2-4-18

SWING DEVICE

E175B-E195B

Swing reduction gear

A D

C
D
E
C
B

SM0740

Code

Item

Repairable level (mm)

Wear in #1 planetary shaft

0
39 -0.011

Wear in #2 planetary shaft

0
29 -0.009

Service Limit (mm)

No flaking
B

Remedy
Replace
spider assy

entire

Replace four shafts

as a set

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

tooth face
abnormal wear or seizure
pinion should be
replaced in a set of
Condition of
There should be no cracks
four.)
tooth flank

Gears

Thickness of thrust washer

0
1,6-0.2

1.3

Replace

Thickness of thrust washer

0
2.0-0.2

1.6

Replace

Wear in shaft (diameter of

part coming in contact with
oil seal)

94.9

Replace

0
95-0.087

W2-4-19

E175B-E195B

SWING DEVICE

SPECIAL TOOLS
Dimension: mm (in)

Descrption

Item

Note
14 (0.551")

85 (3.35")
75 (2.95")
30 (1.18")

35 (1.38")

15 (0.591")

M16
100 (3.94")

Piston brake puller

4
(0.158")

44 (1.73")
8 (0.315")

(A)

5
2. 2")
R1 .49
(0

M18

o 8 (0.315")

o 412 (16.23)

Material : mild steel

230 (9.06)

Support

Material : mild steel

(C)

Bearing (10) removing jig

190(7.48) 22(0.86)

(B)

o 270 (10.64)

o 162(6.38)

n.13-o 16
n.13-(o .06)
P.C.D 146 (5.75)

VIEW X
SM1359

W2-4-20

SWING DEVICE

E175B-E195B

Dimension: mm (in)

Descrption

Note

Bearing (11) removing jig

Material : mild steel

Material : mild steel

(G)

(H)

o 125 (4.95)

Oil seal (30) installing jig

Material : mild steel

o 105 (4.14)

Material : mild steel

o 140 (5.51)

Bearing (11) press-fit jig

o 95 (3.74)

Oil seal (12) intalling jig

50

Material : mild steel

(L)

o 150 (5.91)

t=10 or more

160 (6.3) or more

(F)

85

9 (0.35)

Bearing (10) removing jig

) t=4.5

35

.
(3

(1.97)

(E)

10 (0.39)

Bearing (10) press-fit jig

9 (0.35)

(D)

o 165 (6.5)

100 (3.94)

Material : mild steel

o 91(3.58)

60 (2.36)

Item

o 158 (6.22)

SM1360

W2-4-21

E175B-E195B

SWING DEVICE

NOTES:

W2-4-22

PILOT VALVE

E175B-E195B

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

E175B-E195B

PILOT VALVE

Installation
1.

Install pilot valve (9) on the frame tightening

securing screws (20) M6x25 complete with
washers.




: 5 mm

: 11.8 Nm (8.7 lbfft)

2.




Connect hoses to pilot valve body (9).

: 19 mm (Port: P)

3


60

: 29.4 Nm (22 lbfft)

: 22 mm (Port: 1 to 8, T)

LEFT SIDE

: 49 Nm (36 lbfft)
3.

Tighten the handgrip on the pilot valve (9),

tighten lock-nut (6) and reconnect the electric
connector.
: 22 mm

4.

Install side panels (2) and (3) tightening

securing screws.

5.

Arrange rubber cap (5) complete with plate (4)

locking the hooks on side panel (2).

RIGHT SIDE
BUCKET
1
(H)

RED

BUCKET
(R)

BLUE

5 SWING (L)

GRAY

6 SWING (R)

RED

7 ARM (H)

BLUE

3 BOOM (H)

GREEN

8 ARM (R)

GREEN

4 BOOM (R)

GRAY








60

W2-5-2

PILOT VALVE

E175B-E195B

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

E175B-E195B

PILOT VALVE

Installation
1.

Install body (8) on the frame tightening securing

screws (9) complete with washers.
: 17 mm
: 37 Nm (27.4 lbfft)

2.

Connect pipes (from 3 through 6) to body (8).

: 19 mm
: 16.7 Nm (12.3 lbfft)
: 22 mm
: 30 Nm (22.0 lbfft)

3.

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



: 24 mm

: 16.7 Nm (12.3 lbfft)

4.

Install the levers tightening securing screws (2)

and the pedals tightening securing screws (1).

: 17 mm
: 46.1 Nm (34.1 lbfft)

: 13 mm

: 23.5 Nm (17.4 lbfft)

5.

Install the cover under the cab

: 19 mm
: 108 Nm (80.0 lbfft)

W2-5-4

60

PILOT VALVE

E175B-E195B

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

E175B-E195B

PILOT VALVE

Disassembly right and left pilot valve

Be sure to thoroughly read "Precautions for
Disassembly and Assembly" on page W1-1-1
before starting the disassembly work.
NOTE: replace O-Ring
operations, as a rule.

every

disassembly

1.

Plug each port of pilot valve, and clean it.

P Port : PF 1/4
14 Port and T: PF 3/8

2.

Fix pilot valve with vise, via a protective plate

(Alminum plate etc.), and remove boot (2).

3.

Remove adjusting nut (1) applying spanners to

circular plate (3).

60

: 22, 32 mm
4.

Remove circular plate (3).

: 32 mm


5.

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

(380001055) to remove it.
: 24 mm

60

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

(


60

W2-5-6

PILOT VALVE
6.

E175B-E195B

Remove plate (5).



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

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

60




60

7.

Pull plug (7) out with a driver.

WARNING

To prevent personal injury, plug (7) must be

removed slowly and evenly until the return spring
(15) force is completely released

8.

Remove push rod (9), plug (7), pressure

reducing valve assy (spool) and the return
springs (15) from casing (22).

NOTE: record combination of port holes on casing

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

60







60

W2-5-7

E175B-E195B
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

E175B-E195B

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

E175B-E195B

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.

E175B-E195B

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

E175B-E195B
7.

PILOT VALVE

nstall joint (4) on casing (22) with special tool

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


(

60

8.

Install circular plate (3) to joint (4).

IMPORTANT: screw it in until it comes in contact

with 4 push rods (9) equally.
The exceeding of screw in may cause malfunction of
machine.

9.

Screw adjusting nut (1), applying Loctite #277

to the thread of joint, until it touches circular
plate (3), and tighten it applying spanner to stop
circular plate returning.
60

: 22 mm
: 68.64.9 Nm (503.6 lbfft)
: 32 mm
*

10. Apply heat-resisting grease (G) to joint (4)

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



60

11. Cover it with boots (2).

12. Spray rust preventives through each port and
attach plug respectively.

60

W2-5-12

PILOT VALVE

E175B-E195B

PILOT VALVE (FOR TRAVEL)

CONSTRUCTION

R
R

K

R
\


\
[

[




I
G
/RFWLWH
J
7 
J



7 


U

X
W 7 




L 7 
N 7 
K





X
W 7 




M

X


T
7 



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7 aa
60

No.

Parts

NOTE: T=tightening torque Nm (lbfft)

Q.ty
No.
Parts

Rubber boots

Foot pedal (Switch plate)

2
(2)

Q.ty

12-x Seal 14203

12-y Wiper ring

6-d

Switch plate

13

Damper spring

6-f

Regulation screw M828

14

Check valve kit

(2)

6-g

Set screw M5x8

14-q Plug M8

6-l

Damping screw

14-r Ball M6, 35

Retaining plate kit

7-h

Plate

7-i
7-j
7-k

(1)

15

Orifice

15-u Plug M6

Capscrew M1020

15-t Orifice M6, 0.6

Shaft

17

(4)
4
4

Shuttle valve kit

(2)

17-w Shuttle valve & orifice

Set screw M410

Flange kit

17-r Ball M6, 35

10

Control spool

17-z Orifice M5, 0.8

11

Return spring

21

Plug

12

Damper flange kit

(4)

22

Valve body

12-o Damper plunger 14

W2-5-13

2
2

E175B-E195B

PILOT VALVE

DISASSEMBLY AND ASSEMBLY

1.

Boot replacement


NOTE: the pilot control unit does not need to be
removed from the machine to perform this
operation.

1) Remove both faulty boots.

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

K

60

2.

Switch plate removal

1) Remove:
The pilot control unit from the machine
Both rubber boots
2) Remove the screw (7-k) locking the axis
using a 2 mm socket wrench. (See Fig.
SM0757 A)
* Reassembly:
Apply a droplet of Loctite #262 on the
locking screw thread.
Torque: 1.2 Nm (0.89 lbfft)
3) Fit a M3 screw on the switch plate axis (7-j)
in order to remove it (Using pliers if
necessary). (See Fig. SM0757 B)
* Reassembly:
Position the axis so that the hole (f) is
aligned with the locking screw (7-k) as
shown on the picture (See Fig. SM0757 C)
4) Mark out the position of the switch plate
before removing it.
5) Repeat the operation for the second switch
plate.
6) Reassemble parts in reverse order.

W2-5-14

N
&

M

'

60

PILOT VALVE
3.

E175B-E195B

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 (lbfft)
2) Set the switch plate (6) horizontally
3) Screw on simultaneously both regulation
screws (6-g) using a flat screw driver
(5.5x150) until feeling some resistance.
NOTE: do not misadjust the two damping screws
(6-l).

J


60

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

regulation screws (6-f) in position.
5) Repeat the operation for the second switch
plate making sure both switch plates are
parallel.

O

I
4.

Retaining plate removal (7-h)

1) Remove
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 lbfft)


60


L
K

60

W2-5-15

E175B-E195B

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.
8) Reassemble parts in reverse order.
6.

E175B-E195B

[

[

&

'

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

E175B-E195B

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.



8) 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

E175B-E195B

3) Unscrew the throttle (15-t) using a 3 mm

socket wrench.
* Reassembly:
Torque: 4 Nm (3 lbfft)
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 lbfft)
60

IMPORTANT: wait for 8 hours before using the

machine to let the Loctite #242 dry completely.

Z

60

W2-5-19

E175B-E195B

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 lbfft)
3) Put the body (22) up-side-down to remove
the ball (14-r).
4) Repeat the operation for the second check
valve kit.
5) Inspect the check valve plugs (14-q), Orings and balls (14-r). If defects are
detected, replace all the assemblies.
6) Reassemble parts in reverse order.

60


T

U

W2-5-20

60

PILOT VALVE

E175B-E195B

DRAIN OF HYDRAULIC PILOT CONTROL UNIT

1.

When removing the retaining plate, the throttle

kit or the shuttle valve kit, it is necessary to
drain the pilot unit.

2.

Reassemble the pilot unit control completely.

3.

Install the pilot unit control in the machine.

4.

Slightly unscrew the check valve plug (14-q)

using a 4 mm socket wrench

5.

Switch on the machine.

6.

Operate gently the pedal until the bubbles

disappear.

7.

Tighten the check valve plug (14-q).

Torque: 5 Nm (3.7 lbfft)

8.

Repeat the operation for the other check valve

plug.

T

W2-5-21

60

E175B-E195B

PILOT VALVE

NOTE:

W2-5-22

SECTION 3

E175B-E195B

UNDERCARRIAGE

CONTENTS
Group 1 - Swing bearing

Group 6 - Upper and lower roller

Removal and installation of swing

bearing ................................................ W3-1-1

Removal and installation of upper

roller .................................................... W3-6-1

Tool table ............................................. W3-1-2

Removal and installation of lower

roller .................................................... W3-6-4

Group 2 - Travel device

Removal and installation of travel
device.................................................. W3-2-1
Disassembly travel device .................. W3-2-2
Disassembly travel device (E175B) .... W3-2-3
Assembly travel device (E175B) ......... W3-2-25
Disassembly travel device (E195B) .... W3-2-51
Assembly travel device (E195B) ......... W3-2-78
Removal and installation of sprocket
(E175B-E195B)................................... W3-2-109
Maintenance standard ......................... W3-2-111
Tool table E175B ................................. W3-2-112
Tool table E195B ................................. W3-2-112

Group 3 - Swivel joint

Removal and installation of swivel joint W3-3-1
Swivel joint disassembly and assemblyW3-3-4
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
Tool table ............................................. W3-5-4

Upper roller disassembly...................... W3-6-7

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

E175B-E195B

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:

212 kg (467 lbs) (E175B); 243 kg (536 lbs) (E195B).
3.

Attach lifting tools (380001026), hoist swing

bearing (4) and remove it.


60

W3-1-1

E175B-E195B

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:

212 kg (467 lbs) (E175B); 243 kg (536 lbs) (E195B).

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 lbfft)

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

E175B-E195B

REMOVAL AND INSTALLATION OF TRAVEL 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.
Preparation
3.

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.

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

continuously while working.

the

vacuum

pump

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 lbfft)
: 27 mm
: 78.5 5 Nm (57.9 3.7 lbfft)
: 36 mm
: 177 18 Nm (130.5 13 lbfft)

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) (E195B),
approx. 245 kg (540 lbs) (E175B).
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 lbfft) (E195B)
: 320 32 Nm (236 23 lbfft) (E175B)

E175B-E195B

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 lbfft)

Preliminary operations

NOTE: 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.

3
2

1
6

7
9

SM0300

NOTE: Initial inspection of hydraulic motor and

gears, can be made without disassembling the track
drive from the machine.
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

E175B

DISASSEMBLY TRAVEL DEVICE (E175B)

Gearbox disassembly

1.

Make sure that the oil is discharged.

2.

Unscrew the socket bolts (1) (Q.ty 10) which fix

the end cover (2) to the gearbox housing (3).
: 8 mm


60

3.

Remove the end cover (2) by using screws (4)

screwed into the oil plugs holes.
: 32 mm

60

W3-2-3

E175B
4.

TRAVEL DEVICE

Remove the O-Ring seal (1) from the end cover

(2).


60

5.

Take out 1st stage sun gear (3).

60

6.

Remove the 1st reduction assembly (4).

60

7.

Take out 2nd stage sun gear (5).

60

W3-2-4

TRAVEL DEVICE
8.

E175B

Remove the 2nd reduction assembly (1).

60

9.

Take out 3rd stage sun gear (2).

60

10. Unscrew the socket bolts (3) (Q.ty 4), which fix
the 3rd reduction assembly to the hydraulic
motor.

60

rd

11. By using a puller, remove the 3 reduction

planet carrier (4) from the hydraulic motor (5).



60

W3-2-5

E175B

TRAVEL DEVICE

12. By using the puller (A) (380001076), remove

the bushes (1) (Q.ty 4) from the hydraulic motor
or from the 3rd reduction planet carrier (2).




60

13. By using the puller (A) (380001076) remove

the planet assemblies of the 3rd reduction (2).

60

14. Lift the gearbox housing (3) positioning it on 2

spacers. By using a press and a metal stopper,
remove the hydraulic motor (4) from the
gearbox housing (3) paying attention to the
eventual falling down of the main bearing's
balls.

60

15. Use a screwdriver to remove the

(5) from the hydraulic motor (4).

1st

half-seal


60

W3-2-6

TRAVEL DEVICE

E175B

16. Use a screwdriver to remove the 2nd half-seal

(1) from the gearbox housing (2).

60

17. Use a puller to remove the bearing inner race

remaining on the hydraulic motor (3).

60

18. Remove the bearing balls from the gearbox

housing (4).

60

W3-2-7

E175B

TRAVEL DEVICE

Disassembly hydraulic motor

DISASSEMBLY OF THE TWO SPEED CONTROL
ASSY
1.

Unscrew the plug (1) from the base plate (2).

60

2.

Remove the O-Ring seal (3) from its seat in the

plug (1).

60

3.

Remove the O-Ring seal (4) from its seat in the

plug (2).


60

W3-2-8

TRAVEL DEVICE
4.

E175B

Take out the spring (1).


60

5.

Unscrew the plug (2) from the base plate.


6.

60

Remove the O-Ring seal (3) from its seat in the

plug (2).


60

7.

Take out the two speed spool (4).

W3-2-9

60

E175B

TRAVEL DEVICE

DISASSEMBLY OF THE RELIEF VALVE.

1.

Unscrew the relief valve (1) from the base plate

(2).


2.

60

Take out the free piston (3) from the relief valve
(1).


60

3.

Remove the O-Ring seal (4) and the backup

rings (5) from their seats in the free piston (3).


4.

60

Remove the O-Ring seal (6) from relief valve

(1).
Repeate the same steps for the 2nd relief valve
disassembly (1).

W3-2-10

60

TRAVEL DEVICE

E175B

DISASSEMBLY OF THE COUNTERBALANCE

VALVE
1.

Unscrew the socket bolts (1) (Q.ty 4), of the 1st

flanged plug assy (2)
: 8 mm


60

2.

Take out the 1st flanged plug (2) and the spring
seat.


60

3.

st

Remove the 1 spring (3).


60

4.

st

Take out the 1 spring seat (4) from the

counterbalance valve spool (5).




W3-2-11

60

E175B
5.

TRAVEL DEVICE

Unscrew the socket bolts (1) (Q.ty 4), of the 2nd

flanged plug assy (2).
: 8 mm


6.

60

Take out the 2nd flanged plug (2) and the spring
seat.


60

7.

Remove the 2nd spring (3).

60

W3-2-12

TRAVEL DEVICE
8.

Take out the 2nd spring seat (1) from the

counterbalance valve spool (2).

E175B

60

9.

Take out the counterbalance valve spool (3).

60

DISASSEMBLY OF FLANGED PLUG

1.

Remove the O-Ring seal (2) from the flanged

plug (4).

60

2.

Unscrew the plug (5) from the flanged plug (6).


60

W3-2-13

E175B
3.

TRAVEL DEVICE

Take out the spring (1) from the plug (2).



60

4.

Remove the O-Ring seal (3) from the plug (2).


5.

60

Take out the ball (4) from the flanged plug (5).
Repeat the same steps for the 2nd flanged plug
disassembly.




W3-2-14

60

TRAVEL DEVICE

E175B

DISASSEMBLY OF THE BASE PLATE.

1.

Unscrew the plugs (1) from the base plate (2).


2.

60

Remove the O-Ring seal (3) from the plug (4).


60

3.

Unscrew the conical plugs (5) from the base

plate (2).

60

4.

Unscrew the conical plugs (5) from the base

plate (2).

W3-2-15

60

E175B
5.

TRAVEL DEVICE

Unscrew the orifices (1) from the base plate.


6.

60

Remove the caulking with a M5 tap before

unscrewing the orifices (2).

60

7.

Unscrew the orifices (2) from the base plate.


60

8.

Unscrew the plug (3) from the base plate.

60

W3-2-16

TRAVEL DEVICE
9.

Remove the O-Ring seal (1) from its seat in the

plug (2).

E175B

60

10. Unscrew the socket bolts (3) (Q.ty 9), of the

base plate.
: 12 mm


60

11. Remove carefully the base plate (4) until pins

are completely out.

60

12. Remove the caulking in the brake pilot hole in

the base plate (4) with a M5 tap.


60

W3-2-17

E175B

TRAVEL DEVICE

13. Unscrew the orifice (1) from the base plate.

60

14. Take out the pins (2).

60

15. Remove the valve plate (3).

60

16. By using a puller, remove the bearing (4) from

the base plate (5).

60

W3-2-18

TRAVEL DEVICE
DISASSEMBLY OF MOTOR SHAFT AND
CYLINDER BLOCK
1.

E175B

Remove the O-Ring seal (1) from its seat in the

flanged hub (2).

60

2.

Remove the O-Ring seal (3) from its seat of the

brake pilot hole in the flanged hub (2).


60

3.

Remove the O-Ring seals (3) from their seat of

the two speed control holes in the flanged hub
(2).

60

4.

Remove the springs (4) from the brake piston.

60

W3-2-19

E175B
5.

TRAVEL DEVICE

Mark the position of the brake piston (1) as a

reference for the reassembling step.

60

6.

Remove the brake piston (1).

60

7.

Remove the O-Ring seals (2) and the backup

rings from their seats in the brake piston (1).


60

8.

Take out the brake disc (3).


60

W3-2-20

TRAVEL DEVICE

9.

E175B

Remove the cylinder block (1).

60

10. Take out the spherical retainer plate holder (2).

60

11. Take out the pins (3) (Q.ty 3) from their seats in
the cylinder block (1).


60

W3-2-21

E175B

TRAVEL DEVICE

12. Disassemble the pistons and the retainer plate

(1).

60

13. Take out the pistons (2) from the retainer plate
(3).


60

14. Remove the swash plate (4) from the flanged

hub (5).




60

15. Take out the steel balls (6) (Q.ty 2) from their
seats in the flanged hub (5).




60

W3-2-22

TRAVEL DEVICE
16. Take out the two speed control pistons (1)
(Q.ty 2).

E175B

60

17. Take out the two speed control springs (2)

(Q.ty 2).

60

18. By using a punch, take out the motor shaft and

the bearing from the the flanged hub.

60

19. By using a puller, take out the bearing (3) from

the motor shaft (4).


60

W3-2-23

E175B

TRAVEL DEVICE

20. By using a screwdriver remove the seal ring (1)

from its seat in the flanged hub.
NOTE - Disassemble the seal ring only in case of
replacement, because this will damage it.


60

W3-2-24

TRAVEL DEVICE

E175B

ASSEMBLY TRAVEL DEVICE (E175)

Preliminary operations
When proceeding with the gearbox reassembly, it is
necessary to follow the rules listed below:
1.

In case of damaged gears, for example a

planet, do not replace the single gear, but the
whole reduction stage.

2.

Replace always the O-Rings and seal rings of

the part to be reassembled after having
carefully cleaned the seats and having buttered
some grease on the seats themselves and on
the O-Rings to make easier the reassembly.

3.

Always replace all the components that seems

to be damaged or with excessive wear, with
original spare parts.

Hydraulic motor assembly

ASSEMBLY OF MOTOR SHAFT AND CYLINDER
BLOCK
1.

Place the seal ring (1) into its seat in the flanged
hub (2).

60

2.

By using the tool (B) (380001077) and a rubber

hammer push the seal ring against the seat
shoulder.

60

W3-2-25

E175B
3.

TRAVEL DEVICE

Place the bearing (1) on the motor shaft (2).


60

4.

By using a tool (C) (380001078) and a rubber

hammer push the bearing (1) against the motor
shaft shoulder (2).

&



60

5.

Place the bearing-motor shaft unit (4) in the

seat inside the flanged hub (5).

NOTE - Be careful when inserting the shaft inside

the motor seal, that must be greased.




60

6.

By using a tool (D) (380001079) hammer push

the bearing-motor shaft unit (4) against the
flanged hub shoulder (5).

'

60

W3-2-26

TRAVEL DEVICE
7.

E175B

Assemble the steel balls (1) (Q.ty 2) into their

seats (2) in the flanged hub.


60

8.

Assemble the two speed springs (3) into their

seats in the two speed pistons (4).


60

9.

Assemble the two speed pistons (4) (Q.ty 2)

into their seats inside the flanged hub.

NOTE - Be sure that the pistons can move freely

into the seats.

60

10. Insert the swash plate (5) inside the flanged

hub being careful that spherical housings (2)
match with the steel balls (1).

60

W3-2-27

E175B

TRAVEL DEVICE

11. Assemble the pins (1) (Q.ty 3) in their seats in

the cylinder block (2).

60

12. Assemble the spherical retainer holder (3) on

the cylinder block (2).
NOTE - The two splines must be aligned together.


60

13. Piston orifice (4) must be open and free of dust

or dirt.

60

14. Assemble correctly the pistons (4) (Q.ty 9) in

the retainer plate (5).

60

W3-2-28

60

TRAVEL DEVICE

E175B

15. Assemble the pistons-retainer plate unit (1) in

the cylinder block (2).


60

16. Assemble the cylinder block unit (2) into the

flanged hub (3) on the motor shaft spline (4).



60

17. Insert the brake disc (5) in the cylinder block

(2).


60

18. Assemble the backup ring (6) into its seat in the
brake piston (7).

60

W3-2-29

E175B

TRAVEL DEVICE

19. Assemble the O-Ring seals (1) into their seats

in the brake piston (2).
Assemble the backup ring (3) into its seat as
shown on the sketch below.

60

60

20. Assemble the brake piston (2) respecting the

markings set out previously and being careful
not to damage the seals already fitted.

60

21. Assemble the O-Ring seal (4) into its seat in the
flanged hub (5).

60

22. Assemble the O-Ring seal (6) into the brake

pilot hole of the flanged hub (5).




60

W3-2-30

TRAVEL DEVICE
23. Assemble the O-Ring seals (1) into their seats
in the two speed control holes in the flanged
hub.

E175B

60

24. Insert the springs (2) in their seats in the brake

piston (3).


60

W3-2-31

E175B

TRAVEL DEVICE

ASSEMBLY OF THE BASE PLATE

1.

Tighten the orifice (1) in the base plate (2).

: 2.5 0.5 Nm (1.85 0.35 lbfft)


60

2.

By using a punch (3) and a hammer deform the

thread hole.

60

3.

Assemble the bearing (4) into its seat in the

base plate (2).




60

4.

By using a tool (E) (380001080) and a rubber

hammer push the bearing (4) against the base
plate seat shoulder (2).

W3-2-32

60

TRAVEL DEVICE
5.

E175B

Place the valve plate (1) on the base plate (2).

NOTE - Bronze layer surface must be upwards.


60

6.

Insert the pins (2).

60
60

7.

Place the base plate (3) on the flanged hub (4).

NOTE - The base plate is centered by two pins and

the second speed oil passages must match together.

60
60

8.

Fix the base plate (2) to flanged hub (4) by

using socket head bolts (5) (Q.ty 9).

: 12 mm
: 205 10 Nm (151.7 7.4 lbfft)


60

W3-2-33

E175B
9.

TRAVEL DEVICE

By using the tool (F) (380001065) assemble the

O-Ring seals (1) in their seats in the plugs (2).

60

10. Tighten the plugs (2).

: 36.8 2.5 Nm (27.2 1.85 lbfft)

60

11. Tighten the orifices (3) in the base plate.

: 2.5 0.5 Nm (1.85 0.35 lbfft)

60

12. Seal the thread of the plugs (4) by Teflon tape.

Tighten the plugs in the base plate.
: 10 1 Nm (7.4 0.75 lbfft)

W3-2-34

60

TRAVEL DEVICE

E175B

13. Tighten the orifices (1) in the base plate.

: 2.5 0.5 Nm (1.85 0.35 lbfft)

60

14. By using a punch and a hammer deform the

thread hole.

60

ASSEMBLY OF THE FLANGED PLUG.

1.

Insert the ball (2) in the flanged plug (3).

60

2.

By using the tool (G) (380001066) assemble

the O-Ring (4) in its seat in the plug (5).

60

W3-2-35

E175B
3.

TRAVEL DEVICE

Insert the spring (1) into the plug (2).

60

4.

Tighten the plug (2).

: 20.6 1.0 Nm (15.25 0.75 lbfft)

60

5.

Assemble the O-Ring (3) in its seat in the

flanged plug (4).

60

ASSEMBLY OF THE COUNTERBALANCE VALVE

1.

Insert the counterbalance valve spool (5).

60

W3-2-36

TRAVEL DEVICE
2.

Insert the 1st spring seat

counterbalance valve spool (2).

(1)

on

E175B

the




60

3.

Insert the 1st spring (3) on the counterbalance

valve spool (2).




60

W3-2-37

E175B
4.

TRAVEL DEVICE

Assemble the 1st flanged plug (1) with proper

spring seat.

60

5.

Tighten the socket bolts (2) (Q.ty 4), of the 1st

flanged plug (1).

: 59 5 Nm (43.7 3.7 lbfft)

60

6.

Insert the 2nd spring seat

counterbalance valve spool (4).

(3)

on

the


7.

60

Insert the 2nd spring (5) on the counterbalance

valve spool (4).


60

W3-2-38

TRAVEL DEVICE
8.

E175B

Assemble the 2nd flanged plug (1) with proper

spring seat.

60

9.

Tighten the socket bolts (2) (Q.ty 4), of the 1st

flanged plug (1).

: 59 5 Nm (43.7 3.7 lbfft)

60

ASSEMBLY OF THE RELIEF VALVE

1.

By using the tool (H) (380001067) assemble

the O-Ring seal (3) in its seat in the relief valve
(4).




60

W3-2-39

E175B
2.

TRAVEL DEVICE

Assemble the 1st backup-ring (1) into its seat in

the free piston (2).


60

3.

Assemble the O-Ring seal (3) into its seat in the

free piston. After this step assembly the 2nd
backup ring as shown on the sketch below.



60


60

4.

Insert the free piston (2) in the relief valve (4)

checking that the groove side is toward inside
of the motor.

60

W3-2-40

TRAVEL DEVICE
5.

E175B

Insert the relief valve (1) inside the base plate

(2).

60

6.

Tighten the relief valve (1).

: 373 20 Nm (276 14.8 lbfft)


60

ASSEMBLY OF THE TWO SPEED CONTROL

1.

By using the tool (I) (380001068) assemble the

O-Ring (3) in its seat in the plug (4).


,


60

2.

Tighten the plug (4).

: 120 5 Nm (88.8 3.7 lbfft)

60

W3-2-41

E175B
3.

TRAVEL DEVICE

Insert the two speed spool (1) in the base plate

(2).

NOTE - Two speed spool have to move smoothly

inside its seat in the base plate.

4.

Insert the spring (3) in the two speed spool (1).

60


60

5.

Insert the spring seat (4) and the washer.


60

W3-2-42

TRAVEL DEVICE
6.

E175B

By using the tool (I) (380001068) assemble the

O-Ring seal (1) in its seat in the plug (2).


,


60

7.

Tighten the plug (3).

: 120 5 Nm (88.8 3.7 lbfft)

W3-2-43

60

E175B

TRAVEL DEVICE

Gearbox assembly
1.

Make ready of the lifetime seal.

Instructions to properly assemble the lifetime
seal:

b. Make sure that sealing surfaces (4) of metal

rings (5) are free from scratches, dinges or
foreign substances; metal ring surfaces
must be perfectly clean and dry.

c. Carefully clean the lapped surface (4) of

metal rings (5) and remove dust or
fingerprints. Then lubrificate them with a thin
oil film, taking care not to oil the other
components.

a. Carefully clean the seats (1 and 2) using, if

necessary, metal brushes or solvent
(surfaces in contact with or (3) must be
perfectly clean and dry).

2.


60

Assemble a half seal (7) on the tool (J)

(380001069).


60

3.

Assemble a half seal (8) on the hydraulic motor.


60

W3-2-44

TRAVEL DEVICE
4.

E175B

Clean carefully the metallic faces of the lifetime

seal (1), and lube them with a thin oil film.


60

5.

Fit the lower ball row (d), into the gearbox

housing (2) holding the inner raceway (c) with
spacers (a) and the tube (F) (380001081).

G
F





6.

Remove the spacer (a).

7.

Drop the upper ball row (e).

8.

Assemble the inner raceway (f).

60

I
H

60

W3-2-45

E175B
9.

TRAVEL DEVICE

By using the tool (J) (380001069), assemble

the half seal on the gearbox housing.
Clean carefully the metal faces of the halfseals.

60

10. By using a tackle position the hydraulic motor

(2) inside the gearbox housing (1).

60

11. By using a press and the tool (L) (380001082),

push the hydraulic motor (2) against the
shoulder of the gearbox housing (1) until
assembly of the unit is complete.

60

12. Screw the safety bush (M) (380001083) in one

of the four holes in the hydraulic motor by using
the socket bolts (3), and turn the unit upside
down.
At the end of above step disassemble the
safety bush.

0

60

W3-2-46

TRAVEL DEVICE

E175B

13. Place the bushes (1) (Q.ty 4) into their seats in

the hydraulic motor (2) and by using a press,
push them against the shoulder inside their
seats until assembly is complete.


60

14. Place the planet assemblies of the 3rd reduction

(3) (Q.ty 4) into their seats in the hydraulic
motor (2), and by using a press, push them
against the shoulder until assembly is
complete.

60

15. Position the 3rd reduction planet carrier (4) on

the hydraulic motor (2) and by using a press
push it against the shoulder.



60

16. Apply Loctite 243 on the socket bolts (5)

(Q.ty 4), and insert them in the thread holes in
the hydraulic motor (2).


60

W3-2-47

E175B

TRAVEL DEVICE

17. Tighten the socket bolts (1) (Q.ty 4).

: 585 Nm torque (431 lbfft)

60

18. Insert the 3rd stage sun gear (2).



60

19. Assemble the 2nd reduction assembly (3).


nd

20. Insert the 2

60

stage sun gear (4).


60

W3-2-48

TRAVEL DEVICE

E175B

21. Assemble the 1st reduction assembly (1).

60

st

22. Insert the 1 stage sun gear (2).

60

23. Assemble the O-Ring seal (3) into its seat in the
end cover (4).


60

24. Assemble the end cover (4) on the gearbox

housing (5).



60

W3-2-49

E175B

TRAVEL DEVICE

25. Fix the cover (1) to the gearbox housing (2) by

using socket bolts (3) (Q.ty 10).

: 8 mm
: 75 Nm (55.5 lbfft)




60

26. Fill the gearbox with the lubricant oil. Tighten

the plugs (4) into the oil draining-filling holes of
the end cover (1).
: 17 mm
: 65 5 Nm (48.1 3.7 lbfft)

60

W3-2-50

TRAVEL DEVICE

E195B

DISASSEMBLY TRAVEL DEVICE (E195B)

Gearbox disassembling method
By using a tackle place the gearbox unit (1) on
a spacer (2).

2.



 

 

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

W3-2-51

E195B
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

W3-2-52

TRAVEL DEVICE
8.

E195B

Remove the 2nd reduction assembly (9).

60

9.

By using pliers remove the circlips (10) from

their seats placed in the hydraulic motors 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

W3-2-53

E195B

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

W3-2-54

TRAVEL DEVICE

E195B



IMPORTANT: 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 necessary

to check and eventually replace the lifetime seals
(18), which 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

W3-2-55

E195B

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

W3-2-56

TRAVEL DEVICE

E195B

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

W3-2-57

E195B
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

W3-2-58

TRAVEL DEVICE
9.

E195B

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

W3-2-59

E195B

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

W3-2-60

TRAVEL DEVICE

E195B

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

W3-2-61

E195B

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

W3-2-62

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

E195B





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

W3-2-63

E195B

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

W3-2-64

TRAVEL DEVICE

E195B

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

W3-2-65

E195B

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

W3-2-66

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

E195B




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

W3-2-67

E195B

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

W3-2-68

TRAVEL DEVICE

E195B

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

W3-2-69

E195B

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

W3-2-70

TRAVEL DEVICE

E195B

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

W3-2-71

E195B

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

W3-2-72

TRAVEL DEVICE

E195B

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

W3-2-73

E195B

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

W3-2-74

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

E195B




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

W3-2-75

E195B

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

W3-2-76

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.

W3-2-77

E195B

E195B

TRAVEL DEVICE

ASSEMBLY TRAVEL DEVICE (E195B)





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

W3-2-78

TRAVEL DEVICE
5.

Place the bearing-motor shaft sub-assembly

(65-64) in the seat inside the flanged hub (44).



E195B





NOTE - 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 bearingmotor 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

W3-2-79

E195B
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
match 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

W3-2-80

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

E195B



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

W3-2-81

E195B

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 seats

in 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

W3-2-82

TRAVEL DEVICE

E195B

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

W3-2-83

E195B

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).





NOTE - bronze layer surface must be upwards.

60

27. Assemble the pins (45) in their seats in the

base plate (17).





60

W3-2-84

TRAVEL DEVICE

E195B

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 lbfft)






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 lbfft)



60

W3-2-85

E195B

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 lbfft)




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 lbfft)




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 lbfft)




60

W3-2-86

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

E195B



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 lbfft)

60



60

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

flanged plug (29).




60

W3-2-87

E195B

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

W3-2-88

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

E195B




60

45. Insert the first spring (31)

counterbalance valve spool (33).

on

the




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

W3-2-89

E195B

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 lbfft)





60

49. Insert the second spring seat (32) on the

counterbalance valve spool (33).





60

50. Insert the second spring (31)

counterbalance valve spool (33).

on

the




60

51. Assemble the spring seat (30) into its seat in

the 2nd flanged plug (29).





60

W3-2-90

TRAVEL DEVICE

E195B

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 lbfft)

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

W3-2-91

E195B

TRAVEL DEVICE

56. Assemble the O-ring seal (25) into its seat in

the free 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 lbfft)



60

W3-2-92

TRAVEL DEVICE

E195B

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 lbfft)



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).



W3-2-93



60

E195B

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 lbfft)



60

67. Correct assembling of the two speed control

valve.

60

W3-2-94

TRAVEL DEVICE

E195B

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 lbfft)



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 lbfft)


60

W3-2-95

E195B

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

W3-2-96

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 lbfft)

E195B



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).

W3-2-97

60

E195B

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 lbfft)

NOTE - it is suggested 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

W3-2-98

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 lbfft)

E195B

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 lbfft)

60

NOTE - it is suggested to operate like that when

motor is completely assembled.

60

87. Correct assembling of the flushing valve.

60

W3-2-99

E195B

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).




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

W3-2-100

TRAVEL DEVICE

E195B

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.

W3-2-101

60

E195B
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

W3-2-102

TRAVEL DEVICE

E195B

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

W3-2-103

E195B

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

IMPORTANT - 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 lbfft) corresponding to
an output multiplier torque of 7250 250 Nm
(5347 184 lbfft).

60

W3-2-104

TRAVEL DEVICE

E195B

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

hydraulic motor.


60

NOTE - stake 45 mm (depth 11.5 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

W3-2-105

E195B

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

W3-2-106

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

E195B



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

W3-2-107

TRAVEL DEVICE
1.

E175B-E195B

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 lbfft)



60

2.

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 lbfft)





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.

W3-2-108

E175B-E195B

TRAVEL DEVICE

REMOVAL AND INSTALLATION OF SPROCKET

(E175B-E195B)
Preparation
1.

Park the machine on a firm, level surface.

2.

Cut-off the engine

3.

Remove the tracks. Refer to the dedicated

group in this section.

Removal
1.

Lift up the track frame with front attachment,

and put it on square timber to stabilize.

NOTE - mass of sprocket approx. 64 kg (141 lbs).

2.

Loosen the screws (2), for the attaching of the

sprocket by means of a socket and remove the
sprocket (1).
: 24 mm (E175B)
: 30 mm (E195B)
Screw M16x60 No. 16 (E175B)
Screw M20x50 No. 20 (E195B)

60



60

W3-2-109

TRAVEL DEVICE

E175B-E195B

Installation
1.

Before installing check the mating portion of the

travel reduction unit and the sprocket, eliminate
burrs and contamination thoroughly.

NOTE - mass of sprocket approx. 64 kg (141 lbs).

2.

Install the sprocket on the coat the sprocket attaching capscrews with Loctite #262 and fasten
the sprocket temporarily.

3.

Remove the wooden blocks under the truck

frame, and move the wooden block under the
sprocket then bring the machine down on the
ground and tighten the screws (2).
: 24 mm (E175B)
: 30 mm (E195B)
: 320 32 Nm (236 22 lbfft) (E175B)
: 570 57 (420 42 lbfft) (E195B)

W3-2-110


60

E175B-E195B

TRAVEL DEVICE

MAINTENANCE STANDARD
Sprocket (E175B-E195B)

%
&
'

60

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

Allowable Limit (mm)

68

60

584.7

575

PCD644.6

659

648

190.0

W3-2-111

Remedy

Build up and
finishing

TRAVEL DEVICE

E175B-E195B

TOOL TABLE E175B

REF.

TOOL NO.

380001076

Push-out jig bushings

DESCRIPTION

380001077

Stopper back-up ring

380001078

Stopper bearing-motor shaft

380001079

Stopper bearing-motor shaft

380001080

Stopper bearing base plate

380001065

Stopper O-Ring plugs

380001066

Stopper O-Ring flanged plug

380001067

Stopper O-Ring relief valve

380001068

Stopper O-Ring two speed control

380001069

Tool half seal gearbox housing

380001081

Tool fitting balls

380001082

Tool fitting hydraulic motor

380001083

Safety bush

TOOL TABLE E195B

REF.

TOOL NO.

XXXXXXXXX

Torque multiplier

DESCRIPTION

XXXXXXXXX

Stopper back-up ring flanged hub

XXXXXXXXX

Stopper O-Rings plugs

XXXXXXXXX

Stopper O-Rings flanged plug

XXXXXXXXX

Stopper O-Rings relief valve

XXXXXXXXX

Stopper O-Rings two speed control

XXXXXXXXX

Stopper fitting O-Rings plug

XXXXXXXXX

Tool half seal gearbox housing

W3-2-112

SWIVEL JOINT

E175B-E195B

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 8) (PF1).

: 36 mm
: 177 18 Nm (130.5 13 lbfft)

Remove tube (5 and 6) (PF1/2).

: 27 mm
: 78.5 5 Nm (57.9 3.7 lbfft)

2.

3.

4.

Remove tubes (3 and 4) (PF1/4).

: 19 mm
: 29.4 5 Nm (21.7 3.7 lbfft)

Remove tubes (1 and 7) (PF1).

: 36 mm
: 177 18 Nm (130.5 13 lbfft)

60

W3-3-1

E175B-E195B
5.

SWIVEL JOINT

Remove drain hose (2).

: 27 mm
: 78.5 5 Nm (57.9 3.7 lbfft)
6.

Remove hoses (4 and 6).

: 36 mm
: 177 18 Nm (130.5 13 lbfft)

7.

Remove hoses (1 and 3).

: 36 mm
: 177 18 Nm (130.5 13 lbfft)

8.

Remove hose (5).

: 19 mm
: 29.4 5 Nm (21.7 3.7 lbfft)





60

9.

Loosen the stop nut (7) M20 of swivel joint and

remove the screw (8) M20x120.

: 36 mm
: 157 Nm (115.8 lbfft)

60

10. Remove two adapters (9 and 10).

: 19 mm
: 36 Nm (26.6 lbfft)




60

W3-3-2

SWIVEL JOINT

E175B-E195B

11. Remove six screws (2) M10x25.

: 19 mm
: 14.7 Nm (10.8 lbfft)

12. Remove clip (1).

: 6.8 Nm (5.0 lbfft)

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 lbfft)


NOTE: Swivel joint weight: 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 weight: 31 kg (68.4 lbs).

W3-3-3

E175B-E195B

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

E175B-E195B

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

E175B-E195B
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 ORing 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

E175B-E195B

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
O-ring.

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

E175B-E195B

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 lbfft)

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 lbfft)

60

W3-3-8

SWIVEL JOINT

E175B-E195B

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

E175B-E195B

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

E175B-E195B

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:
202 kg (445 lbs)(E175B) - 214 kg (472 lbs)(E195B).
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

E175B-E195B

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:
217 kg (478 lbs)(E175B) - 229 kg (505 lbs)(E195B).
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:

90,1 kg (199 lbs)(E175B) - 102 kg (225 lbs)(E195B).
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.

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.

E175B-E195B

 

  




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

E175B-E195B
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

E175B-E195B

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










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

E175B-E195B
5.

TRACK ADJUSTER

Remove idler adjuster assy from jig (380001029).

NOTE: Track adjuster weight:

90,1 kg (199 lbs)(E175B)
102 kg (225 lbs)(E195B).

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 lbfft)

TOOL TABLE
TOOL NO.
380001029

DESCRIPTION

Jig stand track adjuster

W3-4-6

60

FRONT IDLER

E175B-E195B

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

E175B-E195B

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

E175B-E195B

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 cm 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

E175B-E195B

FRONT IDLER

MAINTENANCE STANDARD
Front Idler

& '

(
$
%
60

Unit: mm
Standard

Allowable

84

66

159

500

482

540

20

Remedy

Buildup weld and finishing

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

Axle and Bushing

Unit: mm
Standard

Allowable

Axle

Outside Dia

75

74.2

Bushing

Inside Dia

75

76

Bushing

Flange thickness

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

E175B-E195B

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

E175B-E195B
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 lbfft)

2.

Remove the wooden blocks and the hydraulic

jack.

60

W3-6-2

UPPER AND LOWER ROLLER

3.

E175B-E195B

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 lbfft)

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 lbfft)

W3-6-3

60

E175B-E195B

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

E175B-E195B

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
: 397 39 Nm (293 29 lbfft)

60

W3-6-5

E175B-E195B
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 lbfft)




60

NOTE: Check track sag after thoroughly removing

soil stuck on the track area by washing.

60

W3-6-6

UPPER AND LOWER ROLLER

E175B-E195B

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

E175B-E195B
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

E175B-E195B

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

E175B-E195B

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 lbfft)
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 kg 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 lbfft)
- 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

E175B-E195B

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

E175B-E195B

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
(380001030) (9).

60

W3-6-12

UPPER AND LOWER ROLLER

E175B-E195B

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

E175B-E195B

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
O-Ring (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 lbfft)

W3-6-14

60

UPPER AND LOWER ROLLER

E175B-E195B

MAINTENANCE STANDARD
Upper Roller

&

$
%

60

Unit: mm
Standard

Allowable Limit

84

150

140

130

Remedy
Replace

Lower Roller

'

$
%

&

&

60

Unit: mm
Standard

Allowable Limit

172

181.5

218

23

11.5

150

132

W3-6-15

Remedy
Buildup
weld and
finishing

E175B-E195B

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

1.2

Axle

TOOL TABLE
DESCRIPTION

TOOL NO.
380001053
XXXXXXXXX

Punch for upper roller bushings

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

E175B-E195B

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

E175B-E195B

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
D: 380001012
E: 380001015
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.



60

W3-7-2

TRACKS

E175B-E195B

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

E175B-E195B

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
D: 380001012
E: 380001015
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 lbfft)

IMPORTANT: check track sag after thoroughly removing soil stuck on the track area by washing.

60

W3-7-4

TRACKS

E175B-E195B

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

Allowable Limit

Remedy

761

774

Replace

Master Pin

$
60

Unit: mm
Standard
A
B

Allowable Limit

E175B

E195B

E175B

E195B

212

207

205

200

38

36.5

W3-7-5

Remedy
Replace

E175B-E195B

TRACKS

Master Bushing

&

$
60

Unit: mm
Standard
E175B
A

Allowable Limit

E195B

E175B

129.2

38.7

59

Remedy

E195B
-

38 ++00.87
58.7

40.2

39.5

54.4

54.1

Replace

Grouser Shoe

&
%
$
60

Unit: mm
Standard
E215B

Allowable Limit

E245B

E215B

E245B

220

9.5

25.5

15

W3-7-6

Remedy

Replace

TRACKS

E175B-E195B

TOOL TABLE
DESCRIPTION

TOOL NO.
380001008

Tool fitting/pushing-out master pin

380001009

Tool fitting/pushing-out master pin

380001012

Tool fitting/pushing-out master pin

380001013

Tool fitting/pushing-out master pin

380001015

Tool fitting/pushing-out master pin

W3-7-7

E175B-E195B

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

E175B-E195B

FRONT ATTACHMENT

E175B-E195B

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

4.

Attach each boom cylinder to a crane.

NOTE: boom cylinder weight: 149 kg

Remove cylinder rod end pin (5) and shims (6)
using a hammer and bar.

4
2
SM0201

5 4 2
2
6
4 3

W4-1-1

SM0202

E175B-E195B

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

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).

10

10

Bucket (7) and arm (8) cylinder hoses:

: 36 mm
8

Hammer/crusher hoses (9):

: 36 mm

11

11

Bucket rotation hoses (10):

SM1000

: 27 mm
Anti-drop valves hoses (11):
: 22 mm
12

Close all openings with plugs to keep clean.

8.

Disconnect centralised lubrication hoses (12)

located between the boom cylinders.
: 17 mm

SM1001

W4-1-2

FRONT ATTACHMENT
9.

Loosen lock nuts (13) and remove bolt (14).

: 30 mm

E175B-E195B

14

10. Sling the boom to a hoist. Slightly lift the boom.

NOTE: approximate mass of the front equipment:
2700 kg.

13

SM1002

11. Pull out the boom lower pivot pin (15) to the
frame
using
the
appropriate
puller
(XXXXXXXX).

SM0208

12. Lift the front attachment. Move the machine

away from the front attachment and the hoist.

15

SM1003

W4-1-3

E175B-E195B

FRONT ATTACHMENT

Installation
1.

Lift the front attachment.

14

NOTE: approximate mass of the front equipment:

2700 kg

15

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 (15) using a hammer and

bar.

3.

Install bolt (14) and tighten lock nuts (13).

13

SM1004

10

: 30 mm
: 200 Nm

10

4.

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).

Bucket (7) and arm (8) cylinder hoses:

: 36 mm
: 177 18 Nm
Hammer/crusher hoses (9):
: 36 mm
: 177 18 Nm
Bucket rotation hoses (10):
: 27 mm
: 78 5 Nm
Anti-drop valves hoses (11):
: 22 mm
: 49 5 Nm

W4-1-4

11

11
SM1000

FRONT ATTACHMENT
5.

E175B-E195B

Attach the boom cylinder to a crane.

NOTE: boom cylinder weight: 149 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.

6.

Install shims (6) and insert pin (5).

SM0211

7.

Install stopper (4), tighten bolts (3) and lock

nuts (2):

: 24 mm
: 147 Nm

8.

5 4 2

Connect lubrication hoses (1) to boom cylinder

rod.

2
6

: 17 mm
: 20 Nm
4 3

9.

SM0202

Connect centralised lubrication hoses (12)

located between the boom cylinders.
5

: 17 mm
: 20 Nm

Using a grease gun, inject grease via nipples

(16) (boom) and (17) (boom cylinders).
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
2
SM0201

IMPORTANT: bleed air from hydraulic circuit.

12

17

16

17

SM1005

W4-1-5

E175B-E195B

FRONT ATTACHMENT

Maintenance: monoblock version

I
SM0213

Unit di misura: mm
Standard

Allowable
limit

Pin

85

84

Bushing

85

86.5

Pin

85

84

Boss (Main Frame)

85

86,5

Bushing (Boom Cylinder)

85

86,5

Pin

85

84

Parts name
A

I
J
K

Bushing (Boom Cylinder)

85

86,5

Foro (Boom)

85

86,5

Pin

80

79

Bushing

80

85.5

Pin

80

79

Boss (Arm)

80

81.5

Bushing (Arm Cylinder)

80

81.5

Pin

80

79

Boss (Boom)

80

81.5

Bushing (Arm Cylinder)

80

81.5

Pin

70

69

Boss (Arm)

70

71.5

Bushing (Bucket Cylinder)

70

71.5

Pin

70

69

Bushing

70

71.5

Bushing (Bucket Cylinder)

70

71.5

Pin

65

64

Bushing

65

66.5

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

E175B-E195B

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

4.

SM0215

Attach each boom cylinder to a crane.

NOTE: boom cylinder weight: 149 kg

Remove cylinder rod end pin (5) and shims (6)
using a hammer and bar.
4
2
SM1006

5 4 2

2
6
4 3

W4-1-7

SM0217

E175B-E195B

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.

SM0218

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).
Positioner cylinder hoses (12) (from the control
valve):
: 30 mm

10

9
8

Bucket (7) and arm (8) cylinder hoses:

: 36 mm

9
8

12 12
11

11

Hammer/crusher hoses (9):

: 36 mm

SM1007

Bucket rotation hoses (10):

: 27 mm
13

Anti-drop valves hoses (11):

: 22 mm
Close all openings with plugs to keep clean.
8.

Disconnect centralised lubrication hoses (13)

located between the boom cylinders.
: 17 mm
SM1008

W4-1-8

FRONT ATTACHMENT
9.

Loosen lock nuts (14) and remove bolt (15).

: 30 mm

E175B-E195B

15

10. Sling the boom to a hoist. Slightly lift the boom.

NOTE: approximate mass of the front equipment:
3200 kg.

14

SM1009

11. Pull out the boom lower pivot pin (16) to the
frame
using
the
appropriate
puller
(XXXXXXXX).

SM0223

12. Lift the front attachment. Move the machine

away from the front attachment and the hoist.

16

SM1010

W4-1-9

E175B-E195B

FRONT ATTACHMENT

Installation
1.

Lift the front attachment.

15

NOTE: approximate mass of the front equipment:

3200 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.

14

Install boom foot pin (16) using a hammer and

bar.

SM1011

Install bolt (15) and tighten lock nuts (14).

10

: 30 mm
: 200 Nm
4.

Connect bucket cylinder hoses (7), positioner

cylinder hoses (12) and arm cylinder hoses (8).

9
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
8

12 12
11

11
SM1007

Positioner cylinder hoses (12) (from the control

valve):
: 30 mm
: 83 5 Nm
Bucket (7) and arm (8) cylinder hoses:
: 36 mm
: 177 18 Nm
Hammer/crusher hoses (9):
: 36 mm
: 177 18 Nm
Bucket rotation hoses (10):
: 27 mm
: 78 5 Nm
Anti-drop valves hoses (11):
: 22 mm
: 49 5 Nm

W4-1-10

FRONT ATTACHMENT
5.

E175B-E195B

Attach the boom cylinder to a crane.

NOTE: boom cylinder weight: 149 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.

6.

Install shims (6) and insert pin (5).

7.

Install stopper (4), tighten bolts (3) and lock

nuts (2):

: 24 mm
5 4 2

: 147 Nm

8.

Connect lubrication hoses (1) to boom cylinder

rod.

2
6

: 17 mm
: 20 Nm
4 3

9.

SM0217

Connect centralised lubrication hoses (13)

located between the boom cylinders.
: 17 mm

: 20 Nm

Using a grease gun, inject grease via nipples

(17) (boom) and (18) (boom cylinders).
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
2
SM1006

IMPORTANT: bleed air from hydraulic circuit.

13

18

17

18

SM1012

W4-1-11

E175B-E195B

FRONT ATTACHMENT

Maintenance: triple articulation version

I
SM0238

Unit: mm
Standard

Allowable
limit

Pin

85

84

Bushing

85

86.5

Pin

85

84

Boss (Main Frame)

85

86.5

Bushing (Boom Cylinder)

85

86.5

Pin

85

84

Parts name
A-D-N

I
J-K

Bushing (Boom Cylinder)

85

86.5

Boss (Boom)

85

86.5

Pin

85

84

Boss (Positioner)

85

86.5

Bushing (Positioner Cylinder)

85

86.5

Pin

85

84

Boss (Boom)

85

86.5

Bushing (Positioner Cylinder)

85

86.5

Pin

70

69

Boss (Arm)

70

71.5

Bushing (Bucket Cylinder)

70

71.5

Pin

70

69

Bushing

70

71.5

Bushing (Bucket Cylinder)

70

71.5

Pin

65

64

Bushing

65

66.5

Pin

80

79

Bushing

80

81.5

Pin

80

79

Boss (Positioner)

80

81.5

Bushing (Arm Cylinder)

80

81.5

Pin

80

79

Boss (Arm)

80

81.5

Bushing (Arm Cylinder)

80

81.5

IMPORTANT: be sure to install front attachment bushings using a press.

W4-1-12

Remedy

Replace

FRONT ATTACHMENT

E175B-E195B

STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION

o

g
h

i
j
Section A
d

l
m

B
c

e
b

SM0214

E195B

E195

a (*)

327.3

326

50

b (*)

42

50

630

525

430

1464

433

326

80

428.7

33

433

307

80

20

3.73

449

Section B

E175B

E175

a (*)

327.3

326

b (*)

42

580

525

400.1

1369

433

326

80

399

30

433

307

80

45

449

(*) Arm: 2600 mm

Unit: mm

W4-1-13

E175B-E195B

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

E175B-E195B

E175B-E195B

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.

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).

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).

: 22 mm
5

SM0227

W4-1-16

FRONT ATTACHMENT
6.

E175B-E195B

Disconnected hoses (8) from bucket cylinder

(1).

12

: 10 mm

11

: 36 mm
Put plugs on cylinder pipes and hoses.

10
1

NOTE: bucket cylinder weight: 128 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).

: 22 mm

8.

Remove bucket cylinder (1).

SM0228

W4-1-17

E175B-E195B

FRONT ATTACHMENT

Bucket Cylinder installation

NOTE: bucket cylinder weight: 128 kg

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

: 22 mm

: 120 12 Nm
3.

Connect two hoses (8) to bucket cylinder (1).

: 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.

Install bolt (5) onto pin (6) then tighten lock nuts
(4).
: 22 mm

: 103 10 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

E175B-E195B

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).

: 22 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

NOTE: arm cylinder weight: 194 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

: 24 mm

7.

SM0232

14

Remove arm cylinder (1).

11

13

12

SM0233

W4-1-19

E175B-E195B

FRONT ATTACHMENT

Arm cylinder installation

NOTE: arm cylinder weight: 194 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.

10

Install adjusting shims (7), pin (6), install screw

(5) onto pin (6) and tighten lock-nuts (4).

SM0232

: 22 mm
: 103 10 Nm

IMPORTANT: bleed air from hydraulic circuit.

5

SM0231

W4-1-20

FRONT ATTACHMENT

E175B-E195B

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

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: 149 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.
: 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

E175B-E195B

FRONT ATTACHMENT

Boom cylinders installation

NOTE: boom cylinder weight: 149 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.

: 24 mm
: 220 22 Nm
3.

9
8

Connect hoses (7) to boom cylinder.

: 30 mm

SM0234

: 137 Nm
4.

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.

: 17 mm
: 20 Nm
5 4 2

8.

Using a grease gun, inject grease via nipples

(10).

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

IMPORTANT: bleed air from hydraulic circuit.

4
2
SM0201

W4-1-22

FRONT ATTACHMENT

E175B-E195B

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.

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

: 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

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

: 24 mm

7.

SM0232

14

Remove positioner cylinder (1).

11

13

12

SM0233

W4-1-23

E175B-E195B

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.

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

SM0232

5.

Install adjusting shims (7), pin (6), install screw

(5) onto pin (6) and tighten lock-nuts (4).
7

: 24 mm

: 147 Nm
IMPORTANT: bleed air from hydraulic circuit.

SM0237

W4-1-24

FRONT ATTACHMENT

E175B-E195B

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

E175B-E195B

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: 80 mm (XXXXXXXX) (E175B)
- bucket cylinder: 85 mm (XXXXXXXX)(E195B)

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: 128 kg (E175B)
bucket cylinder mass: 149 kg (E195B)
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).
: 12 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: 75 mm (XXXXXXXX) (E175B)
- Bucket cylinder: 80 mm (XXXXXXXX) (E195B)

IMPORTANT: be sure that the rings are installed

correctly.

2.

3.

4.

E175B-E195B

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.

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.

Install O-Rings (10) and backup ring (9) to

cylinder head (7).

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).
: 12 mm
: 171 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: 80 mm (XXXXXXXX) (E175B)
: 4810 Nm
- bucket cylinder: 85 mm (XXXXXXXX) (E195B)
: 5730 Nm
W4-1-27

E175B-E195B

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: 194 kg (E175B)
arm cylinder mass: 220 kg (E195B)
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.

E175B-E195B

Loosen piston (15) using special tool

(xxxxxxxxx).
Remove shim (21) cushion bearing (13) and
cushion seal (14).
Piston nut (15) Turning Special Tool:
- 95 mm (XXXXXXXX) (E175B)
- 100 mm (XXXXXXXX) (E195B)

W4-1-29

E175B-E195B

FRONT ATTACHMENT
9.

Arm cylinder assembly

1.

Install bushing (5) to cylinder head (7) using a

press.
Special tools for bushing installation (5):
- 90 mm (XXXXXXXX) (E175B)
- 95 mm (XXXXXXXX) (E195B)

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 rings are installed

correctly.

IMPORTANT: be sure that the cushion seal slit

faces toward the piston and that the cushion bearing
oil groove faces the correct direction.

2.

Install seal (3), back-up ring (2), elastic ring (6)

and seal (4) on the cylinder front sleeve (7).

10. Install snap ring (25) and cushion seal (26) to

cylinder rod (11). Install cushion bearing (27)
and stopper (28) to cylinder rod (11).

3.

Install wiper ring (1) to cylinder head (7) using a

plastic hammer.

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.

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)

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).
: 14 mm

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):
- 95 mm (XXXXXXXX) (E175B)
: 8200 Nm
- 100 mm (XXXXXXXX) (E195B)
: 9345 Nm
W4-1-30

: 267 Nm

FRONT ATTACHMENT

E175B-E195B

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

E175B-E195B

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: 196 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).

: 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)
-100 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

E175B-E195B

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).
: 14 mm
: 367 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):
- 100 mm (XXXXXXXX)
: 10280 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

E175B-E195B

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: 149 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).
: 12 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.

E175B-E195B

Loosen nut (24) using special tool (xxxxxxxxx).

Remove piston (15), shim (21) cushion bearing
(13).
Socket to loosen nut (24):
- boom cylinder: 85 mm (XXXXXXXX)

W4-1-35

E175B-E195B

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: 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 (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).
: 12 mm
: 171 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: 85 mm (XXXXXXXX)
: 3790 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 ( 80 mm)
XXXXXXXXX for arm cylinder ( 90 mm)
XXXXXXXXX for bucket cylinder ( 75 mm)
XXXXXXXXX for positioner arm cylinder ( 85 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

E175B-E195B

E175B-E195B

FRONT ATTACHMENT

Maintenance standard: rod

SM0243

Cylinders (E175B)

STANDARD (A)

Boom

80 0.03

Arm

90 0.03

Bucket

75 0.03

Positioning (*)

85 0.03

(*) Triple articulation version

Cylinders (E195B)

Remedy

Replace
or plate with chromium

Unit: mm

STANDARD (A)

Boom

80 0.03

Arm

95 0.03

Bucket

80 0.03

Positioning (*)

85 0.03

(*) Triple articulation version

Remedy

Replace
or plate with chromium

Unit: mm

W4-1-38