Service Manual - E215B-E245B - 5 - EN

TROUBLESHOOTING
M0103
TROUBLESHOOTING
E215B-E245B
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
E215B-E245B
TROUBLESHOOTING (BY ERROR CODES)
E215B-E245B
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
E215B-E245B
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
E215B-E245B
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
E215B-E245B
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
E215B-E245B
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
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
T5-1-5
E215B-E245B
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.
Screen
No.
Checking object
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
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.
checking screen
No.
Screen
No.
Checking object
1
Mechatro controller

2
3
T5-1-6
E215B-E245B
Table 5
Error code
A225
Trouble
Judging condition
Check adjustment data, and judge the data is correct or not.
Symptom
Control in the
Control can be done by default value.
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
Mechatro controller

2
3
Table 6
Error code
A235
Trouble
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
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
Mechatro controller

2
3
T5-1-7
E215B-E245B
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
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
Mechatro 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
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
Mechatro controller

2
3
T5-1-8
E215B-E245B
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

checking screen
No.
Screen
No.
Checking object
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
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

checking screen
No.
Screen
No.
Checking object
Boom up pressure sensor SE-3 When B013 is cancelled and other error occurs after exchanging the connector
with other sensor.

When B013 is displayed after the connector is exchanged with other sensor.
CN-126F
CN-101F
Mechatro controller
T5-1-9
E215B-E245B
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
Returned
in
normal condition
Screen
No.
B-1 BOOM RAISE

checking screen
No.
Screen
No.
Checking object
Boom up pressure sensor SE-3 When B014 is cancelled and other error occurs after exchanging the connector
with other sensor.

CN-126F
CN-101F
Mechatro controller
Table 12
Error code
B022
Trouble
Boom down pressure sensor outputs error.
Judging condition
Symptom
The boom down operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-2 BOOM LOWER

checking screen
No.
Screen
No.
Checking object
Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on after
SE-4
Wiring between boom down

CN-127F
CN-101F
Mechatro controller
T5-1-10
E215B-E245B
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

Control in the
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
normal condition
Screen
No.
B-2 BOOM LOWER

checking screen
No.
Screen
No.
Checking object
Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the connector
with other sensor.
SE-4

CN-127F
CN-101F
Mechatro 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

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-2 BOOM LOWER

checking screen
No.
Screen
No.
Checking object
Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on after
SE-4

CN-127F
CN-101F
Mechatro controller
T5-1-11
E215B-E245B
Table 15
Error code
B032
Trouble
Arm-in pressure sensor outputs error.
Judging condition
Symptom
The arm-out operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-3 ARM OUT

checking screen
No.
Screen
No.
Checking object
Arm-out pressure sensor SE-8
When B032 is cancelled and other error occurs by turning starter switch on after
Wiring between arm-out pressure

sensor and controller
CN-131F
CN-101F
Mechatro 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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-3 ARM OUT

checking screen
No.
Screen
No.
Checking object
When B033 is cancelled and other error occurs after exchanging the connector
with other sensor.
Wiring between arm-out pressure

CN-131F
CN-101F
Mechatro controller
T5-1-12
E215B-E245B
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.

Control in the
event of failure
Set output of P1, P2 unload proportional valves to 0 mA. (Valve emergency mode)
Returned
in
normal condition
Screen
No.
B-3 ARM OUT

checking screen
No.
Screen
No.
Checking object
Wiring
between
arm-out
CN-131F
CN-101F
Mechatro 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
normal condition
Screen
No.
B-4 ARM IN

checking screen
No.
Screen
No.
Checking object
1
Arm-in pressure sensor

SE-7

Wiring between arm-in pressure

CN-130F
CN-101F
Mechatro controller
T5-1-13
E215B-E245B
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
normal condition
Screen
No.
B-4 ARM IN

checking screen
No.
Screen
No.
Checking object

SE-7
When B043 is cancelled and other error occurs after exchanging the connector
with other sensor.
Wiring between arm-in pressure

CN-130F
and repair it if necessary..
CN-101F
Mechatro controller
T5-1-14
E215B-E245B
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
normal condition
Screen No.
Service diagnosis
Screen No.
checking screen
Screen No.
B-4 ARM IN
Checking object

SE-7
When B044 is cancelled and other error occurs by turning starter switch on
after exchanging the connector with other sensor.
Wiring between arm-in pressure When B044 is displayed after turning the starter switch on after the connector
CN-130F
CN-101F
Mechatro controller
T5-1-15
E215B-E245B
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
normal condition
Screen
No.
B-5 BUCKET DIG

checking screen
No.
Screen
No.
Checking object
Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on after
SE-1
Wiring between bucket digging

CN-124F
CN-101F
Mechatro 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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-5 BUCKET DIG

checking screen
No.
Screen
No.
Checking object
SE-1

CN-124F
CN-101F
Mechatro controller
T5-1-16
E215B-E245B
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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-5 BUCKET DIG

checking screen
No.
Screen
No.
Checking object
SE-1

CN-124F
CN-101F
Mechatro 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
Symptom
The bucket dump operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-6 BUCKET DUMP

checking screen
No.
Screen
No.
Checking object
SE-2

CN-125F
CN-101F
Mechatro controller
T5-1-17
E215B-E245B
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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-6 BUCKET DUMP

checking screen
No.
Screen
No.
Checking object
SE-2

CN-125F
CN-101F
Mechatro 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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-6 BUCKET DUMP

checking screen
No.
Screen
No.
Checking object
SE-2

CN-125F
CN-101F
Mechatro controller
T5-1-18
E215B-E245B
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
normal condition
Screen
No.
B-7 SWING

checking screen
No.
Screen
No.
Checking object
1
Swing pressure sensor
SE-5
2
Wiring between swing pressure When B072 is displayed after turning the starter switch on after the connector
CN-169F
CN-103F
Mechatro 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

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-7 SWING

checking screen
No.
Screen
No.
Checking object
1

SE-5

CN-169F
CN-103F
Mechatro controller
T5-1-19
E215B-E245B
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

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-7 SWING

checking screen
No.
Screen
No.
Checking object
1
SE-5
2
CN-169F
CN-103F
Mechatro 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
Symptom
The travel right operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-9 TRAVEL (R)

checking screen
No.
Screen
No.
Checking object
1
Travel right pressure sensor

SE-9

Wiring between travel right

CN-301F
CN-102F
Mechatro controller
T5-1-20
E215B-E245B
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.

Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
normal condition
Screen
No.
B-9 TRAVEL (R)

checking screen
No.
Screen
No.
Checking object
1

SE-9


CN-301F
CN-102F
Mechatro controller
T5-1-21
E215B-E245B
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.

Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned
in
normal condition
Screen
No.
B-9 TRAVEL (R)

checking screen
No.
Screen
No.
Checking object
1

SE-9


CN-301F
CN-102F
Mechatro controller
T5-1-22
E215B-E245B
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
Symptom
The travel left operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-10 TRAVEL (L)

checking screen
No.
Screen
No.
1
Checking object
Travel left pressure sensor
SE-10
2
Wiring between travel left

CN-302F
CN-102F
Mechatro 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.

Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
normal condition
Screen
No.
B-10 TRAVEL (L)

checking screen
No.
Screen
No.
1
Checking object
SE-10
2

CN-302F
CN-102F
Mechatro controller
T5-1-23
E215B-E245B
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.

Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned
in
normal condition
Screen
No.
B-10 TRAVEL (L)

checking screen
No.
Screen
No.
1
Checking object
SE-10
2

CN-302F
CN-102F
Mechatro controller
T5-1-24
E215B-E245B
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
normal condition
Screen
No.
16
B-11

checking screen
No.
Screen
No.
Checking object
Option selector position detect When B113 is cancelled and other error occurs by turning starter switch on after
pressure sensor
SE-29
Wiring between option selector

position detect pressure sensor
and controller
CN-162F
CN-104F
Mechatro controller
T5-1-25
E215B-E245B
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
normal condition
Screen
No.
16
B-11

checking screen
No.
Screen
No.
Checking object
Option selector position detect When B114 is cancelled and other error occurs by turning starter switch on after
pressure sensor
SE-29

position detect pressure sensor
and controller
CN-162F
CN-104F
Mechatro 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
Symptom
The P1 side option operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-16 P1 OPT.

checking screen
No.
Screen
No.
Checking object
1
P1 side option pressure sensor

SE-20

Wiring between P1 side option

CN-304F
CN-102F
Mechatro controller
T5-1-26
E215B-E245B
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.

Control in the (Hydraulic pump emergency mode)
event of failure
But normal control is done when the left control pedal selection is ON.
Returned
in
normal condition
Screen
No.
B-16 P1 OPT.

checking screen
No.
Screen
No.
Checking object
1

SE-20


CN-304F
CN-102F
Mechatro controller
T5-1-27
E215B-E245B
Table 40
Error code
B164
Trouble
Judging condition
The input voltage from P1 side option pressure sensor is 4.7 or more.
Symptom
The P1 side option does not work.

Control in the (Hydraulic pump emergency mode)
event of failure
But normal control is done when the left control pedal selection is ON.
Returned
in
normal condition
Screen
No.
B-16 P1 OPT.

checking screen
No.
Screen
No.
Checking object
1

SE-20

CN-304F
CN-102F
Mechatro 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
Symptom
The P2 side option operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
B-17 P2 OPT.

checking screen
No.
Screen
No.
Checking object
1

SE-11


CN-304F
CN-102F
Mechatro controller
T5-1-28
E215B-E245B
Table 42
Error code
B173
Trouble
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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-17 P2 OPT.

checking screen
No.
Screen
No.
Checking object
1

SE-11

CN-303F
CN-102F
Mechatro controller
Table 43
Error code
B174
Trouble
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.

Control in the
event of failure
Returned
in
normal condition
Screen
No.
B-17 P2 OPT.

checking screen
No.
Screen
No.
Checking object
1

SE-11


CN-303F
CN-102F
Mechatro controller
T5-1-29
E215B-E245B
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
Symptom
The P1 pump operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
C-1 PUMP P1

checking screen
No.
Screen
No.
1
Checking object
P1 pump pressure sensor
When C012 is cancelled and other error occurs by turning starter switch on after
SE-22
2
Wiring between P1 pump

CN-139F
CN-103F
When C012 is displayed after turning the starter switch on after the connector
Mechatro 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
Returned
in
normal condition
Screen
No.
C-1 PUMP P1

checking screen
No.
Screen
No.
1
Checking object
SE-22
2

CN-139F
CN-103F
Mechatro controller
T5-1-30
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
C-1 PUMP P1

checking screen
No.
Screen
No.
1
Checking object
SE-22
2

CN-139F
CN-103F
Mechatro 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
Symptom
The P2 pump operability becomes poor.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
C-2 PUMP P2

checking screen
No.
Screen
No.
1
Checking object
SE-23
2

CN-140F
CN-103F
Mechatro controller
T5-1-31
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
C-2 PUMP P2

checking screen
No.
Screen
No.
1
Checking object
SE-23
2

CN-140F
CN-103F
Mechatro 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
event of failure
Returned
in
normal condition
Screen
No.
C-2 PUMP P2

checking screen
No.
Screen
No.
1
Checking object
SE-23
2

CN-140F
CN-103F
Mechatro controller
T5-1-32
E215B-E245B
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
normal condition
Screen
No.
C-3 BOOM-HEAD

checking screen
No.
Screen
No.
Checking object
1
Boom head pressure sensor

SE-24
Wiring between boom head

CN-140F
CN-103F
Mechatro 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
normal condition
Screen
No.
C-3 BOOM-HEAD

checking screen
No.
Screen
No.
Checking object
1
Boom head pressure sensor

SE-24

Wiring between boom head

CN-706F
CN-104F
Mechatro controller
T5-1-33
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.

checking screen
No.
Screen
No.
Checking object
1
P1 unload proportional valve

PSV-D
When D012 is cancelled and other error occurs by turning starter switch on after
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
Mechatro 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
normal condition
Screen
No.

checking screen
No.
Screen
No.
Checking object
1

PSV-D


CN-120F
CN-105F
Mechatro controller
T5-1-34
E215B-E245B
Table 54
Error code
D022
Trouble
P2 unload proportional valve and output transistor ON are failure.
Judging condition
Symptom
Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned
in
normal condition
Screen
No.

checking screen
No.
Screen
No.
Checking object
1

PSV-B


CN-118F
CN-105F
Mechatro controller
T5-1-35
E215B-E245B
Table 55
Error code
D023
Trouble
P2 unload proportional valves wiring is disconnected.
Judging condition

Symptom
Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned
in
normal condition
Screen
No.

checking screen
No.
Screen
No.
Checking object
1

PSV-B

CN-118F
CN-105F
Mechatro 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
normal condition
Screen
No.
D-3 S-TRAVEL

checking screen
No.
Screen
No.
Checking object
straight
Travel
valve
Wiring between Travel straight

CN-119F
CN-105F
Mechatro controller
PSV-C
proportional When D032 is cancelled and other error occurs by turning starter switch on after
T5-1-36
E215B-E245B
Table 57
Error code
D033
Trouble
Travel straight proportional valves wiring is disconnected.
Judging condition

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
normal condition
Screen
No.
D-3 S-TRAVEL

checking screen
No.
Screen
No.
Checking object
straight
Travel
valve
Wiring between Travel straight

CN-119F
CN-105F
Mechatro controller
PSV-C
proportional When D033 is cancelled and other error occurs by turning starter switch on after
T5-1-37
E215B-E245B
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
normal condition
Screen
No.
D-4 ARM IN-2-SPEED

checking screen
No.
Screen
No.
Checking object
Arm-in spool 2 proportional When D062 is cancelled and other error occurs by turning starter switch on after
valve
PSV-A
Wiring between Arm-in spool 2

CN-121F
CN-105F
Mechatro controller
T5-1-38
E215B-E245B
Table 59
Error code
D063
Trouble
Arm-in spool 2 proportional valves wiring is disconnected.
Judging condition

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
normal condition
Screen
No.
D-4 ARM IN-2-SPEED

checking screen
No.
Screen
No.
Checking object
Arm-in spool 2 proportional When D063 is cancelled and other error occurs by turning starter switch on after
valve
PSV-A
Wiring between Arm-in spool 2

CN-121F
CN-105F
Mechatro controller
Table 60
Error code
D152
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
2
3
T5-1-39
E215B-E245B
Table 61
Error code
D153
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
2
3
Table 62
Error code
E012
Trouble
P1 pump proportional valve and output transistor ON are failure.
Judging condition
Symptom
event of failure
Returned
in
normal condition
Screen
No.
E-1 PUMP P1

checking screen
No.
Screen
No.
1
Checking object
P1 pump proportional valve
When E012 is cancelled and other error occurs by turning starter switch on after
When replacing of connector is executed, turn off power source once.
PSV-P1

CN-141F
CN-105F
When E012 is displayed after turning the starter switch on after the connector
Mechatro controller
T5-1-40
E215B-E245B
Table 63
Error code
E013
Trouble
P1 pump proportional valves wiring is disconnected.
Judging condition

(If output is 100mA or less, judging is not done.)
Symptom
event of failure
Returned
in
normal condition
Screen
No.
E-1 PUMP P1

checking screen
No.
Screen
No.
1
Checking object
PSV-P1

CN-141F
CN-105F
Mechatro controller
T5-1-41
E215B-E245B
Table 64
Error code
E022
Trouble
P2 pump proportional valve and output transistor ON are failure.
Judging condition
Symptom
event of failure
Returned
in
normal condition
Screen
No.
E-2 PUMP P2

checking screen
No.
Screen
No.
1
Checking object
PSV-P2

CN-142F
CN-105F
Mechatro controller
Table 65
Error code
E023
Trouble
P2 pump proportional valves wiring is disconnected.
Judging condition

Symptom
event of failure
Returned
in
normal condition
Screen
No.
E-2 PUMP P2

checking screen
No.
Screen
No.
1
Checking object
PSV-P2

CN-142F
CN-105F
Mechatro controller
T5-1-42
E215B-E245B
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

checking screen
No.
Screen
No.
1
Checking object
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.
Mechatro controller
T5-1-43
E215B-E245B
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

checking screen
No.
Screen
No.
1
Checking object
ATT boost solenoid valve
When F013 is cancelled and other error occurs by exchanging the connector
for other solenoid valve.
SV-2
2
Wiring between ATT boost

CN-117F
CN-105F
valve.
Mechatro controller
T5-1-44
E215B-E245B
Table 68
Error code
F021
Trouble
Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition
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

checking screen
No.
Screen
No.
Checking object
1
Swing parking solenoid valve

SV-1
for other solenoid valve. Check solenoid valve unit for possible failure. If failure
found, replace it.
Wiring between swing parking

CN-123F
CN-105F
valve.
Mechatro controller
Table 69
Error code
F023
Trouble
Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
Symptom
Swing parking is not available or is leaving available.
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
F-1 POWER BOOST

checking screen
No.
Screen
No.
Checking object
1
Swing parking solenoid valve

SV-1

Wiring between swing parking

CN-123F
CN-105F
valve.
Mechatro controller
T5-1-45
E215B-E245B
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
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

checking screen
No.
Screen
No.
Checking object
Travel 1, 2 speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
SV-3
Wiring between travel 1, 2

speed solenoid valve and
controller
CN-123F
CN-105F
valve.
Mechatro controller
T5-1-46
E215B-E245B
Table 71
Error code
F033
Trouble
Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
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

checking screen
No.
Screen
No.
Checking object
Travel 1, 2 speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
SV-3
Wiring between travel 1, 2

speed solenoid valve and
controller
CN-122F
CN-105F
valve.
Mechatro controller
Table 72
Error code
F041
Trouble
Option selector solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition
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

checking screen
No.
Screen
No.
Checking object
1
Option selector solenoid valve

SV-13


CN-251F
CN-105F
valve.
Mechatro controller
T5-1-47
E215B-E245B
Table 73
Error code
F043
Trouble
Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
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

checking screen
No.
Screen
No.
Checking object
1
Option selector solenoid valve

SV-13


CN-251F
CN-105F
valve.
Mechatro controller
Table 74
Error code
G011
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
2
3
T5-1-48
Table 75
Error code
G013
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
2
3
Table 76
Error code
G023
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned
in
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
1
2
3
T5-1-49
E215B-E245B
E215B-E245B
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
normal condition
Screen
No.
G-3 MEAS 1 (for mechatro controller)

checking screen
No.
G-3 MEAS 2 (receive from engine controller)
Screen
No.
Checking object
Engine speed sensor
Measure the resistance between terminals of speed sensor.

Check wiring for possible failure according to the wiring checking
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
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
normal condition
Screen
No.
G-3 MEAS 1 (for mechatro controller)

checking screen
No.
G-3 MEAS 2 (receive from engine controller)
Screen
No.
Checking object
1
Engine speed sensor

SE-13

Measure the resistance between terminals of speed sensor.
Normal value: 1.6~2.0k
Wiring between engine speed

CN-136F
CN-106F
Mechatro controller

(Controller is broken by only applying power to grounding of signal.).
T5-1-50
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
H-1 ACCEL VOLT.

checking screen
No.
Screen
No.
Checking object
1
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
CN-402F
CN-102F
Mechatro 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
Control in the
event of failure
Returned
in
normal condition
Screen
No.
H-1 ACCEL VOLT.

checking screen
No.
Screen
No.
Checking object
1
Accel potentiometer
SE-16

Measure the resistance between terminals of accel potentiometer.
1.6~2.0k .
Wiring
between
accel
CN-402F
CN-102F
Mechatro controller
T5-1-51
E215B-E245B
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
normal condition
Screen
No.
12
H-2 BOOM

checking screen
No.
Screen
No.
Checking object
1
Boom angle potentiometer

SE-17

Measure the resistance between terminals of boom angle potentiometer.
4.0~6.0k .
Normal value: 0 to all resistance (4.0~6.0)k
Wiring between boom angle

CN-702F
CN-103F
Mechatro controller
T5-1-52
E215B-E245B
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
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
12
H-2 BOOM

checking screen
No.
Screen
No.
Checking object
1
Boom angle potentiometer

SE-17

Measure the resistance between terminals of boom angle potentiometer.
4.0~6.0k .
Wiring between boom angle

CN-702F
CN-103F
Mechatro controller
T5-1-53
E215B-E245B
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
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
12
H-3 ARM

checking screen
No.
Screen
No.
Checking object
1
Arm angle potentiometer

SE-18

Measure the resistance between terminals of arm angle potentiometer.
4.0~6.0k .
Wiring between arm angle

CN-703F
CN-103F
Mechatro controller
T5-1-54
E215B-E245B
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
Control in the
Normal control.
event of failure
Returned
in
normal condition
Screen
No.
12
H-3 ARM

checking screen
No.
Screen
No.
Checking object
1
Arm angle potentiometer

SE-18

Measure the resistance between terminals of arm angle potentiometer.
4.0~6.0k .
Wiring between arm angle

CN-703F
CN-103F
Mechatro controller
T5-1-55
E215B-E245B
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
normal condition
Screen
No.
10
H-9 FUEL LEVEL

checking screen
No.
Screen
No.
1
Checking object
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
CN-152F
CN-104F
Mechatro 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
normal condition
Screen
No.
10
H-9 FUEL LEVEL

checking screen
No.
Screen
No.
1
Checking object
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
CN-152F
CN-104F
Mechatro controller
T5-1-56
E215B-E245B
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
normal condition
Screen
No.
checking screen
No.
Screen
No.
Checking object
Wiring between gauge cluster

and controller
CN-600F
CN-101F
Mechatro controller
T5-1-57
E215B-E245B
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

checking screen
No.
K-3 KEY SWITCH OFF
Screen
No.
Checking object
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
T5-1-58
E215B-E245B
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

checking screen
No.
Screen
No.
Checking object
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.

When no failure found after checking on wiring and R014 is left displayed.
T5-1-59
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
25
CW MOTOR RLY

checking screen
No.
Screen
No.
Checking object
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
Wiring between wiper motor

forward rotation relay and When R024 is left displayed with the relay removed.
controller
CN-109F, CN2-1
Fuse& relay box
E-1
Mechatro controller
T5-1-60
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
25
CCW MOTOR RLY

checking screen
No.
Screen
No.
Checking object
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
Wiring between wiper motor

forward rotation relay and When R034 is left displayed with the relay removed
controller
CN-109F, CN2-1
When no failure found after checking on wiring and R034 is left displayed
Fuse& relay box
E-1
Mechatro controller
T5-1-61
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
25
MOTOR RELAY

checking screen
No.
Screen
No.
Checking object
1
Washer motor relay

R-32

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
CN-112F, CN2-1
Fuse& relay box
When no failure found after checking on wiring and R044 is left displayed
E-1
Mechatro controller
T5-1-62
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
22
D13

checking screen
No.
Screen
No.
Checking object
1
Swing flasher relay

R-19

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
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
T5-1-63
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
22
D14

checking screen
No.
Screen
No.
Checking object
1
Swing flasher relay

R-19

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

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
T5-1-64
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
23
D15

checking screen
No.
Screen
No.
Checking object
1
Travel alarm relay

R-8

When error is cancelled after removing of travel alarm relay, check relay unit for
Wiring between travel alarm When R154 is left displayed with the relay removed
CN-109F, CN2-2
Fuse & relay box
E-1
Mechatro controller
T5-1-65
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
K-1 AIS RELAY 2

checking screen
No.
Screen
No.
1
Checking object
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.
Wiring between auto idle stop When R164 is left displayed with the relay removed
relay 2 and controller
CN-109F, CN2-2
Fuse & relay box
E-1
Mechatro controller
T5-1-66
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
K-3 ENG STOP

checking screen
No.
Screen
No.
1
Checking object
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.
Wiring between engine forcibly When R174 is left displayed with the relay removed
stop relay and controller
CN-109F, CN2-2
Fuse & relay box
E-1
Mechatro controller
T5-1-67
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
K-4 LOCK LEVER

checking screen
No.
Screen
No.
Checking object
1
Safety lock lever relay

R-26

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

CN-109F, CN2-2
Fuse & relay box
E-1
Mechatro controller

T5-1-68
E215B-E245B
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
event of failure
Returned
in
normal condition
Screen
No.
K-2 SAFETY RLY

checking screen
No.
Screen
No.
Checking object
1
Safety lock lever relay

R-26

When error R214 is cancelled after removing of safety relay, check relay unit for
Wiring between safety lock lever

CN-109F, CN2-2
Fuse & relay box
Mechatro controller
E-1

Check that no power 24V is produced on relay (-) line according to the wiring
T5-1-69
E215B-E245B
[MEMO]
T5-1-70
TROUBLESHOOTING (BY TROUBLE)
E215B-E245B
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
E215B-E245B
1.
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
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
Operation No.18 Travel right full lever
& idling
Operation No.19 Travel left full lever &
idling
T5-2-2

No.
Sections
E215B-E245B
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

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

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
P2 pump
proportional valve
Carry out service
diagnosis
No.9 E-1 P1 pump

E-2 P2 pump
Operation No. 1 Operation is nil


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.
Pressure sensor of
P1, P2 pump
Check pressure

relief
Check pressure sensor and

replace it if necessary
Pump regulator
Visual check

resistance against sliding
Free from abnormal damage, etc on outside
surface
Replace
Pump
Visual check
Replace
When removing, inside parts (cylinder
T5-2-3
E215B-E245B
3.
Move at lever neutral position
No. Sections
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

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
Pressure sensor
Carry out service

diagnosis

Replace pressure sensor
All low pressure sensors are 0MPa to
0.1 MPa
Actual measuring
P2 unload
proportional valve
Carry out service

diagnosis


of unload
proportional valve
proportional valve
secondary pressure
A7 and A8 of 8
sections solenoid
block

Check that P1/P2 unloads secondary

pressures is within the range of 2.7 MPa
or more in control lever neutral and high
idling operation
T5-2-4
No. Sections
E215B-E245B
Carry out service

diagnosis
No.9 E-1 P1 pump

E-2 P2 pump

Actual measuring
P2 pump
proportional valve

of P1, P2 pump
proportional valve
proportional valve
secondary pressure
directly. (Ports a3,
a4)

0.5 to 1.0 MPa in control lever neutral
and high idling operation

Check regulator
Command current
Carry out service
value of short-circuit diagnosis.
No.15 D-15
Operation No. 1 Operation is nil.


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.

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
Boom up pressure
sensor
Carry out service

diagnosis

Check and replace pressure
Operation No.3 boom up full lever and sensor
relief
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

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
P2 unload
proportional valve
Carry out service

diagnosis


relief
T5-2-5
E215B-E245B
No. Sections

of P1, P2 unload
proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block

pressures are within the range of
0.5~1.2 MPa in boom up full lever and
high idling operation
Actual measuring
P2 pump
proportional valve
No.9 E-1 P1 pump

E-2 P2 pump
Operation No.4 boom up full lever & in
operation


of P1, P2 pump
proportional valve
proportional valve
secondary pressure
directly (Ports a3,
a4)

1.8 to 3.0 MPa in boom up full lever and
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

breakage
Replace
10
Lock valve poppet

<Trouble>
Both P1 and P2
pressures are low.
Visual check

outside surface
Replace
(Check on the casing side for
damage)
11
Conflux check valve Visual check

<Trouble>
Only P2 pressure is
high.

outside surface
Replace
damage)
12
Holding valve for

boom (poppet)
<Trouble>
Both P1 and P2
pressures are high.
Visual check

outside surface
Replace
damage)
13
Boom spool
<Trouble>
Only P1 pressure is
high.
Visual check

Spring is free from breakage.
Replace
damage)
14
Check boom spool

and recirculation
<Trouble>
Only P1 pressure is
low.
Disassembly and
investigation

sliding
Replace spool assembly
15
Conflux spool
<Trouble>
Only P2 pressure is
high.
Visual check

outside surface
Replace
damage)
Carry out service

diagnosis
T5-2-6
E215B-E245B
No. Sections
16
Main relief valve

<Trouble>
Relief pressure is
low.
Check set pressure See Service Diagnosis Data List

Reset or replace
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.
Slow boom down, insufficient power for lifting up body
No. Sections
Boom down
pressure sensor
Carry out service

diagnosis

sensor.
Check remote control valve.
Remote control
valve
Measure remote
control pressure of in boom down full lever and high idling When equipped with multi
boom down directly operation
changing lever pattern.
Actual measuring
current value of P1
unload proportional
valve
Carry out service

diagnosis

of P1 unload
proportional valve
proportional valve
secondary pressure
A7 of 8 sections
solenoid block.
Check that P1 unload secondary

1.2 MPa in boom down full lever and
Actual measuring
current value of P1
pump proportional
valve
No.9 E-1 P1 pump

Operation No.5 boom down full lever
& in operation

of P1 pump
proportional valve
proportional valve
secondary pressure
directly (Ports a3,
a4)
Check that P1 pump proportional valve Replace proportional valve

2.5 MPa in boom down full lever and
Actual measuring
current value of
travel straight
proportional valve
Check that the value is not change

Check pressure sensor of
regardless of operation
travel
& idling
check proportional valve
and controller for possible
idling
failure.
Carry out service

diagnosis
Carry out service

diagnosis

& in operation
P1 unload valve (cut valve)

& in operation
T5-2-7


E215B-E245B
No. Sections
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.

regardless of operation No 15 D-15
travel.
Operation No.18 travel right full lever
& idling. Operation No.19 travel left full
lever & idling
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
11
Remote control
valve
Check targeted
remote control
valve

breakage
Replace
12
Lock valve poppet

<Trouble>
Boom down is low.
Visual check

outside surface
Replace
damage)
13
Holding valve
Visual check
(poppet)
<Trouble>
Boom down is slow.

resistance against sliding Free from
abnormal damage, etc on outside
surface
Replace
damage)
14
Boom spool
Visual check
<Trouble>
Boom down is slow.

outside surface
Replace
damage)
15
Check boom spool

and recirculation
<Trouble>
Machine can not be
lifted by supporting
with boom.
Disassembly and
investigation

sliding
16
short-circuit valve
spool.
Visual check.

resistance against free from abnormal
is free from breakage.
Replace (Check on the casing

site for damage).
Carry out service

diagnosis
T5-2-8
E215B-E245B
No. Sections
17
Main relief valve

<Trouble>
Relief pressure is
low.

Reset or replace
relief
18
Over load relief

valve
<Trouble>
Machine can not be
lifted by supporting
with boom.
Visual check
7.
No.
Free from dust entered in port relief

valve.
Replace
Slow arm in, insufficient power

Sections
Arm in pressure
sensor
Carry out service

diagnosis

Operation No.6 arm in full lever and
relief
Remote control
valve pressure
Measure directly
remote control
pressure of arm in
in arm in full lever and high idling
operation
Pump pressure
sensor
Carry out service

Operation No.7 arm in full lever and in
pump pressures in
operation
operation.

pressure sensor
Actual measuring
P2 unload
proportional valve
Carry out service

diagnosis


of P1, P2 unload
proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block.

1.2 MPa in arm in full lever and high
idling operation.
Actual measuring
P2 pump
proportional valve
No.9 E-1 P1 pump

E-2 P2 pump
Operation No.7 Arm in full lever & in
operation
Carry out service

diagnosis

Operation No.6 Arm in full lever &
relief
T5-2-9

sensor

E215B-E245B
No.
Sections

of P1, P2 pump
proportional valve
proportional valve
secondary pressure
directly. (Ports a3,
a4)

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

Operation No.6 Arm in full lever &
relief
Operation No.7 Arm in full lever & in
operation

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

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

travel
& idling
idling
failure.
11

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
12
Remote control
valve
Check targeted
remote control
valve

breakage
Replace
13
Main relief valve

<Trouble>
Relief pressure is
low.

Reset or replace
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.
Carry out service

diagnosis
T5-2-10

No.
Sections
E215B-E245B
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
valve.
Seat is free from abnormality.
16
Arm 1 spool
<Trouble>
P1, P2 pressure is
high.
Visual check

outside surface
Replace
damage)
17
Arm 2 spool
<Trouble>
P1, P2 pressure is
high or low.
Visual check

outside surface
Replace
damage)
18
Check arm 2 spool

and recirculation
<Trouble>
Arm in power is
poor.
Disassembly and
investigation

sliding
19
Check lock valve

poppet
<Trouble>
Both P1, P2
pressures are high.
Visual check

sliding
outside surface
Replace
damage)
8.
No
.
Slow independent arm out (in the air)

Sections
Arm out pressure

sensor
Carry out service

diagnosis

Operation No.8 arm out full lever and sensor
relief
Remote control
valve
Measure directly
remote control
in arm out full lever and high idling
pressure of arm out operation
Pump pressure
sensor
Carry out service

Operation No.9 arm out full lever and
pump pressures in
in operation
operation.

pressure sensor
Actual measuring
P2 unload
proportional valve
Carry out service

diagnosis


Operation No.8 Arm out full lever &
relief
T5-2-11
E215B-E245B
No
.
Sections

of P1, P2 unload
proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block

1.2 MPa in arm out full lever and high
idling operation
Actual measuring
P2 pump
proportional valve
No.9 E-1 P1 pump

E-2 P2 pump
Operation No.9 Arm out full lever & in
operation


of P1, P2 pump
proportional valve
proportional valve
secondary pressure
directly (Ports a3,
a4)

1.5 to 2.7 MPa in arm out full lever and
(Secondary pressure is affected by oil
temperature and attachment weight)
Actual measuring
current value of
travel straight
proportional valve

travel
& idling
idling
failure.

of travel straight
the proportional
proportional valve
valve secondary
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block

10
Remote control
valve
Check targeted
remote control
valve

breakage
Replace
11
Main relief valve

<Trouble>
Relief pressure is
low.

Reset or replace
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
valve. Seat is free from abnormality

outside surface
T5-2-12
Replace
damage)
No
.
Sections
E215B-E245B
14
Arm 2 spool
Visual check
<Trouble>

outside surface
Replace
damage)
15
Check arm 2 spool

and recirculation
<Trouble>
Both P1, P2
pressures are low.
Disassembly and
investigation
(spring side)

sliding
16
Check lock valve

poppet
<Trouble>
Both P1, P2
pressures are high.
Visual check

sliding
outside surface
Replace
damage)
9.
Slow bucket digging
No. Sections
Bucket digging
pressure sensor
Carry out service

diagnosis

Operation No.12 bucket digging full
lever and relief

sensor
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
idling operation
Pump pressure
sensor
Carry out service

Operation No.13 Bucket digging full
pump pressures in
lever and in operation
operation.

pressure sensor
Actual measuring
P2 unload
proportional valve
Carry out service

diagnosis


of P1, P2 unload
proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block

1.2 MPa in bucket digging full lever and
Actual measuring
P2 pump
proportional valve
No.9 E-1 P1 pump

E-2 P2 pump
lever & in operation

of P1, P2 pump
proportional valve
proportional valve
secondary pressure
directly (Ports a3,
a4)
Carry out service

diagnosis

lever & relief


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
E215B-E245B
No. Sections
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

lever & relief

11

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
12

<Trouble>
Only P2 pressure is
low.

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

sliding
damage.)
outside surface
14
Remote control
valve
Check targeted
remote control
valve

breakage
15
Main relief valve

Reset or replace
Operation No.3 Boom up full lever and
relief
16
Travel straight spool Visual check

<Trouble>

outside surface
Replace
damage)
17
Bucket spool
<Trouble>
Both P1, P2
pressures are high.
Visual check

outside surface
Replace
damage)
18
Over load relief

valve
Check targeted
spool visually
Free from dust entered in over load relief Replace

valve.
T5-2-14
Replace
E215B-E245B
10. Slow bucket dump

No.
Sections
Bucket dump
pressure sensor
Carry out service

diagnosis

Operation No.14 Bucket dump full
lever and relief
Remote control
valve
Measure directly
remote control
pressure of bucket
dump
in bucket dump full lever and high idling When equipped with multi
operation
Pump pressure
sensor
Carry out service

pump pressures in
lever and in operation
operation.

pressure sensor
Actual measuring
P2 unload
proportional valve
Carry out service

diagnosis

lever & relief


of P1, P2 unload
proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block

0.5~1.2 MPa in bucket dump full lever
and high idling operation. Replace
proportional valve
Actual measuring
P2 pump
proportional valve.
No.9 E-1 P1 pump

E-2 P2 pump
lever & in operation


of P1, P2 pump
proportional valve
proportional valve
secondary pressure
directly (Ports a3,
a4)

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

lever & relief

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

sensor

Check that travel straight secondary

pressure is 2.7 MPa or more in bucket
dump full lever and high idling operation
T5-2-15
E215B-E245B
No.
Sections
10

<Trouble>
Only P2 pressure is
low.

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
damage.)
12
Remote control
valve
Check targeted
remote control
valve

breakage
Replace
13
Main relief valve

<Trouble>
Relief pressure is
low.

Reset or replace
Operation No.3 Boom up full lever and
relief
14

<Trouble>

outside surface
Replace
damage)
15
Bucket spool
<Trouble>
Both P1, P2
pressures are high.
Visual check

outside surface
Replace
damage)
16
Over load relief

valve
Check targeted
spool visually
Free from dust entered in over load relief Replace

valve.
11. Swing operation not functioned/slow

No. Sections
Swing pressure
sensor
Carry out service

diagnosis

Operation No.11 Swing full lever and
in operation

sensor
Remote control
valve
Measure directly
remote control
pressure of swing
in boom up full lever and high idling
operation
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
T5-2-16
No. Sections
E215B-E245B
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

in operation
Check high pressure sensor
Actual measuring
current value of P2
unload proportional
valve
Carry out service

diagnosis

Operation No.11 Swing full lever & in
operation


of P2 unload
proportional valve
proportional valve
secondary pressure
A5 of 8 sections
solenoid block
Check that P2 unload secondary

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

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

travel
& idling
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

Carry out service

diagnosis
T5-2-17

E215B-E245B
No. Sections
13
Command current
Carry out service
value of short-circuit. diagnosis

travel.
lever & idling
failure.
14

of proportional valve the secondary
in short-circuit valve. pressure of the
proportional valve
in short-circuit
valve. (G Port)

regardless of neutral/operation.
Replace proportional valve.
15
Remote control
valve

breakage
Replace
16

<Trouble>
P2 pressure is low.

outside surface
Replace
damage)
17
Swing spool
Visual check
<Trouble>

outside surface
Replace
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
19
Swing relief valve

<Trouble>
Relief pressure is
low.

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.
outside surface (brake plate etc)
Tooth surface is not worn abnormally

and is not chipped.
T5-2-18
E215B-E245B
12. Noise during swing operation

No. Sections
Carry out service No.3 F-2 SWING-BRAKE

diagnosis
Lever neutral: COMP ON, MEAS
ON
Check swing pressure

sensor
Check harness
Measurement of Lever neutral: 0 MPa

solenoid valve A2 In operation: 4 MPa or more
port
Swing parking
brake solenoid
Boost check valve Visual check

(Sound of
cavitation at
stopping)
When removing, free from abnormal Replace

By-pass check
valve
(Sound of
cavitation at
stopping)
Visual check

Swing motor
(Brake valve/
friction plate)
Visual check
Disassemble and inspect abnormal Replace

wear and scuffing
Swing motor
piston
Visual check

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
Swing
sensor
Remote
valve
Swing parking brake Carry out service No.3 F-2 SWING-BRAKE

solenoid
diagnosis
Lever neutral: COMP ON, MEAS ON
pressure Carry out service Engine stop & starter key ON

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
E215B-E245B
No.
Sections
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
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
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.
15. Slow travel speed/weak

No.
Sections
Travel right and left Carry out service See Service Diagnosis Data List
pressure sensor
diagnosis
Operation No.18 Travel right full lever sensor
and idling
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
No.
Sections
E215B-E245B
Actual
measuring Carry out service No.9 D-1 P1 unload valve (cut valve)
current value of P1/ diagnosis
P2
unload
proportional valve
& idling
idling

Secondary pressure Measure

the
of P1, P2 unload proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block
Actual
measuring Carry out service No.9 E-1 P1 pump
E-2 P2 pump
P2
pump
proportional valve
& idling
idling

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
pressure sensor other than
travel
straight
sensor for travel
proportional valve
& idling
idling
failure

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
travel.
lever & idling
failure.
Check that P1/P2 unload secondary Replace proportional valve

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

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
E215B-E245B
No.
Sections
11 Remote
valve
control Check
remote
valve

breakage
Check sealing ability of shuttle valve and
entry of dust in orifice
12 Travel straight spool Visual check

<Trouble>
13 Travel spool
Visual check
<Trouble>
targeted spool
Pump pressure is
high.
14 short-circuit
spool.
valve Visual check.

Free from abnormal damage, etc on damage)
outside surface
of When removing, free from abnormal Replace
outside surface
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
If P1 is low, right travel

motorfs relief valve is failed.
If P2 is low, left travel
Visual check
Inner parts (piston, cylinder block, valve Replace

plate, brake valve spool) are to be free
from abnormal resistance against
sliding.
in Visual check

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
19 Travel reduction
Visual check
Tooth surface is not worn abnormally Replace

and is not chipped.
T5-2-22
inspect
E215B-E245B
16. Travel deviation

No.
Sections
Travel right and left Carry out service See Service Diagnosis Data List
pressure sensor
diagnosis
Operation No.18 Travel right full lever sensor
and idling
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
travel
straight
sensor for travel
proportional valve
& idling
idling
failure.

directly 0.8 MPa or less in high idling operation Replace proportional valve
proportional regardless of neutral/operation
proportional valve
valve
secondary
pressure
Actual
measuring Carry out service No.8 D-1 P1 unload valve (cut valve)
P2
unload
proportional valve
& idling
idling

the
of P1, P2 unload proportional valve
proportional valve
secondary pressure
A7 and A5 of 8
sections solenoid
block
Actual
measuring Carry out service No.9 E-1 P1 pump
E-2 P2 pump
P2
pump
proportional valve
& idling
idling

of P1, P2 pump proportional valve
secondary pressure
proportional valve
directly (Ports a3,
a4)
control Measure
remote
control in travel right (left), forward (reverse) full
pressure of travel lever and high idling operation
right and left


operation
Travel right (P1 unload): 0.5 to 1.0 MPa
Travel left (P2 unload): 0.5 to 1.0 MPa

operation
Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more
T5-2-23
E215B-E245B
No.
9
Sections
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.

outside surface
Spring is free from breakage
of When removing, free from abnormal Replace
outside surface
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.

breakage
Check sealing ability of shuttle valve and
entry of dust in orifice

<Trouble>
14 Travel motor
Visual check
If P1 is low, right travel

If P2 is low, left travel
Replace as necessary
Inner parts (piston, cylinder block, valve Replace

plate, brake valve spool) are to be free
from abnormal resistance against
sliding.
reduction Take sample oil Sampling oil does not include a lot of Disassemble and
from
travel metal powder.
reduction gear
16 Travel reduction
Visual check
Tooth surface is not worn abnormally Replace

and is not chipped.
17 Pump regulator
Visual check

outside surface
18 Pump
Visual check
When removing, inside parts (cylinder Replace

T5-2-24
inspect
E215B-E245B
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
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
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
damage)
in Visual check
Remove dust or replace
18. Travel parking on a slope is not held

No.
Sections
Pilot
sensor
Remote
valve
Parking brake
travel motor
Orifice of passage Visual check

for parking brake in
travel motor
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
control Check
remote
valve

breakage
in Visual check

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
Actual
measuring Carry out service No. 8 D-3 S-TRAVEL is should be Check voltage of low
COMP 557 mA and MEAS 55730 mA
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.
Above mentioned values indicate while
boom-up and full lever operation are
performed).
failure.
T5-2-25
E215B-E245B
No.
Sections

directly
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
valve
lever and in boom-up full lever at high
travel sensor.
idling
failure.

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)

outside surface
Short-circuit
spool.

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
Pressure sensor for Carry out service See Service Diagnosis Data List
optional attachment diagnosis
Operation No.16 P2 side OPT full sensor
lever and relief
Remote
valve
Actual
measuring Carry out service See Service Diagnosis Data List
Operation No.16 P2 side OPT full largely differed from the
P2
unload
lever and relief
proportional valve
control Measure
remote
control in optional attachment full lever and high
pressure of travel idling operation
right and left
T5-2-26
No.
Sections
E215B-E245B

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
A7 and A5 of 8
sections solenoid
block
Actual
measuring Carry out service See Service Diagnosis Data List
Check voltage of low
Operation No.16 P2 side OPT full
travel
straight
lever & relief
sensor
for
optional
proportional valve
attachment
failure.

directly
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

<Trouble>
Only P1 pressure is
low.
No problem for sliding ability of main Clean or replace

Relief pressure
Remote
valve

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.

<Trouble>

outside surface
11 Spool for optional Visual check

attachment
<Trouble>
P1, P2 pressures
are high.

outside surface
12 Over
valve
load
relief Check
targeted Free from dust entered in over load relief Replace
spool visually
valve
T5-2-27
E215B-E245B
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
Visual check
N&B selector spool

outside surface
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
Visual check

outside surface
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
E215B-E245B
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
E215B-E245B
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)
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

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.

When the resistance is 1 M
or more, it is in
normal condition.
TESTER
SM0107
T5-2-30

4.
Checking connector terminal for contact

Insert male terminal into female terminal unit,
and then check that the inserting force is
equivalent to other female terminals.
If looseness is there, replace the female
terminal with new one.
Clean the dirt terminal.
E215B-E245B
INSERT
MALE TERMINAL
FEMALE TERMINAL
SM0108
ATTENTION
Do not insert the male terminal the thickness differs.
It may cause loose connection.
5.
Caution which should be paid in measuring

voltage
When measuring the power supply to electric
equipment at connector position with the
grounding terminal contained inside of
connector, measure the voltage between
grounding inside of connector and power
terminal.
When measuring the voltage between frame
body grounding and power source, the
disconnection of wiring to grounding inside of
connector cannot be identified.
Since the voltage may vary between with
connector connected and with connector not
connected. Measure the voltage with each
connector connected whenever possible.
6.
Checking the general view of connector

CRIMPED
PART
a. Check the terminal crimped condition.

Pull one electric cable with the about 3kg
force, and make sure that the cable does
not come out of the terminal.
When came out, replace the terminal and
crimp it again.
b. Check connector for imperfect insertion
Check that all top ends form a line on the
same position as seen from the connector
engaged side.
When moved along, push it in further
through wire inserting hole.
c. Check connector for intruding of water.
Pull out the connector and check that the
inside is free from intruding of water.
When water intruding is found, check
rubber plug for damage and also that the
sealing is fitted properly.
T5-2-31
RUBBER
PLUG
RECEPTACLE.
CONTACT
PLUG
SEALING
(is housed in plug)
DOUBLE LOCK
PLATE FOR PLUG
DOUBLE LOCK
PLATE FOR CAP
CAP
TAB.CONTACT
RUBBER PLUG
SM0109
E215B-E245B
7.
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

2.2 TROUBLE
1.
Engine does not stop.
2.
"CPU DATA COMMUNICATION ERROR" is displayed on multi display.
3.
Auto accel does not actuate. (The engine speed does not automatically slow down.)
4.
Auto accel does not actuate. (The engine speed does not automatically speed up.)
5.
Wiper does not function.
T5-2-33
E215B-E245B
E215B-E245B
1.
Engine does not stop.
No
.
Sections
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
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

3.
No
.
Auto accel does not actuate. (The engine speed does not automatically slow down.)
Sections
Engine
coolant Check
engine
temperature
coolant
temperature by
carrying
out
service diagnosis.
Gauge cluster
Low
sensor
4.
No
.
E215B-E245B
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
pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is raised with control lever
operated.
T5-2-35
E215B-E245B
5.
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
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)
E215B-E245B
1. TROUBLE DIAGNOSIS MODE

The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not
be detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal
output.
1.
Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not operated, both selector valve and proportional valve are
automatically actuated, the sensor detects the machine condition and the mechatro controller identifies
the normal condition or failed condition of the system.
2.
How to use and flow chart

The operation is performed through gauge cluster.
No.1 Select service adjustment select screen.
(Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing
buzzer stop switch on the service diagnosis screen No.1.)
No.2 Select Trouble diagnosis mode
(Move the cursor to the desired position with screen change switch "
", and press the select switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2"

(Move the cursor to the desired position with screen change switch "
", and press the select switch.)
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.
T5-3-1
E215B-E245B
No.1
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
E215B-E245B
No.4 CASE OF DIAG MODE 2

SENSOR CHECK
CHECK
START ENG
ENGINE SPEED
0000 rpm
PRESSURE
C-1 00.0M
PROPO-VALVE
E-1 005mA
D-1 300mA
C-2 00.0M
DIAG MODE 2
LOWER BOOM
START
TO GROUND
E-2 005mA
D-2 300mA
Turn engine on
manually.
AT CONTROL LEVER IS
NEUTRAL
Example: Case of boom up

WHEN FINISHING OF
DIAGNOSIS IS REQUIRED.
BOOM UP
BOOM UP
OK
PRESSURE 0.0
MPa
PRESSURE 1.5
MPa
PRESSURE 3.0
BACK TO No.3
MPa
In the normal condition, OK is

displayed when the control
lever is moved to stroke end.
SM0115
SEARCHABLE OPERATION
Boom up
Boom down
Bucket digging
Bucket dump
Arm in
Arm out
Swing
Travel right
Travel left
P1 side option
P2 side option
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground.
If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or
death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail
to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. Place
the bucket on the ground between both crawlers.
2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate
attachment.
When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UNLOAD PSV NG" is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not
appear. If necessary, examine the presence or absence of trouble referring to the trouble history.
T5-3-3
E215B-E245B
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
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
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
E215B-E245B
Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display)
Possible cause
Remedy

against the command
Check P2 unload proportional valve
P2 UN-LOAD PSV NG
against the command
P2 UN-LOAD SPOOL
NG
P1 B-P CUT NG
P2 B-P CUT NG
Check P2 unload spool and replace it

if necessary

Stuck at closing side
Check P1 by-pass cut valve and


Stuck at closing side
Check P2 by-pass cut valve and

P1 PUMP PSV NG

against the command
Check P1 pump proportional valve
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

against the command
Check P2 pump proportional valve
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

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
Check travel straight spool and

PUMP 1 PRESS. SENPressure is recognized lower than it is

SOR NG
Check P1 high pressure sensor and

PUMP 2 PRESS. SENPressure is recognized lower than it is

SOR NG
Check P2 high pressure sensor and

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

T5-3-5
E215B-E245B
[MEMO:]
T5-3-6

Service Manual - E215B-E245B - 5 - EN

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TROUBLESHOOTING

SECTION AND GROUP CONTENTS

Troubleshooting (by Error Codes)

Group 2 - Troubleshooting (by trouble)

Group 3 - Troubleshooting (Trouble

TROUBLESHOOTING (BY ERROR CODES)

1. JUDGMENT OF ACTUAL THING AT SITE

GET TO THE SITE AS QUICKLY AS POSSIBLE

Attending the field to verify actual thing

Verify model, serial number, situation of trouble and

Verifying background of trouble occurred

HOW TO DIAGNOSE TROUBLE

EXPLANATION OF THE CAUSE OF TROUBLE

Confirm the symptoms of the trouble

2. Treatment of damaged parts

Diagnosing fail by means troubleshooting

TROUBLESHOOTING (BY ERROR CODES)

2. CLASSIFICATION OF FAILURE AND TROUBLESHOOTING

3. THE BLOWN FUSE OF MECHATRO CONTROLLER

The blown fuse of mechatro controller

4. TROUBLESHOOTING BY ERROR CODE

Engine adjustment (A adjustment) is not adjusted yet or is failed.

Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed.

Unload valve adjustment (C adjustment) is not adjusted yet or is failed.

Written data of ROM adjustment data is incorrect.

Writing of ROM adjustment data is incorrect.

Written data of ROM hour meter data is incorrect.

Writing of ROM hour meter data is incorrect.

Writing of proportional valve adjustment data is incorrect.

Incorrect output of boom up pressure sensor

Disconnection of boom up pressure sensor

Short-circuit of boom up pressure sensor

Incorrect output of boom down pressure sensor

TROUBLESHOOTING (BY ERROR CODES)

Disconnection of boom down pressure sensor

Short-circuit of boom down pressure sensor

Incorrect output of arm out pressure sensor

Disconnection of arm out pressure sensor

Short-circuit of arm out pressure sensor

Incorrect output of arm in pressure sensor

Disconnection of arm in pressure sensor

Short-circuit of arm in pressure sensor

Incorrect output of bucket digging pressure sensor

Disconnection of bucket digging pressure sensor

Short-circuit of bucket digging pressure sensor

Incorrect output of bucket dump pressure sensor

Disconnection of bucket dump pressure sensor

Short-circuit of bucket dump pressure sensor

Incorrect output of swing pressure sensor

Disconnection of swing pressure sensor

Short-circuit of swing pressure sensor

Incorrect output of travel right pressure sensor

Disconnection of travel right pressure sensor

Short-circuit of travel right pressure sensor

Incorrect output of travel left pressure sensor

Disconnection of travel left pressure sensor

Short-circuit of travel left pressure sensor

Disconnection of pressure sensor of optional selector positioning

Short-circuit of pressure sensor of optional selector positioning

Incorrect output of P1 optional side pressure sensor

Disconnection of P1 side optional pressure sensor

Short-circuit of P1 side optional pressure sensor

Incorrect output of P2 optional side pressure sensor