Training Manual 20-30 Tons BJ Series - EN

CRAWLER EXCAVATOR
20-30 tons BJ series
Torino Training Center

BJ series 20-30 tons
MECHATRO CONTROL SYSTEM
Turin Training Centre

Update October 2009
3
CAB DISPLAY
LOW PRESSURE
(INFORMATION FOR
SENSORS
OPERATOR)
HIGH PRESSURE INPUT OUTPUT ELECTRIC SIGNALS TO
SENSORS
SOLENOID VALVES
ON-OFF
ENGINE RPM
ELECTRIC SIGNALS TO
DISPLAY(WORK
PROPORTIONAL
MODE SELECTION)
SOLENOID VALVES
MECHATRO is the link between electrical system and hydraulic system.

Is designed to set the correct flow rate according the position of the lever and to set
the position of some spools on the main control valve according on the operation.
4
LOW PRESSURE SENSORS
When the levers are actuated the secondary pilot pressure (in output from pilot valve)
Moves the spool in the main control valve, andthe same pressure is measured by the
low pressure sensor and an electrical signal is sent to the mechatro controller.
The secondary pilot pressure is proportional according to the stroke of the lever.
Low pressure sensor block located on the

left side under the operator cab.
5
THE LOW PRESSURE SENSORS ARE POWERED

AT 5 VOLTS BY THE CONTROLLER.
IN THE OUTPUT THE ELECTRIC SIGNAL MOVES

FROM 0.5 VOLT THROUGH 4.5 VOLT.
VCC SUPPLY
VOUT OUTPUT SIGNAL
GND GROUND
INPUT PRESSURE FROM 0 TO 3 MPa
6
HIGH PRESSURE SENSORS
Are used to measure the delivery pressure of the pumps according to the load.
The signal is sent to the controller and is processed to set the correct flow rate
according the P/Q curve.
The electrical signal in output is proportional to the pressure.
Input pressure from 0 to 50 MPa

High pressure sensors are equipped with a different connector.
7
Flywheel housing
The signal from engine speed sensor SE-13

is in input to the controller, is managed to set
the ECU output according to throttle position
and work mode selection
The HINO engine is also build up with Engine main revolution sensor and Engine
sub-revolution sensor( timing sensor) for engine managment.
8
ON-OFF SOLENOID VALVES
The ON-OFF solenoid valve are 24 Volt powered ,and feed by primary
pilot pressure 5.0 MPa.
Following functions are powered by the controller:
SV-1 SWING PARKING BRAKE N.O. type
SV-3 TRAVEL SECOND SPEED N.C. type
SV-2 POWER BOOST N.C. type
Fuse directly powered through switch on the left armrest
SV-4 PILOT CONTROLS ACTIVATION N.C type
9
PROPORTIONAL SOLENOID VALVES

The proportional solenoid valves are feed by primary pilot pressure 5.0 MPa and
direct current powered by the controller.
The output of valves is secondary pilot pressure according to the input signal
350mA ≈ 0.6 MPa 750 mA ≈ 3.0MPa oil in pressure shift the spools on C/V or shift the
position of the spool on the regulator of main pumps.
There are two kinds of valves: normally open and normally closed according to the
work that have to do.
The machine is made up with 6 proportional solenoid valves.
PSV-P1 PSV-P2 fitted on the regulators of the pumps, are used to set the flow rate
according to the positive control. The secondary pilot pressure works on a spool on
the regulator.
PSV-B P2 UNLOAD , PSV-D P1 UNLOAD , PSV-C TRAVEL STRAIGHT fitted on the

solenid valve block, are used to shift the spools on the C/V according to the operation
of joystick and foot pedal.
10
PSV-A ARM2 SPEED is N.O. type , powered by the controller, and feed by the
secondary pilot pressure coming from joystick ARM IN operation.
Oil in pressure in output from the valve, according to the electrical signal, shift the
second spool of arm in ARM IN operation.
Due to PSV-A, arm 2 spool is controlled by MECHATRO, regardless the secondary

pilot pressure coming from joystick controller can set the position of the spool to
prevent cavitation of arm cylinder by activating recirculation function.
To ARM 2 spool
From joystick arm

in operation
11
PSV-A
SV-2
PSV-D SV-3
PSV-C SV-1
PSV-B
SV-4
Solenoid valve block location
12
13
14
NEW HOLLAND CONSTRUCTION
Training Shared Services
CLUSTER E 215BJ E 265BJ E 385BJ
15
MECHATRO CONTROLLER
DISPLAY STANDARD SCREEN
CLOCK
SELF DIAGNOSIS, FAULT

CODE- WARNING
MACHINE CONDITIONS
AFTER KEY SWITCHED IN ON THE SCREEN FOR OPERATOR IS

DISPLAYED ON MULTI SCREEN
16
Turin Training Centre Strictly private and confidential
MECHATRO CONTROLLER WORK MODE
WORK MODE
S standard max 1900 rpm E 265BJ

H heawy max 2100 rpm
S standard max 1800 rpm E215BJ

H heawy max 2000 rpm
H WORK MODE S WORK MODE
17
MECHATRO CONTROLLER WORK MODE
B WORK MODE A WORK MODE
BRAKER 1- WAY NIBBLER 2- WAY
18
MECHATRO CONTROLLER FLOW RATE ADJUSTMENT
From this screen press enter
Adjust the correct flow rate by using arrow up and down
When target value is reached press enter
19
MECHATRO CONTROLLER
W code is stored on
trouble history
WARNING ICONS when the machine works in a dangerous state

This code are not related to electrical failure on components
20
MECHATRO CONTROLLER
To check the trouble history ,with key switch on press 5 times BUZZER STOP
OPERATION FAULT
HOURS CODE
21
MECHATRO CONTROLLER
IN CASE OF ELECTRICAL FAILURE DETECTED FROM THE CONTROLLER,

THE DISPLAY SHOWS A CODE IN THIS FORMAT
LAST DIGIT:
B 013
Type of failure,
disconnection , short
circuit
FIRST DIGIT SYSTEM

SECOND AND THIRD DIGIT:
FAILURE:
Specified component
Sensor,solenoid,
potentiometer ...
22
MECHATRO CONTROLLER Function for operator
From base screen press SCREEN CHANGE BUTTON
This screen display the remaining time to the end of

reccomended interval timing to carry out the maintenance
Change oil and filter
One by one the display shows : ENGINE OIL, FUEL FILTER,

HYDRAULIC FILTER, HYDRAULIC OIL .
23
To change the interval timing after carry out the maintenance

press ENTER and with arrrow UP and DOWN set the
desired value or press BUZZER STOP to go back to the
reccomended default value.
Confirm the new value by pressing ENTER
24
From base screen press ENTER
This screen shows SWITCH STATUS to enable or disable

the following functions:
AUTO WARM-UP
AUTO IDLE STOP
SWING FLASHER
CLOCK/CONTRAST to change the setting for data and hour
Press ENTER
25
AUTO WARM-UP function :
OFF function disable
ON function enable
Press ENTER , and with arrow UP turn it in ON and confirm

the selection with ENTER
26
AUTO WARM-UP FUNCTION
When the coolant temperature is lower thand 10°C at engine starting the display shows
WARM and automatically the procedure start in order to warm the hydraulic oil and
coolant, according the following step:
1. Engine running at 1050 rpm for 3 minutes without using pumps

2. Engine running at 1050 rpm for 3 minutes with the pumps at medium displacement
3. Engine running at 1600 rpm for 5 minutes with the pumps at maximum displacement
4. Engine running at 1600 rpm for 10 minutes with the pumps at maximum
displacement and unloading valve close (high pressure).
Complete procedures need 21 minutes, is shut off if any levers is shifted, and restart if
levers go back in neutral for 10 seconds.
Is also shut off when coolant reach 70°C for at least 1 minute
27
AUTO IDLE STOP function :
OFF function disable
ON function enable
With lever in neutral and armrest in UP POSITION after 1

minute (adjustable ) the controller shut off the engine and the
battery relay.
If equipped this function enable and disable the alarm for

swing operation.
28
MECHATRO CONTROLLER Function for Service
From the cluster the serviceman can:
Check parameters SERVICE DIAG SCREEN 1-2-3
Unit parameters setting ADJUSTING MODE 1
Calibration A-B-C ADJUSTMENT
Active diagnosis FAULT DIAG MODE 1-2
29
MECHATRO CONTROLLER Function for Service
Service diagnosis display screen
The service diagnosis display screen shows all of electrical signals analogical/digital
in input & output to the MECHATRO controller.
Is divided in 3 screen
Service diag 1 parameters grouped per components
Service diag 2 parameters grouped per operation
Service diag 3 machine information
30
MECHATRO CONTROLLER Service diagnosis display
Service diagnosis 1: screen 2-28
Operation procedure:
Keep pressed BUZZER STOP and turn key switch ON
31
MECHATRO CONTROLLER
Part number MECHATRO controller
Software version
Engine speed set

Engine speed measured SE-13
Engine speed reading from ECU
Switch engine oil pressure, coolant temperature
Working MODE
Accelerator potentiometer
Electrical signal to ECU engine for speed set
32
MECHATRO CONTROLLER
Solenoid valve for power boost activation SV-2
Solenoid valve for swing parking brake SV-1
Solenoid valve for first- second travel speed SV-3
Auto idle stop relay 2 control for main relay
Relay stop engine

Key switch
Alternator
Lock lever SV-4
33
MECHATRO CONTROLLER
Low pressure sensor
Low pressure sensor
P1 OPT foot petal for two piece boom

P2 OPT foot pedal for N&B operation
34
MECHATRO CONTROLLER
High pressure sensor

Pump P1 SE-22
Pump P2 SE-23
Pressure sensor for overload alarm
Proportional solenoid valve
Unload P1 PSV-D
Unload P2 PSV-B
Travel straight valve PSV-C
Arm-in 2 spool inverse PSV-A
35
MECHATRO CONTROLLER
Proportional solenoid valve
Pump P1 P2
Adjusting current on overload
Switch
36
MECHATRO CONTROLLER
Solenoid valve
Selector valve for N&B operation SV-13
Position of spool
Selector switch MODE work
Low pressure sensor

Selector valve for N&B operation
37
MECHATRO CONTROLLER
Digital input
Check MECHATRO connector
Digital output
Check MECHATRO connector
38
MECHATRO CONTROLLER
Wiper relay
MERIT system
Satellite control not available for EU market
39
MECHATRO CONTROLLER
Engine data
Boost pressure
Barometric pressure
Fuel temperature
Intake air pressure
Engine oil pressure
40
MECHATRO CONTROLLER
SERVICE DIAG 2
Parameters grouped by operation
Boom operation
By checking the service diagnosis data list (on workshop

manual) as a reference to decide normal/abnormal status
41
MECHATRO CONTROLLER
SERVICE DIAG 3
MACHINE INFORMATION
ADJUSTMENT Parameters related to the A B C calibration

Max rpm no load
Current at pump adjustment
Current correction at pump adjustment
P1 P2 unload correction current
42
MECHATRO CONTROLLER
Machine information
Total hour MECHATRO
Partial hour MECHATRO
Working hours in ATT, travel, swing ,OPT operation
Number of cranking
PUMP PRESSURE
Total hour Last 10 hours
Level 1 low
Level 4 high
COOLANT TEMPERATURE
Total hour Last 10 hours
Level 1 low
Level 4 high
43
MECHATRO CONTROLLER ADJUSTING MODE 1
FROM SCREEN 1 SERVICE DIAG 1 KEEP PRESSED

BUZZER STOP
AND IN THE SAME TIME PRESS 3 TIMES ENTER
PRESS ENTER
44
WITH ARROW UP-DOWN KEY SELECT THE DATA
TO ACTIVATE WIPER ONLY FOR SPECIAL CAB
TO ADJUST THE TIME FOR AUTO STOP FUNCTION
45
TO ENABLE AND DISABLE SELF DIAGNOSIS FOR

P1-OPT TWO PIECE BOOM OPERATION
TO ENABLE AND DISABLE SELF DIAGNOSIS FOR

P2-OPT N&B OPERATION
46
TO ENABLE AND DISABLE ALARM IN SWING OPERATION
TO USE P1 OPTIONAL FOOT PEDAL FOR P4 PUMP

BUCKET ROTATION
47
SELECTION FOR OTIONAL SISTEM N&B OPERATION
1 NO SELECTOR VALVE
2 ELECTRICAL SELECTOR VALVE MECHANICAL RELIEF VALVE
3 ELECTRICAL SELECTOR VALVE ELECTRIC RELIEF VALVE
TO ACTIVATE THE ENGINE SPEED SHOWS ON DISPLAY

OPERATOR
48
TO CHANGE THE AUTO IDLE FUNCTION.

FROM 18 TILL 6
18 SMOOTH RESPONSE
6 QUICK RESPONSE
TO CHANGE THE WORKING MODE AT START
49
OFF FUNCTION ACTIVE
AT FIRST START OF THE MACHINE FOR 3 min ON ARM IN

OPERATION THE SYSTEM USE ONLY 1 PUMP
TO ADJUST THE LOW IDLE OF THE ENGINE @ 800 RPM

USING WITH FUNCTION OF HINO Dx
50
CHANGE ON TO DRAIN HYDRAULIC PRESSURE ON

THE SYSTEM
START ENGINE, PUT THE ARMREST IN DOWN

POSITION AND OPERATE ON ALL ALL LEVER.
THERE IS NO OPERATION ON THE MACHINE AND THE
PRESSURE WILL BE RELEASED.
SET KEY SWITCH IN OFF
51
MECHATRO CONTROLLER A-B-C ADJUSTMENT
MECHATRO CONTROLLER
DIESEL ENGINE
PROPORTIONAL SOLENOID VALVE FOR PUMP & UNLOAD
In case of repairing or replacement of this components carry out the A-B-C

ADJUSTMENT
Condition of calibration
Warm up engine , hydraulic oil temperature >50°C air conditioned switch OFF, key start
switch OFF
In case of MECHATRO controller replacement , errors code A215,A225,A015 are

related to the missing calibration (adjustment data are not entered)
52
A ADJUSTMENT ENGINE
This adjustment is performed to set the relation between the accelerator command
voltage in output from mechatro controller to the engine controller
B ADJUSTMENT PUMP
This adjustment is performed to correct the output variation by matching the
hydraulic output with engine rated output
C ADJUSTMENT UNLOAD
This adjustment is performed to correct the bleeding rate of unloading valve to
improve manoeuvrability.
53
Keep pressed MODE switch
For 10 secons and in the same time turn key

switch in ON.
Keep pressed BUZZER STOP switch for

10 seconds
The display shows this screen
Press ARROW key to skip A-B adjustment and

perform only C adjustment
54
Press ENTER
Start engine and press ENTER
55
The sistem manage the engine speed in order to

reach the low and high idle
In this screen, press ENTER to limit high idle at

desired rpm
Adjustment is done, to skip B-C adjustment press

BUZZER STOP
56
The sistem manage the electrical signal to the

proportional valve PSV-P1/P2 and check the
engine speed in order to matching the hydraulic
power with the engine power
B adjustment is done
57
The sistem manage the electrical signal to the

proportional valve PSV-B/D and check the engine
speed in order to set the bleding rate of unloading
valve
C adjustment is done
Calibration completed
58
Service diag 3 pag.41 to check the parameters related to the adjustment
59
TROUBLE DIAGNOSIS MODE
Mechatro controller always check the electrical function of the components

connected , sensors, solenoid valve…self diagnosis function.
The system detect only electrical failure: disconnection, short circuit, abnormal
signal..
The system cannot detect mechanical problems, such as stuck or broken valve,
stuck spools…
To detect this kind of problem for serviceman is useful for troubleshooting run the
Trouble diagnosis mode.
DIAG MODE 1 to diagnose unload system, pumps , travel straight valve and
engine
DIAG MODE 2 to diagnose the secondary pilot pressure, in output from joystick
60
Select service adjustment mode,

press ARROW key and select FAULT DIAG
MODE
Presss ENTER
61
Select the desired mode

Confirm the selection by press ENTER
The system check the sensor, follow step by step

the instruction from cluster start engine, lower the
boom to the ground and confirm with ENTER
62
Start engine and confirm with ENTER
Lower the boom to the ground and confirm with

ENTER, raise up the armrest.
63
The controller , step by step , change the

electrical signal to the proportional solenoid
valve( unloading, pump , travel straight) and
check if the response of the system is right
according the program stored inside.
64
When performance is done the system shows,if

found errors, and the data of the test.
If the system found some errors, for

troubleshooting refer to the shop manual.
65
Select the desired mode

Confirm the selection by press ENTER
Follow step by step the instruction from cluster

start engine, lower the boom to the ground and
confirm with ENTER
66
Lower the boom to the ground and confirm with

ENTER
The system set the engine revs at high idle
67
Without any movment of the attachment slowly

move the levers until the buzzer sound and the
system shows operation/OK.
OK means that this secondary pilot

pressure(boom up in this case) reach the correct
target value
Press BUZZER STOP when test is done to exit

from the diag mode 2
68
A-B-C ADJUSTMENT
69
A-B-C ADJUSTMENT
THERE ARE 3 KINDS OF ADJUSTMENT OF MECHATRO CONTROLLER AS

SHOWN BELOW:
A ADJUSTMENT ENGINE
B ADJUSTMENT PUMP
C ADJUSTMENT UNLOADING
A ADJUSTMENT IS PERFORMED TO SET THE RELATION BETWEN THE

ACCELERATION COMMAND VOLTAGE OUTPUT FROM CONTROLLER TO
ECU
B ADJUSTMENT IS PERFORMED TO CORRECT THE OUTPUT VARIATION

BETWEN HYDRAULIC POWER AND ENGINE POWER
C ADJUSTMENT IS PERFORMED TO CORRECT THE OPEN VARIATION OF

UNLOADING VALVE
70
A-B-C ADJUSTMENT
A-B-C ADJUSTMENT ARE CARRY OUT WHEN THE FOLLOWING PARTS

ARE REPLACED OR REPARIED
MECHATRO CONTROLLER
ENGINE OR ECU
HYDRAULIC PUMP OR PROPORTIONAL SOLENOID VALVE PSV-P1/P2
UNLOADING PROPORTIONAL SOLENID VALVE
CONDITIONS FOR ADJUSTMENT
WARM-UP ENGINE
HYDRAULIC OIL TEMPERATURE TO 50°C
AIR CONDITIONED OFF
71
A-B-C ADJUSTMENT
WHEN MECHATRO CONTROLLE IS REPLACED THE DISPLAY SHOWS THIS

ERROR CODE BECAUSE THE ADJUSTMENT DATA IS NOT ENTERED
A215 A225 A015 A025
72
A-B-C ADJUSTMENT
Keep pressed MODE switch
For 10 secons and in the same time turn key

switch in ON.
Keep pressed BUZZER STOP switch for

10 seconds
Change screen by pressing arrow key and

skip A-B adjustment and perform only C
adjustment ,
73
A-B-C ADJUSTMENT
Start engine press ENTER switch
The screen shows MEMORY ENGINE and reach

the maximum idle speed
74
A-B-C ADJUSTMENT
at this point the A calibration is done, to skip B

and C calibration press BUZZER STOP key,
otherwise, the system start with B calibration
B calibration in progress, proportional solenoid

valve of pump are actuated and the loading pump
is increased
75
A-B-C ADJUSTMENT
B calibration is done , the system automatically

turn in C adjustment
C adjustment in progress, unloading valve are

actuated in order to det the correct opening rate
76
A-B-C ADJUSTMENT
C calibration is done , the system automatically

turn on the main screen
Page 41 to check the calibration data.
77
78
HYDRAULIC SYSTEM
MAIN CONCEPT
Turin Training Center

Update October 2009
79
MAIN CONCEPT
High Efficiency System

FSV FSV
Totally reviewed system to
achieve “High speed”, “High- E E
Power” and “Energy saving”

1.Enlarged C/V & hydraulic piping
2.New Unload-valve improving for
E
E
Unloadin
g valve
Straight
Propel Propel
hydraulic Bleeding control E

Propel Boom conflux Unloading
3.New 2-Arm-Spool
valve valve
4.Improved Pump efficiency Boom Swing
5.Further specification up of ; Bucket Arm 1

-Swing torque up on 20t/13t
-Propelling torque up on E Arm 2 OPT1(N&B)
20t/30t/13t FSV FSV
6.Fine regulation of Main Pump
and Main Control Valve by new OPT2 N&B
(jib etc.) Selector
Mechatro-control system For P4 pump
(rotation)
80
MAIN CONCEPT
Improving fine operation

FSV FSV
Aiming High-speed and E E
Operation ability
1.”New 2-Arm-spool” is effective in;

-Faster Arm-in operation speed
E
E
Unloadin
g valve
Straight
Propel
Propel
-Shock less operation at shifting E

Propel Boom conflux Unloading
re-circulation cut & conflux point.

valve valve
Boom Swing
2.”Maximize spool-traveling-amount”
to improve maneuverability. Bucket Arm 1
3. “Computerized 2-Arm-spool” for

E Arm 2 OPT1(N&B)
fine maneuverability on simul-
-taneous operation of Arm-in, FSV FSV
Boom and bucket operation. OPT2 N&B

(Jib etc.) Selector
For P4 pump
(rotation)
81
MAIN CONCEPT
High Reliability FSV

FSV
Achieved Advanced Mechatro E E
Control system, furthermore,
Accomplished Fail-safe-system
1. “Main pump Emergency mode” E

Unloadin
g valve
Straight
Propel
E
Propel
Propel Boom conflux Unloading E

valve valve
2. “Main control valve Emergency

mode” that controller Boom Swing
automatically switching when

Bucket Arm 1
system fail.
Arm 2 OPT1(N&B)
3. “Failure diagnosis function” that E
controller self troubleshooting for FSV FSV
power train components and OPT2 N&B

multi display automatically report. (Jib etc.) Selector
For P4 pump
(rotation)
82
MAIN CONCEPT
Option-Port Variation
FSV FSV
New style main control valve allowing E E
optional valves adoption easier to
comply market requirement as well as
its diversity.
E
E
Unloadin
g valve
Straight
Propel
Propel
1.Standardize “Optional spool”
E
built-in main control valve Propel Boom conflux Unloading
valve valve
2.Bolt up “N&B selector valve” Boom Swing
directly to main control valve

Bucket Arm 1
3.Bolt up “P4 pump control valve”

E Arm 2 OPT1(N&B)
directly to main control valve.
FSV FSV
OPT2 N&B
(Jib etc.) Selector
For P4 pump
(rotation)
83
MAIN PUMP & UNLOADING VALVE
Control Valve ･Located at pump inlet line

･Applied to both P1 / P2 side
Unloading valve
･Fuel saving (Minimize
backpressure at C/V)
･Improve maneuverability
PSV
Unloading PSV 84
MAIN PUMP & UNLOADING VALVE LEVER IN NEUTRAL
Control Valve Lever in NEUTRAL

(Low-press. sensor 0.5V)
PSV shifts Unload valve

(Port FULLY OPENED)
Unloading valve
Oil FULL AMOUNT

PSV RETURN back to tank
Center by-pass cut spool

always closed if PSV on Energy saving and
By-pass cut spool Less Fuel consumption
Unloading PSV 85
MAIN PUMP & UNLOADING VALVE LEVER SHIFTED
Control Valve Lever in SHIFTED position

(Low-press. sensor ON)
Unload valve shifted middle

(Port in BLEED position)
Unloading valve
ADJUST OIL VOLUME

to main control valve
PSV
Center by-pass cut spool
always closed if PSV on
By-pass cut spool
Improve maneuverability
86
Unloading PSV
ARM OUT OPERATION
P1 P2
P1 Unload spool P2 Unload spool
Arm 2 spool Arm spool 1

(re-circulation&conflux)
87
ARM OUT OPERATION
P1 P2
88
ARM IN LIGHT LOAD Conflux & Recirculation
P1 P2
PSV
89
ARM IN HEAVY LOAD Conflux & Recirculation cut
P1 P2
PSV
90
BUCKET OPERATION
P1 P2 P2 unloading
Spool
Straight Travel Valve
P1 unloading spool
Bucket spool
91
BUCKET OPERATION CONFLUX
P1 P2
PSV
92
EMERGENCY MODE
Low-pressure
Low-pressure sensor
sensor
C/V Mechatro-controller
Mechatro-controller
Unloading
Unloading PSV
PSV
Breakdown
Cut signal to PSV

Unloading valve
Springs fully switch to;
- CLOSE Unloading valve
- OPEN Cut-valve
PSV
Cutting valve opening completely
Same circuit as “6E”

Unloading PSV 93
94
HYDRAULIC SYSTEM
PILOT SYSTEM
95
PILOT SYSTEM
Pilot system is made up on:

Pilot pump
Solenoid valve block
Low pressure sensor block
Joystick and foot pedal
Pilot pump is gear type pump and discharge oil in

pressure to the solenoid valve block and on the
regulatuors on the main pumps.
Primary pilot pressure 5.0 MPa supply the solenoid valve block , that is made up to 4
solenoid valve ON –OFF type and 4 Proportional Solenoid Valve.
The solenoid valve are used for these following operation:
SV-4 LEVER LOCK : activation of hydraulic control by supply the joystick and foot pedal
SV-1 SWING PARKING BRAKE : to release and lock the swing parking brake
SV-3 TRAVEL SPEED CHANGE : to change the travel speed
SV-2 ATT. BOOST :to set the secondary stage of main relief valve (boost pressure )
96
PILOT SYSTEM solenoid valve block
To function ON-OFF normally closed type: 24 Volt power

supply and feed by 5.0 MPa primary pilot
pressure.
SV-4 LOCK LEVER: 24 Volt power supply from

swich SW-11 when armrest left is in down
position.
To tank
SV-3 TRAVEL SPEED CHANGE :24 Volt
From pilot pump power supply from MECHATRO controller
according the selection on the cluster.
Function deactivated
SV-2 ATTACHMENT BOOST: 24 Volt from
MECHATRO controller when swich on the
joystick is keep pressed & boom up or bucket
dig or arm in operation.
97
To function Coil is 24 Volt powered, spool change his

position and 5.0 MPa primary pilot pressure
feed he function.
SV-4 LOCK LEVER: primary pilot pressure feed

the joystick and foot pedal to activate all
hydraulic function .
To tank
SV-3 TRAVEL SPEED CHANGE : primary pilot
From pilot pump pressure feed the travel motor to change the
displacement and set the second speed travel
Function activated
SV-2 ATTACHMENT BOOST: primary pilot
pressure feed the main relief valve in order to
dset the second stage pressure.
98
To swing parking brake ON OFF normally open type: 24 Volt power

supply and feed by 5.0 MPa primary pilot
pressure.
SV-1 SWING PARKING BRAKE: 24 Volt power

supply from MECHATRO.
To tank Swing parking brake is disengaged is swing

and arm in operation. There is a 5 seconds
From pilot pump delay to engage the brake afterward a swing
operation.
0 Volt parking brake released
99
To swing parking brake 24 Volt parking brake engaged
Swing parking brake are iside the swing

hydraulic motor and are negative type brake.
To tank The force of the springs is used to lock the

brake system.
From pilot pump
100
To function PROPORTIONAL SOLENOID VALVE

normally closed type: PWM signal power
supply from controller and feed by 5.0 MPa
primary pilot pressure.
PSV-B P2 UNLOAD ; PSV-D P1 UNLOAD to

shift the position of unload and by pass cut
To tank spools fit on the main control valve.
From pilot pump PSV-C TRAVEL PRIORITY to shift the position
of the travel priority spool on the main control
valve.
Secondary pilot pressure in output to the PSV is according to the signal send to
the controller.
350 mA ≈ 0.8 MPa

750 mA ≈3.0 MPa
101
PILOT SYSTEM
To 2 Arm-in spool PROPORTIONAL SOLENOID VALVE PSV-A

normally open type: PWM signal power supply
from controller and feed by secondary pilot
pressure from joystick in arm in operation.
To tank According to the signal send from the controller

the secondary pilot pressure in output to PSV-A
From joystick Is used to shift the position of the second spool
arm in of arm( in arm in operation) in order to set
recirculation function.
102
MAIN CONTROL VALVE Feed line
P2 P1
Main control valve is made up in two parts bolted together.

Green line central passage
Red line parallel passage
103
MAIN CONTROL VALVE Return line
To tank The return line from cylinder and

hydraulic motors are collect on the main
return line, the check return valve set a
counterpressure on the main control
Oil cooler valve.
This counterpressure is used as a boost
pressure for low pressure passage(return
Make up lines).
Check return check To prevent cavitation problem on swing
valve valve hydraulic motor, in make up operation
check valve opens and oil from tank feed
low pressure passage.
Check valve for
cooler
Main return
line
Return line for bucket and
arm cylinder head side
104
MAIN CONTROL VALVE Return lines
To tank On the return line T1 oil flows back to

tank through the cooler; return line T2 is
directly connected to the tank.
For the oil flow cooler looks like a
restrictor.
Accorting to the temperature hydraulic oil

change his viscosity.
The hot oil can flows to the tank pass-by

the cooler due to less viscosity.
Hot oil is thickness can not open the
cooler check valve and flows back to tank
through the cooler
Check valve for

cooler
105
MAIN CONTROL VALVE Return lines
To tank Oil cold by-pass the cooler and flows

back to tank directly
Oil cold is more viscous , can open the

check valve, skip the cooler and flows
back to tank
Check valve for

cooler
106
MAIN CONTROL VALVE Main relief valve
PL port from
SV-2
The boosted pressure of main relief valve is obtained by feed 5.0 MPa on PL
port, that increase the force of the spring in order to set the second stage of
main relief valve.
The highest pressure is led to the main relief valve via check valve CMR1 CMR2
(Check Main Relief valve).
107
ATTACHMENT OPERATION Boom up
Pilot line
from joystick
For boom up operation the sytem use

2 pumps & 2 spools; boom conflux
Pilot line spool is supply directly by the parallel
from joystick passage.
Parallel passage is keep closed by the
unloading valve and by pass cut valve
108
ATTACHMENT OPERATION Boom down antidrift valve
Pilot line
from joystick To prevent natural falling when boom is left
in up position the main control valve is fitted
with anti drift valve.
Rod Antidrift valve CRb is fitted on the head side

of boom cylinder and is made up in two
chambers.
Head
When attachment is raised from the ground,
the pressure on the head side of boom
cylinder is used to keep closed the antidrift
valve.
In boom down operation secondary pilot

pressure from joystick shift the boom spool
and release the antidrift valve by
discharging the pressure on the large
chamber.
109
ATTACHMENT OPERATION Boom down constant recirculation
During boom down operation, the oil that return to tank from head side of the
cylinder, is recirculated to the rod side, through the check valve inside the boom
spool.
Recirculation is cut off when the pressure on rod side is higher than pressure of
head side.
110
ATTACHMENT OPERATION Bucket dig combined flow
The combined flow of two pumps is

obtained by shifting the travel priority
valve into the middle position, the by
pass cut valves and the unloading
spools closed.
The flow of the two pumps is

combined in the parallel passage.
The combined flow of two pumps for dig and dump is only on single
bucket operation
111
ATTACHMENT OPERATION Bucket dig stroke limiter
To prevent cavitation during bucket dig

operations and to provide combined
movments of bucket and boom, the
travel stroke of the spool is limited.
As a result reduce flow rate that supply

bucket cylider in case of low engine
speed.
The function is activated to the

controller by send an electrical signal
to SV-2
Pilot line from joystick

bucket dump
Pilot line from SV-2
112
ATTACHMENT OPERATION Arm spools
ARM 1 supply by P2 Pilot line

from joystick
ARM2 supply by P1 both side of
the spool
Pilot line
from joystick
Pilot line
from PSV-A
113
ATTACHMENT OPERATION Arm in light load
The ARM 2 spool in arm-in operatiion is

managed by mechatro.
From joystick secondary pilot pressure is
led to ARM 1 spool and PSV-A.
In order to increase the speed the arm
cylinder is feed by two pumps.
To prevent cavitation oil returning from the
rod side of cylinder is recirculated variably
to the head side at arm 2 spool. On the
main control valve.
To shift the ARM 2 spool into the

recirculation position, the
controller change the electrical
signal send to the PSV-A that
reduce the secondary pilot Pilot line Recirculation position
pressure. from joystick
ARM-IN
operation
114
ARM 2 SPOOL
RECIRCULATION RECIRCULATION
POSITION CUT-OFF
POSITION
PILOTING FROM PILOTING FROM

ANTI CAVITATION PROPORTIONAL
JOYSTICK ARM NEUTRAL POSITION
EXTENSION SOLENOID VALVE
PSV-A
115
ARM 2 SPOOL
RECIRCULATION RECIRCULATION
POSITION CUT-OFF
POSITION
PARALLEL PASSAGE CLOSED
PILOTING FROM ANTI CAVITATION PILOTING FROM

JOYSTICK ARM NEUTRAL POSITION PROPORTIONAL
EXTENSION SOLENOID VALVE
PSV-A
THIS POSITION OF SPOOL ARM 2 IS NOT SHOWN IN THE HYDRAULIC
DIAGRAMS, FORCED RECIRCULATION, SWING PRIORITY IN COMBINED
OPERATION ARM-IN LIGHT LOAD & SWING
116
MAIN CONTROL VALVE
P1 PUMP P2 PUMP
TRAVEL RIGHT TRAVEL LEFT
BOOM SWING
BUCKET ARM 1
ARM 2 OPTION
117
TRAVEL HYDRAULIC SYSTEM
THE TRAVEL SPOOLS ARE SUPPLIED DIRECTLY FROM THE CENTRAL

PASSAGE
118
TRAVEL HYDRAULIC SYSTEM COMBINED OPERATIONS
THE TRAVEL PRIORITY IS SHIFTED BY THE MECHATRO
PUMP P2 SUPPLIES THE TRAVEL SPOOLS
PUMP P1 SUPPLIES THE ATTACHMENT SPOOLS
119
TRAVEL PRIORITY OPERATING LOGIC
BUCKET COMBINED FLOW
COMBINED FLOW (NIBBLER)
SWING PRIORITY
120
TRAVEL MOTOR
121
TRAVEL MOTOR
Reduction Auto 2-speed

unit change The travel motor is made up of this
following parts:
Piston motor, swash plate type 2
displacement
Counterbalance valve to disengage
parking brake ,set speed according the
supply flow rate, prevert overurn speed.
Auto 2-speed change , to set the
position of swash plate of motor.
Parking brake when motor stops
mechanical brake is activated to
prevent rotation of motor.
Reduction unit epicycle 2-stage.
Parking Crossover
brake relief valve
Counterbalance
Hydraulic
valve
motor
122
TRAVEL MOTOR Travel operation second speed selected
The pressure of the

5.0 MPa from system rise up, and
SV-3 through this passage
delivery pressure
shift the position of
counterbalance valve
Lever shifted, oil in

pressure from main
Via this internal link
control
delivery valve feed the
pressure is
traveltomotor
used unit.
disengage
Hydraulic
the parkingmotor
brake,
cannot run duemotor
and hydraulic to the
parking brake
run locked,
and oil cannot flows
to tank due to the
check valve closed
123
TRAVEL MOTOR Automatic downshift
When delivery
Auto 2-speed pressure rise up to
change 27.3 MPa the
automatic downshift
set high displacement
on hydraulic motor,in
order to reduce speed
and increase torque.
Delivery pressure
acts on the spool for
speed change.
Delivery
pressure
Springs set the tilting

angle larger and
hydraulic motor
reduces to low speed
124
TRAVEL MOTOR Overspeed prevention counterbalance function
Speed of hydraulic
motor is according to
the supply flow rate
from main control
valve.
In case the speed
became larger than
supplied flow rate, the
delivery pressure
reduce, and the
counterbalance valve
moves onto the
middle position and
slowly reduce the
passage of oil and
reduce the speed of
the huydraulic motor.
125
TRAVEL MOTOR Overspeed prevention counterbalance function
Slowly the
counterbalance moves
to the neutral position.
By reducing the oil
passage reduce flow
rate,(that flows back to
tank) and reduce the
speed of hydraulic
motor.
When pressure rise up

again counterbalance
valve moves in order to
set the opening area in
appropriate condition
according to the speed
of the hydraulic motor.
126
TRAVEL MOTOR Components
Supply lines Pilot line SV-3
Crossover relief valve
2-speed changeover spool
Drainage line
Counterbalance valve
Check valve
127
OPTIONAL SYSTEM
NIBBLER & BRAKER
128
HYDRAULIC CIRCUIT N&B Selector valve
Return from
Return to tank
tool
Solenoid valve
SV-13
Primary pilot
pressure
Low pressure
sensor SE-29
129
HYDRAULIC CIRCUIT N&B SPECIFICATION
Parallel Return line to

passage P2 tank
Overload
relief valve
Optional spool
Supply to tool
Selector valve
Direct return to tank
Low pressure
sensor SE-29 SV-13
Return from 5.0 MPa from

tool SV-4
130
HYDRAULIC CIRCUIT selector valve braker 1way
Selector valve is feed by primary pilot

pressure from SV-4.
Return to 5.0 MPa supply the solenoid valve SV-13
tank In braker 1way the controller energize
SV-13, the solenoid valve change his
position and primary pilot pressure shift
the selector valve.
The oil flows back to tank directly by

pass the main control valve
Primary pilot pressure

from Lever Lock
When the selector spool is full shifted low
pressure sensorReturn
SE-29 from
send an electrical
braker
signal to the controller
131
HYDRAULIC CIRCUIT Braker 1way
By pressing the foot pedal forward

secondary pilot pressure shift the spool.
Parallel Parallel passage( pump P2) feed the
passage P2 spool and oil flows to the braker.
Secondary pilot
Supply line to
pressure from
braker
foot pedal
The oil that return to the braker flows
back to tank directly,and skip main control
valve and cooler.
Adjust overload relief valve according to

the tool specification
Tank
Return
from braker
132
HYDRAULIC CIRCUIT Nibbler 2way single flow
Return line to
tank
By pressing the foot pedal backward

Parallel passage( pump P2) feed the
spool and oil flows to the nibbler.
Return to
nibbler through
main control
valve
Supply to
nibbler 133
HYDRAULIC CIRCUIT Nibbler 2way single flow
Return line to
tank
By pressing the foot pedal forward

Parallel passage( pump P2) feed the
spool and oil flows to the nibbler.
Supply to
nibbler

Return to
nibbler through
main control
valve 134
HYDRAULIC CIRCUIT Nibbler 2way double flow
Nibbler operation can get double flow by select double flow on swich on the rigth
consoole in the operator cab.
In single flow pump P2 supply the OPT spool, in double flow

pump P2 + P1 feed the OPT spool.
Double flow is obtained by shifting the Travel priority valve ad keep closed unloading
valve + by pass cut valve P1 & P2 side.
Via an internal passage of main c/v the flow from P1 pump is added to the parallel
passage P2 side in order to feed the spool.
135
HYDRAULIC CIRCUIT Bucket rotation
Drain pressure side: pilot line from SV-

drain,high pressure sensor,return to tank
Pilot line
(both side)
Relief valve
bottom side
(both side)
Parallel
Supply line from passage P2
pump P4 on the Delivery lines to
PTO attachment
136
MAIN HYDRAULIC PUMP OPERATION
137
HYDRAULIC PUMP
REGULATOR
PILOT OIL PUMP
HIGH PRESSURE SENSORS

138
REGULATOR
SCREW TO ADJUST
INPUT HORSEPOWER AT
EMERGENCY MODE
PROPORTIONAL
SOLENOID VALVE
PSV-P2 SCREW TO ADJUST
FLOW CHARACTHERISTIC
139
PILOT OIL PUMP
PILOT OIL FILTER
SCREW TO ADJUST
PILOT PRESSURE
140
HYDRAULIC PUMP
High pressure sensor

Port for pressure gauge
SE-22 pump P1
Pump P1
Port for pressure gauge

High pressure sensor Pump P2
SE-23 pump P2
141
HYDRAULIC PUMP
PSV- P1
Pilot
pressure
PSV- P2
Delivery
Servospool pressure
Total power
control
Sleeve
Positive control
Servopiston
142
HYDRAULIC PUMP
Engine running
and dives the
main pump,
delivery
pressure is
generated
143
HYDRAULIC PUMP
Engine running and

dives the pilot pump,
pilot pressure is
generated and acts
on the regulator
144
HYDRAULIC PUMP
Pilot pressure is in hand to the

proportional solenoid valve, when
the key switch is in ON the
controller supply the coil and
secondary piot pressure shift the
spool for emergency mode.
145
HYDRAULIC PUMP POSITIVE CONTROL
Secondary pilot pressure from

proportional solenoid valve is in
hand to the spool of positive control.
Turin Training Centre 146

HYDRAULIC PUMP POSITIVE CONTROL flow rate increase
ELECTRICAL SIGNAL
ON PSV-P1
INCREASE
147
SERVOSPOL MOVES LEFTWARD

AND CL PORT (LARGE AREA OF
SRVOPISTON) IS CONNECTED
TO THE TANK AND THE
SERVOPISTON
MOVES LEFT
148
WHEN SERVOPISTON
MOVES LEFT THE SWASH
PLATE CHANGE THE TILTING
ANGLE AND FLOW RATE
INCREASE .
149
AT SAME TIME THE FEED-BACK

LEVER, CONNECTED TO THE
SERVOPISTON MOVES AND
SHIFT THE SLEEVE , THAT CLOSE
THE PORT OF SERVOSPOOL.
SERVOPISTON STOPS AND THE
SISTEM REACH A BALANCE
CONDITION
150
HYDRAULIC PUMP POSITIVE CONTROL flow rate decrease
ELECTRICAL SIGNAL
ON PSV-P1
DECREASE
151
SERVOSPOL MOVES
RIGHTWARD AND CL PORT
(LARGE AREA OF SRVOPISTON)
IS CONNECTED TO THE
DELIVERY PRESSURE. THE
SAME PRESSURE ACTS ON THE
SERVOPISTON .
152
THE PRESSURE ACTS WITH

MORE FORCE ON THE LARGE
AREA AND THE SERVOPISTON
MOVES RIGHTWARD.
153
AT SAME TIME THE FEED-BACK

LEVER, CONNECTED TO THE
SERVOPISTON MOVES AND
SHIFT THE SLEEVE , THAT CLOSE
THE PORT OF SERVOSPOOL.
SERVOPISTON STOPS AND THE
SISTEM REACH A BALANCE
CONDITION
154
POSITIVE CONTROL FLOW RATE INCREASE
ACCORDING TO THE STROKE OF THE

JOYSTICH LOW PRESSURE SENSORS SEND
AN ELECTRICAL SIGNAL TO THE CONTROLLER
( from 0,5 till 4.5 Volt)
MECHATRO PROCESS THIS SIGNAL AND

SEND AN ELECTRICAL SIGNAL THAT
INCREASE IN 350mA TILL 750mA TO THE
PROPORTIONAL SOLENOID VALVE PSV-P1/P2
AND SET THE CORECT FLOW RATE
155
POSITIVE CONTROL FLOW RATE DECREASE
WHEN THE JOYSTICK IS SHIFTED TO THE

NEUTRAL POSITION: (LOW PRESSURE
SENSORS DECRERASE HIS SIGNAL)
THE CONTROLLER DECREASE THE FLOW
RATE BY DECREASING THE ELECTRICAL
SIGNAL TO THE PROPORTIONAL SOLENOID
VALVE .
P/Q CONTROL: HIGH PRESSURE SENSORS

SE22-SE23 SENDS AN ELECTRICAL SIGNAL
TO THE CONTROLLER THAT PROCESS THIS
SIGNAL ACCORDING TO THE P/Q CURVE
AND REDUCE THE ELECTRICAL SIGNAL TO
THE PROPORTIONAL SOLENOID VALVE
PSV-P1/P2 AS A RESULT FLOW RATE
DECREASE TO AVOID STALL ENGINE
156
OVERLOAD PREVENTION
THE PRESSURE OF THE SYSTEM WORKS ON

SPOOL 623 AGAINST THE FORCE OF THE
SPRINGS 625-626.
WHEN THE SPOOL 623 MOVES SHIFT THE
SPOOL 2 IN THE FIRST POSITION , AND OIL IN
PRESSURE OF THE SYSTEM IS IN HAND TO
THE LARGE AREA OF THE SERVOPISTON
SERVOPISTON MOVES RIGHT AND FLOW

RATE DECREASE
157
COSTRUCTION OF REGULATOR
158
INPUT HORSEPOWER ADJUSTMENT IN EMERGENCY MODE
159
FLOW CHARACTERISTIC ADJUSTMENT
160
P/Q CURVE
161
P/Q CURVE
162
BJ SERIES
ELECTRICAL SYSTEM

Update November 2009
163
FUSE & RELAY BOX
ENGINE CONTROLLER
FUSE & RELAY BOX
MECHATRO CONTROLLER
Electrical component location:

on the operator cab, behind the
seat under the plastic cover
there is controllers , fuse and
relay.
164
BATTERY RELAY , RELAY & FUSE LINK
GLOW RELAY
STARTER RELAY
FUSE LINK E-15

STARTER RELAY
GLOW RELAY
ALTERNATOR
BATTERY RELAY
165
ELECTRICAL SYSTEM SYMBOL
Square : connection to fuse box
Triangle : signal connection to

another function
On the electrical diagrams not all of the wires that make up the harness are shown
on the drawing.
There is two interruption simbols :Square and triangle .
166
ELECTRICAL SYSTEM
BATTERY RELAY
167
Battery relay
Key switch ON to
engine controller
Key switch
Key switch
ON to
MECHATRO
controller
168
ACC
Key switch in ACC

position power supply
for cigarette lighter,
horn,DC-DCconverter
169
ON
Key ON to
MECHATRO
170
Key ON to
engine controller
ON
Key ON to
MECHATRO
171
First step: 24 Volt from key
switch supply the coil of
battery relay through
AUTO IDLE STOP RELAY 1
ON
Key ON to
MECHATRO
172
Battery relay closes the
contact and fuse box & relay
is powered
ON
Key ON to
MECHATRO
173
From fuse box & relay power
supply is led to all relays
ON
Key ON to
MECHATRO
174
AUTO IDLE STOP RELAY 2
supply the coil for battery
relay
Ground to
MECHATRO
controller 109-11
ON
Key ON to
MECHATRO
175
Second step: auto idle stop
relay 2 disable AUTO IDLE
STOP RELAY 1
ON
Key ON to
MECHATRO
176
KEY ON engine stop: L
terminal of alternator is
ground, and alternator relay
change position
ON
Key ON to
MECHATRO
177
ENGINE START
KEY SWITCH IN START POSITION:
24 Volt in input to MECHATRO controller

24 Volt in input to engine controller to enable the injection function
24 Volt in input to R-2 starter relay.
R-2 change his position and close the contact and starter motor runs.
178
ENGINE START
START
Start to
MECHATRO
179
Start to engine
controller
START
Start to
MECHATRO
180
Starter relay close the contact
and starter motor runs
181
Engine running, the alternator
charge L terminal change
from ground to 28 Volt , and
change the position of
alternator relay
ALTERNATOR
RELAY
182
From alternator relay 24 Volt
signal charge on MECHATRO
controller.
ALTERNATOR
RELAY
183
signal charge on
HOURMETER.
184
signal charge on BATTERY
RELAY.
185
ENGINE STOP
KEY SWITCH IN OFF POSITION:
No signal of key to MECHATRO controller

No signal of key to engine controller to disable the injection function.
The controller of the engine cut the injection and the engine stops
186
The engine stops:
Alternator stops to charge and L
terminal turn to ground .
ALTERNATOR RELAY
opens the contact .The coil of battery
relay still keep closed from AIS 2
187
The ground of AIS-2 is managed by
MECHATRO.
When alternator stops to charge after
few seconds of delay MECATRO cut
the ground signal to AIS-2, and
battery relay opens
188
ENGINE STOP
In case of low engine oil pressure MECHATRO controller, via R-25

ENG. EMERGENCY STOP RELAY shut off the engine
Cut off electrical signal KEY ON position to the engine controller
189
Low engine oil pressure
engine stop condition
190
BJ SERIES AFME-CIS
HINO ENGINE J05E-TG

Update November 2009
191
COMMON RAIL SYSTEM
COMMON RAIL SYSTEM IS MADE BY THIS FOLLOWING COMPONENTS:
SUPPLY PUMP
COMMON RAIL
INJECTORS
ECU
SENSORS , SWITCHES, RELAY
192
COMMON RAIL SYSTEM
Common rail
Pressure sensor
(4)Flow damper
Engine
Speed Common rail (5)Injector
sensor (6)Pressure
Cylinder limiter
Recognition (3)Plunger
sensor
(2)Suction
Control
valve
(1) Feed pump
Supply pump
193
SUPPLY PUMP
SUPPLY PUMP
THE SUPPLY PUMP DISCHARGES THE FUEL IN HIGH PRESSURE ON

COMMON RAIL. TO SET THE CORRECT PRESSURE A SCV VALVE
IS USED
SCV SUCTION CONTROL VALVE MANAGED BY ECU WORKS IN
ORDER TO SET THE CORRECT FUEL PRESSURE ON THE RAIL
194
SUPPLY PUMP
Supply pump consist by 3 folowing parts:
Feed pump:charging fuel to SCV and plunger
SCV suction control valve set the amount of fuel to

plunger
Plunger discharge fuel in pressure to the rail
SCV (Suction Control Valve)
Feed pump Shaft
195
SCV VALVE
SCV suction control valve : fuel metering solenoid valve

Metering fuel amount to adjust the common rail pressure
Return Cylinder SCV Current
Average current
Spring
Small
Flow
Large
Pump body
Current
Large
Flow Flowing amount
Small
196
PLUNGER
Punger driven by engine rotation, and discharging fuel in high pressure to the
common rail
Exhalation valve
SCV
Inhalation valve Plunger
Suctioning Discharging Not discharging

(Increase pressure) (Decreasing pressure)
Suctioning Discharging
Plunger Condition not discharging
SCV close port to cut fuel
to plunger to decrease pressure
Cam lift
197
COMMON RAIL SYSTEM
COMMON RAIL STORE AND DISTRIBUTES FUEL IN HIGH PRESSURE ON

INJECTORS
INJECTORS INJECTION QUANTITY AND TIMING ARE SET BY THE

OPENING AND CLOSING TIME OF TWV TWO WAY VALVE
Solenoid
Valve seat
To the fuel tank Valve spring
From common Orifice Return
rail
Control room
Orifice Inlet
Piston
Nozzle
Nozzle
needle
【 No Injection 】【 Start injection 】【 Stop Injection
198 】
LAYOUT COMPONENT
199
LAYOUT COMPONENT
200
BOOST PRESSURE SENSOR
MEASURE THE INTAKE AIR SUCTION CONTROL VALVE

PRESSURE ENERGIZED FROM ECU SET
THE COMMON RAIL
PRESSURE
201
ENGINE SUB SPEED SENSOR
ENGINE SPEED SENSOR TO MEASURE THE COMMON

SET THE CORRECT TIMING RAIL PRESSURE
Located on common rail
assembly
202
FUEL TEMPERATUR SENSOR
Flyweel housing
inspection
window cylinder
No.1 at
TDC
MEASURE THE FUEL

ENGINE MAIN
TEMPERATURE
SPEED SENSOR
FOR ECU
Located on high pressure supply
pump
203
ENGINE SPEED SENSOR
SECONDARY ENGINE SPEED

SENSOR FOR MECHATRO
SE-13
Located on flyweel housing
204
OIL PRESSURE SWITCH
ENGINE OIL PRESSURE ON THERMOSTAT CASE WE

SENSOR INPUT ON FOUND THE COOLANT
MECHATRO CONTROLLER TEMPERATURE SENSORS
205
INJECTOR HARNESS
CONNECTOR FOR INJECTORS ON THE COUNTERWEIGHT

POWER SUPPLY SIDE THERE IS 3 CONNECTOR
THAT CONNECT THE ENGINE
HARNESS TOTHE
CONTROLLER
206
HINO ENGINE DIAGNOSIS
Hino Diagnostic eXplorer
USE OF KIT VH090AKIT-E

207
CONNECTION OF PC WITH ENGINE ECU
CONNECTOR IN THE CAB
CONNECTING CABLE WITH INTERFACE HINO-BOWIE
208
CONNECTION OF PC WITH ENGINE ECU
CONNECTING CABLE BETWEEN HINO-BOWIE AND PC ON

USB PORT
SOFTWARE TO BE INSTALLED ON THE

PC
209
CHARACTERISITICS & FUNCTION OF THE HINO DX
USE OF A PERSONAL COMPUTER WITH WINDOWS OPERATING SYSTEM
PARAMETERS AND DATA CAN BE SAVED DIRECTLY ON THE PC
DIAGNOSTIC TROUBLE CODE (DTC) ARE CONNECTED WITH

TROUBLESHOOTING DISPLAYS
DIAGNOSYS INSPECTION OF ELECTRICAL COMPONENTS BY THE DTC
INSPECTION OF OPERATING PARAMETERS
INSPECTION OF COMPONENTS FUNCTIONALITY: INJECTORS CUT OUT,

TURBOCHARGER CHECK, COMMON RAIL FUEL PRESSURE MANUAL
INSPECTION.
INJECTOR CALIBRATION : QR CODE
INFORMATION ON PAST WORK

210
USE OF THE HINO DX
DOUBLE CLICK
ICON
PASSWORD AND USER

ID , CLICK
“OK”
211
USE OF THE HINO DX
MAIN SCREEN
212
USE OF THE HINO DX
FROM THE MAIN DISPLAY THE DIAGNOSIS- DTC -LOAD IS SELECTED

213
USE OF THE HINO DX
THE ICON ON THE LEFT SIDE INDICATES THE COMMUNICATION

BETWEEN THE HINO-BOWIE AND ENGINE ECU AND THE DATA
RELATIVE TO THE DTC ARE DOWNLOADED
214
USE OF THE HINO DX
AT THE END OF THE DOWNLOAD THE COMMUNICATION BETWEEN THE HINO-

BOWIE AND ECU IS CUT-OFF
215
USE OF THE THE HINO DX
TO USE ALL THE FUNCTIONS OF THE DELL’ HINO DX SYSTEM FIX IS SELECTED
THE INFORMATION ON THE WORK

PERFORMED IS ENTERED INTO THIS
DISPLAY
216
USE OF THE HINO DX
THE ECU IS CONNECTED TO THE HINO-BOWIE, IT IS

POSSIBLE TO USE ALL THE FUNCTIONS
217
DIAGNOSTIC INFORMATION
DIAGNOSTIC INFORMATION BY TYPE OF FAILURE OR

DTC LIST
218
TROUBLESHOOTING BY TYPE OF FAILURE
219
DTC LIST
220
FAULT INFORMATION
DTC SHOWN ALSO DESCRIPTION OF THE DTC

ON THE MONITOR IN
THE CAB
221
FAULT INFORMATION
KEY FOR THE DISPLAY OF THE

DETAILS
TROUBLESHOOTING STEP BY STEP

222
FAULT INFORMATION
DESCRIPTION OF THE CONDITIONS IN WHICH THE TROUBLE OCCURED
223
FAULT INFORMATION
THE INACTIVE DTC ARE CANCELLED BY THE CLEAR KEY
224
DATA MONITOR
WITH THIS FUNCTION IT IS POSSIBLE TO SHOW THE OPERATING

PARAMETERS OF THE ENGINE
225
DATA MONITOR
THE PARAMETERS TO BE
INSPECTED ARE SELECTED
226
DATA MONITOR
READING OF THE PARAMETERS SELECTED

227
ACTIVATION TEST INJECTOR CUT OUT
IT IS POSSIBLE TO MAKE THE

CUT-OFF OF EACH SINGLE
INJECTOR TO CHECK THE
OPERATION
Injector 1 deactivated
228
COMMON RAIL FUEL PRESSURE MANUAL INSPECTION
AS FOR THE EGR VALVE

TEST IT IS POSSIBLE TO
CHECK THE RAIL
PRESSURE
229
TURBOCHARGER CHECK
ENGINE REACH THE MAXIMUM SPEED,

UNDER NORMAL CONDITIONS THE
PRESSURE OF THE INTAKE AIR MUST
EXCEED 110 KPa
230
INJECTOR CALIBRATION
THE DATA RELATIVE TO THE CALIBRATION OF THE INJECTORS ARE DIRECTLY

MEMORISED IN THE ENGINE CONTROLLER
231
QR CODE
CALIBRATION DATA
EACH INJECTORS HAVE HIS CODE
232
WRITE CALIBRATION DATA

TO ECU
ON THIS SCREEN IS POSSIBLE TO WRITE CALIBRATION DATA ON ECU
AFTER ADD ALL NECESSARY DATA
233
THE SOFTWARE ON SECTION

OPERATION BY SYSTEM
ENABLE TO SAVE CALIBRATION
DATA OF INJECTORS ON PC
AND AFTER DOWNLOAD WHEN
ECU WILL BE CONNECTED
Injector calibration data can be

made in advance.
234
ADD DATA RELATED TO THE INJECTOR
CLICK ON BUTTON SAVE TO FILE
NAME FILE AND FOLDER DESTINATION
235
CAUTION
Impact on the Machine when you fail to write injector correction value correctly.
When you fail to write correction value to new ECU.

ECU recognizes abnormality, lets the check engine lamp lit and
controls to decrease the injection quantity thus unable to rev up
smoothly decreasing the output.
If you fail to write or make a mistake in writing the correct cylinder when
replacing injectors.
Engine control shall be made by the mistaken correction value,
causing large variation of injection quantity, engine revolution and
torque.
If you write the correction value wrongly.
If you wrongly write correction value of 30 digits of one injector, the
Software will detect wrong input according to the checksum function
and recognizes it unacceptable.
236
Main control valve
237
P1 BY PASS CUT P2 BY PASS CUT VALVE
VALVE
238
P2 PUMP
TAVEL LEFT
P2 UNLOAD
BOOM
CONFLUX
SWING
ARM 1
OPTION
239
P1 PUMP
TAVEL
PRIORITY P1 UNLOAD
TAVEL RIGHT
BOOM
BUCKET
ARM 2
240
TOP
P1 PUMP
INLET
P2 PUMP
INLET
P2 UNLOAD TRAVEL
PRIORITY
241
(P3)
PBp2 PBp1
P2 PUMP P1 PUMP
PBa2
PAo MU
PBa1
PCc
Pss PBb
PBs
XAb
PB1 PAr
MAIN RELIF VALVE
PAL PCb
242
(P3)
PCAP2
LCAT2 LCc
PBa2 PAa2
PBc
PAc
PCc
PBb
PAb
PAr PBr
PCb PTb
CRb
Dr PL
LCb CP1
CMR2 CMR1
CT1
243
MAIN CONTROL VALVE
ALL THE VALVES ILLUSTRATED IN THE PICTURES
ARE EXTERNAL SERVICEABLE
244
HANDY CHECKER
245
HANDY CHECKER
Personal computer, HANDY CHEKER software, and connection cable are used to
download software on MECHATRO CONTROLLER
380002253
246
HANDY CHECKER
From desktop double click on

HANDY_CHECKER_3
Double click on me103900 icon
247
HANDY CHECKER
HANDY_CHECKER_3 base screen, click on Download
248
HANDY CHECKER
Connect the harness from PC to MECHATRO controller and press button CHECK
249
HANDY CHECKER
The system shows this icon:
Click on OK
250
HANDY CHECKER
Now the PC is connected with the MECHATRO controller
251
HANDY CHECKER
Click on REFERENCE button to choose the file to download
252
HANDY CHECKER
Select folder and file to

download
253
HANDY CHECKER
The file ready to download is write on this screen , to star downloading press
START button
confirmation for downloading
254
HANDY CHECKER
When the process go ahead a blu bar is show
255
HANDY CHECKER
Download completed , press END button
256
HANDY CHECKER
Close work from PC, turn key switch in OFF position and disconnect harness
257
HANDY CHECKER
Check the software version on page 1 ; service diag 1
258
BREAKER ADJUSTMENT
259
MECHATRO CONTROLLER BREAKER SETTING
FROM SCREEN SERVICE DIAG 1 KEEP PRESSED

BUZZER STOP
AND IN THE SAME TIME PRESS 3 TIMES ENTER
PRESS ENTER
260
MECHATRO CONTROLLER OPTIONAL SETTING
WITH ARROW UP AND DOWN SELECT
ADJ OPT
AND PRESS ENTER
SELECT FROM SET 1-9 AND PRESS ENTER
261
WITH ARROW UP AND DOWN SELECT THE DESIRED

FLOW RATE
PRESS ENTER
262
START THE ENGINE AND PRESS FORWARD THE FOOT

PEDAL
SET THE DESIRED PRESSURE VALUE BY PRESSING

ARROW UP AND DOWN
263
AT THE DESIRED PRESSURE SETTING PRESS ENTER
SETTING COMPLETED
264
TO CHECK THE SETTING OF OPT SYSTEM
SIGNAL TO ELECTRICAL RELIEF VALVE AND

CONVERTED VALUE OF PRESSURE
SELECTOR VALVE POSITION
265
266
ENGINE DIAGNOSIS CODE 17–7
Table of failure code

JP31002170601001
NOTICE • For the system status by indication of failure code(DTC code) in the table, refer to "1. Pre-
inspection, Inspection, Engine ECU".
"Reference : Inspection, Engine ECU, Engine diagnosis code"
Diagnosis
[a] Failure diagnosis and DTC
monitor Estimated failure cause Page
[b] Alarm display (alarm status) code
code
a. Engine does not start P0335 13 Engine speed main sensor circuit
17-15
Engine stopped. malfunction
P0606 3 CPU malfunction (Hard detection)

17-49
b. Failure code(DTC code) (Detection of hardware)
indication. P0629 74 SCV out put short to BATT
17-45
(+B short-circuit)
a. Low output P0200 59 ECU charge circuit high input 17-50

P0611 59 ECU charge circuit low input
b. Failure code(DTC code) 17-50
indication.
a. Low output (LOW idle 800rpm P2120 22 Accelerator sensor 1 and 2

fixing) malfunction
17-32
b. Failure code(DTC code)
indication.
a. Low output P0217 6 Engine overheat 17-19
a. Difficult to start engine. P0540 25 Preheat circuit malfunction

17-48
(Open/ground short-circuit)
P0540 25 Preheat circuit malfunction

17-48
(+B short-circuit)
a. Low output P0234 39 Turbocharger over boost 17-23
267
17–8 HINO ENGINE DIAGNOSIS CODE
Diagnosis
code
a. Low output P0088 68 Excessive common rail pressure

17-23
(1st step)
b. Failure code(DTC code) P0088 69 Excessive common rail pressure

17-23
indication. (2nd step)
P0088 76 Excessive common rail pressure,

17-24
supply pump excess forced feed
P0108 37 Boost pressure sensor circuit high

17-21
input
P0117 11 Coolant temperature sensor circuit

17-18
low input
P0118 11 Coolant temperature sensor circuit

17-18
high input
P0191 67 Common rail pressure sensor

17-25
malfunction
P0192 67 Common rail pressure sensor circuit

17-26
low input
P0193 67 Common rail pressure sensor circuit

17-26
high input
P0201 51 Injector circuit malfunction -cylinder 1 17-40

P0237 37 Boost pressure sensor circuit low input 17-21
P0605 3 Flash ROM error 17-49

P0607 3 Monitoring IC malfunction in CPU 17-49
P0628 75 SCV malfunction

17-45
(Full discharge mode)
P1211 57 Injector common 1 short to GND

Failure of ground short-circuit and 17-36
common 1
P1212 57 Injector common 1 short to BATT

Failure of +B short-circuit and 17-38
common 1

17-38
Failure of open and common 1
268
ENGINE DIAGNOSIS CODE 17–9
Diagnosis
code
a. Low output P1214 58 Injector common 2 short to GND

Failure of ground short-circuit and 17-36
common 2
b. Failure code(DTC code)
indication. P1215 58 Injector common 2 short to BATT
Failure of +B short-circuit and 17-38
common 2
17-38
Failure of open and common 2
P1601 2 Injector correction data conformily

17-49
error
P2228 15 Atmospheric pressure sensor circuit

17-35
low input
P2229 15 Atmospheric pressure sensor circuit
17-35
high input
P2635 75 Supply pump SCV sticking 17-47
P2635 77 Supply pump malfunction 17-47
a. Other problems P0182 14 Fuel temperature sensor circuit low

17-20
input
b. Failure code(DTC code) P0183 14 Fuel temperature sensor circuit high

17-20
indication. input
P0340 12 Engine speed sub sensor circuit

17-16
malfunction
P0686 5 Main relay malfunction 17-50
P2122 22 Accelerator sensor circuit 1 low

17-28
voltage
P2123 22 Accelerator sensor circuit 1 high voltage 17-28

P2127 22 Accelerator sensor circuit 2 low voltage 17-30
P2128 22 Accelerator sensor circuit 2 high

17-30
voltage
P1133 23 Emergency accelerator sensor

17-33
malfunction high input
269
17–10 ENGINE DIAGNOSIS CODE
Diagnosis
code
a. Other problems P0219 7 Engine overrun 17-19

P0263 61 Cylinder 1 contribution/balance fault 17-43
b. No indication P0266 62 Cylinder 2 contribution/balance fault 17-43

P0617 45 Starter signal malfunction 17-51

P2635 79 Supply pump abnormal pressure
17-47
record
U1001 9 Interruption of CAN communication

-
(machine)
Function, movement
Description of function
and operation
270
E 215BJ specification
21. MECHATRO CONTROL SYSTEM
(3) Service diagnosis data list

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use these data
to decide normal/abnormal status.
• The values in following display are reference values with standard attachment attached machine.
• The value of pressure sensor is calculated taking variation into accounts. When compared to performance
check reference criteria, measure it with the aid of calibrated measuring instrument.
• The current of proportional valve is not the measured value, but command value. The measured value
should be confirmed by the value in the displayed value for each proportional valve.
• The current value of pump proportional valve is reference value because it varies according to pump
pressure and adjusted torque value.
• The value in display during operation shows the value in steady state, rather than, at start of operation.
• Check on machine after sufficiently warming up machine.
• The value in display may differ according to software version. Contact our dealer/distributor.
Operation No.1 : No operation Operation No.2 : No operation

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1770~1830
POWER SHIFT 0 mA POWER SHIFT 0 mA
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.31 BOOM No.31 BOOM

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 11.0~16.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 11.0~16.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 560~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 560~750 mA
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
21-35 271
Operation No.5 : Boom down in full lever operation & in

operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 12.5~16.0 M
C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 600~617 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427~477 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 12.5~16.5 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 12.5~16.5 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 550~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 550~750 mA
21-36 272
Operation No.8 : Operation No.9 :

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 15.0~22.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~22.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 488~677 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 488~677 mA
* Measure the values after a lapse of 5 minutes or after * Measure the values after a lapse of 5 minutes or after
release of low temperature mode release of low temperature mode

Swing in full lever operation & relief Swing in full lever operation & in operation
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 10.0~15.0 M
E-2 P2-PSV 528~750 mA E-2 P2-PSV 750 mA
21-37 273

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 4.0~8.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 4.0~8.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 650~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 540~563 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 6.0~15.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 6.0~15.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 577~750 mA
E-2 P2-PSV 415~435 mA E-2 P2-PSV 415~435 mA
21-38 274

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
A mode Hi idle B mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 459~584 mA E-1 P1-PSV 500 mA
E-2 P2-PSV 459~584 mA E-2 P2-PSV 665~750 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
* Conflux switch is ON. Relief set pressure is value of * Conflux switch is OFF. Relief set pressure is value of
shipping. shipping.

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
No.34 TRAVEL No.34 TRAVLE
C-1 P1-PRES 5.0~12.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 5.0~12.0 M
B-9 TRAVEL(R) 2.0~2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
21-39 275
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.2 PERFORMANCE INSPECTION STANDARD TABLE
Unless otherwise specified, measure it on "H" mode.
Table13-1
Measuring Position Standard Tolerance Adjusting Measuring
Inspection Item Unit
Position Size Port value Hi Lo Point condition
NAS 9
Class
Cleanliness of hydraulic oil Hydraulic oil in tank — — — Sampling
Standard Measuring condition
or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23)
°C
— Atmospheric temp
50°C~-10°C
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — (122°F~14°F)
H mode Lo idle 1000 + 30 - 30 LOW throttle
Engine speed
H mode Hi idle 2000 + 30 - 30 Full throttle (HI idle)
not required
Adjustment
Measure the engine
B mode Hi idle 2000 + 30 - 30 Perform all
speed at multi display on min-1
A mode Hi idle 2000 + 30 - 30 measurement with
the gauge cluster.
Decel 1050 + 30 - 30 the air-conditioner
S mode Hi idle 1800 + 30 - 30 "OFF".
Pilot primary pressure circuit G pump a4 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
P1 a1
valve pressure
ATT MR1 Boom up

Main relief
34.3 (4970) + 0.7 (+100) - 0.5 (-73)

P2 a2
P1 a1
Boost 37.8 (5480) + 1.0 (+145) - 0.5 (-73) MR1
P2 a2
R 37.8 (5480) 0 - 4.0 (-580) OR4 Boom down
Boom a1
High pressure circuit
H 39.7 (5760) 0 - 5.9 (-855) OR3 Boom up

Over load relief valve pressure
R 39.7 (5760) 0 - 5.9 (-855) OR8 Arm out

Main pump
Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.5 (-711) (psi) OR2 Bucket dump
Bucket a1
H 39.7 (5760) 0 - 5.9 (-855) OR1 Bucket digging
RH 29.0 (4205) + 6.0 (+870) 0 OR6 Swing RH
Swing a2
LH 29.0 (4205) + 6.0 (+870) 0 OR5 Swing LH
FW —
RH a1 34.3 (4970) + 0.7 (+100) - 0.5 (-73) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 34.3 (4970) + 0.7 (+100) - 0.5 (-73) RH and LH
RV —
13-4 276
Standard
Inspection item Unit
value
Sprocket revolution 1st speed 30.5 ~ 27.5
min-1
(RH,LH) 2nd speed 50.4 ~ 45.6
Up 2.5 ~ 3.1
Boom
Down 2.2 ~ 2.8
Operating speed
Operating time of In 3.0 ~ 3.6

Arm sec (At no load)
cylinder Out 2.3 ~ 2.9
Digging 2.2 ~ 2.8
Bucket
Dumping 1.7 ~ 2.3
RH
Swing speed 4.2 ~ 5.4 sec / 1 rev
LH
1st speed Iron shoe 19.5 ~ 21.5
Travel speed sec / 20 m
2nd speed Iron shoe 11.9 ~ 13.1
Amount of travel
2nd speed 0 ~ 240 mm / 20 m
deviation
Parking brake drift 15 degree gradient 0 mm / 5 min
Performance of Swing Neutral position after
Performance
55 ~ 75 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 160
ATT amount of drift Boom cylinder 14 mm / 10min (At no load)
Arm cylinder 11
Amount of horizontal play at the bucket tooth 30 ~ 50 mm
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in
advance.
(1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out

13-5 277
21.2.8 MECHATRO CONTROL EQUIPMENT

(1) C-1 Mechatro controller
1) Outside view
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
2) List of connectors
Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
25 DL EARTH / OPEN(5V
26 GP 0V
27 CANH1 E/G ECU CAN communication
28 CANL1 E/G ECU CAN communication
29 DO 20 Spare Output EARTH/OPEN
30 DO 21 Safety relay Output EARTH/OPEN
32 DO 23 Rotary light (yellow) Output EARTH/OPEN
33 DO 24 Rotary light (green) Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN
21-47 278
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
22 D1 37 Spare Input GND / OPEN
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
16 Reserved
21-48 279
CN104 1 GA 0V
2 A17 Boom head Input 0.5~4.5V
5 A18 Boom rod Input 0.5 4.5V
6 GA 0V
7 GA 0V
8 A19 Extra pressure source Input 0.5~4.5V
12 GA 0V
14 GA 0V
15 A22 Fuel level Input 0.5~4.5V
16 GP 0V
18 GA 0V
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
24 GA 0V
25 GA 0V
28 DI 1 Cab slow up and down Input GND / OPEN
CN105 1 +24V Battery relay output side 20~32V
2 +24V Battery relay output side 20~32V
(sensor analog output)
4 DO 7 Travel 1,2 speed select valve Output 24V/OPEN
5 DO 8 Swing P/B select valve Output 24V/OPEN
7 DO 11 Attachment boost select valve Output 24V/OPEN
8 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0~800mA
11 D1+ P1 unload Output +0~800mA
12 D1- -0~800mA
14 D2- -0~800mA
15 D3+ Travel straight Output +0~800mA
16 D3- -0~800mA
17 D4+ Arm in Output +0~800mA
18 D4- -0~800mA
19 D5+ P1 pump Output +0~800mA
20 D5- -0~800mA
22 D10- OPT changeable relief 1 Output -0~800mA
24 D6- -0~800mA
25 D7+ Cab slow stop valve Output +0~800mA
26 D7- -0~800mA
27 D8+ Boom cushion Output +0~800mA
28 D8- -0~800mA
29 D9+ Arm cushion Output -0~800mA
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V
21-49 280
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ Accel motor A phase (spare) Output +24V 1.5A
4 F1- Accel motor A phase (spare) Output +24V 1.5A
5 F2+ Accel motor B phase (spare) Output +24V 1.5A
6 F2- Accel motor B phase (spare) Output +24V 1.5A
7 OIL Oil level (spare) 0
8 OILG
10 D11- -0~800mA
11 D12+ Spare Output +0~800mA
12 D12- -0~800mA
14 D13- -0~800mA
16 D14- -0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shiled GND
23 CANH2 Proportional vlave expand unit CAN communication
24 CANL2 CAN communication
CN107 1 DI 3 Key switch (GLOW) Input +24V/OPEN
2 DI 8 Water separetor Input EARTH / OPEN
3 DI 9 E/G oil pressure Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
5 DI 11 Stroke end check Input EARTH / OPEN
6 DI 12 Spare Input EARTH / OPEN
7 DI 13 E/G coolant level Input EARTH / OPEN
10 DI 20 ECU main relay Input EARTH / OPEN
12 DI 32 Hand control nibbler Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
14 DI 39 Extra pressure Input EARTH / OPEN
17 Reserved
21-50 281
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Spare Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 High reach hoisting at fixed position Input GND / OPEN
6 DI 16 Wiper rise up Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
8 DI 18 ATT boost Input GND / OPEN
9 DI 19 Nibbler open check SW Input GND / OPEN
10 DI 21 Elevator cab up check Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation / Input
clamp open or close GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
15 DI 26 Hand control breaker Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 High reach (hoist at travel) Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
24 Reserved Reserved
25 H1+ Accel signal 1 0~5V
26 H2- 0V
28 H2- 0V
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Bucket move limitation Output GND / OPEN
6 DO 6 Reserved Output GND / OPEN
7 DO 12 Rotary light (RH) Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Extra pressure release Output GND / OPEN
15 Reserved
16 GP IT controller 0V
17 TXD2 Tranmission RS232C communication
19 RTS Spare RS232C communication
20 CTS Spare RS232C communication
21 SHG2 Shiled GND
22 DO 10 Cab up and down switching valve SV 24V/OPEN
21-51 282
E 265BJ specification 21. MECHATRO CONTROL SYSTEM

• The current value of pump proportional valve is reference value because it varies according to pump pres-
sure and adjusted torque value.

C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 12.0~17.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 12.0~17.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 560~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 560~750 mA
21-35 283
Operation No.5 : Boom down in full lever operation & in op-

eration
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 10.5~14.0 M
C-2 P2-PRES 0.7~2.0 M
E-1 P1-PSV 585~605 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 435~485 mA
G-3 ENG SPEED 2070~2160
POWER SHIFT 0 mA
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 12.5~16.5 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 12.5~16.5 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 550~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 550~750 mA
21-36 284

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 15.0~22.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~22.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 488~677 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 488~677 mA

C-1 P1-PRES 0.5~1.8 M C-1 P1-PRES 0.5~1.8 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 10.0~15.0 M
E-2 P2-PSV 557~660 mA E-2 P2-PSV 660 mA
21-37 285

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 3.5~7.5 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 3.5~7.5 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 650~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 510~533 mA

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 8.0~17.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 8.0~17.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 577~750 mA
E-2 P2-PSV 415~435 mA E-2 P2-PSV 425~445 mA
21-38 286

No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.5~1.8 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 459~584 mA E-1 P1-PSV 500 mA
E-2 P2-PSV 459~584 mA E-2 P2-PSV 665~750 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
shipping. shipping.

C-1 P1-PRES 4.5~11.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 4.5~11.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
21-39 287
The mode is already "S" mode when power is thrown.

Table13-1
NAS 9
Class
or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23)
°C
— Atmospheric temp
50°C~-10°C
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — (122°F~14°F)
Engine speed
not required
Adjustment
Measure the engine
B mode Hi idle 2100 + 30 - 30 Perform all mea-
A mode Hi idle 2100 + 30 - 30 surement with the
the gauge cluster.
Decel 1050 + 30 - 30 air-conditioner
S mode Hi idle 1900 + 30 - 30 "OFF".
P1 a1
valve pressure
ATT MR1 Boom up

Main relief
34.3 (4970) + 0.7 (+100) - 0.5 (-73)

P2 a2
P1 a1
Boost 37.8 (5480) + 1.0 (+145) - 0.5 (-73) MR1
P2 a2
R 37.8 (5480) 0 - 4.0 (-580) OR4 Boom down
Boom a1
H 39.7 (5760) 0 - 5.9 (-855) OR3 Boom up

R 39.7 (5760) 0 - 5.9 (-855) OR8 Arm out

Main pump
Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
Bucket a1
RH 28.5 (4130) + 4.0 (+580) + 1.0 (+145) OR6 Swing RH
Swing a2
LH 28.5 (4130) + 4.0 (+580) + 1.0 (+145) OR5 Swing LH
FW —
RH a1 34.3 (4970) + 0.7 (+100) - 0.5 (-73) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 34.3 (4970) + 0.7 (+100) - 0.5 (-73) RH and LH
RV —
13-4 288
Standard
value
Sprocket revolution 1st speed 32.7 ~ 29.5
min-1
(RH,LH) 2nd speed 52.9 ~ 47.9
Up 2.8 ~ 3.4
Boom
Down 2.3 ~ 2.9
Operating speed
Operating time of cylin- In 3.2 ~ 3.8

Arm sec (At no load)
der Out 2.6 ~ 3.2
Digging 2.5 ~ 3.1
Bucket
Dumping 2.0 ~ 2.6
RH
LH
Amount of travel devia-
2nd speed 0 ~ 240 mm / 20 m
tion
Performance
55 ~ 75 degree
parking brake
ATT amount of drift Boom cylinder 7 mm / 5min (At no load)
Arm cylinder 6
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in ad-
vance.

13-5 289

1) Outside view
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
CN101 1 GA 0V
6 GA 0V
7 GA 0V
12 GA 0V
13 GA 0V
18 GA 0V
21 GP 0V
22 SHG1 Shield GND
26 GP 0V
21-47 290
CN102 1 GA 0V
6 GA 0V
7 GA 0V
12 GA 0V
13 GA 0V
18 GA 0V
19 GA 0V
CN103 1 GA 0V
6 GA 0V
7 GA 0V
12 GA 0V
13 GA 0V
16 Reserved
21-48 291
CN104 1 GA 0V
6 GA 0V
7 GA 0V
12 GA 0V
14 GA 0V
16 GP 0V
18 GA 0V
19 GA 0V
24 GA 0V
25 GA 0V
12 D1- -0~800mA
14 D2- -0~800mA
16 D3- -0~800mA
18 D4- -0~800mA
20 D5- -0~800mA
24 D6- -0~800mA
26 D7- -0~800mA
28 D8- -0~800mA
30 D9- +0~800mA
21-49 292
2 SHGF Shield GND
8 OILG
10 D11- -0~800mA
12 D12- -0~800mA
14 D13- -0~800mA
16 D14- -0~800mA
19 D12- -0~800mA
21 E1- 0V
22 SHG3 Shiled GND
17 Reserved
21-50 293
19 Reserved
20 GP
26 H2- 0V
28 H2- 0V
15 Reserved
21 SHG2 Shiled GND
21-51 294
E 385BJ specification 21. MECHATRO CONTROL SYSTEM

• The current value of pump proportional valve is reference value because it varies according to pump
pressure and adjusted torque value.

C-1 P1-PRES 0.2~2.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 0.2~2.0 M C-2 P2-PRES 0.2~2.0 M

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 13.0~18.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 13.0~18.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 630~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 630~725 mA
21-35 295
Operation No.5 : Boom down in full lever operation & in

operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 5.0~9.0 M
C-2 P2-PRES 0.2~2.0 M
E-1 P1-PSV 600~620 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427~477 mA
G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 9.0~13.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 9.0~13.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 750~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 750~770 mA
21-36 296

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 15.0~22.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~22.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 570~680 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 570~680 mA

C-1 P1-PRES 0.2~2.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 10.0~15.0 M
E-2 P2-PSV 615~770 mA E-2 P2-PSV 770 mA
21-37 297

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 7.0~11.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 7.0~11.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 670~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 600~620 mA

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 15.0~24.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~24.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 550~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 550~770 mA
21-38 298

No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 530~665 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 530~665 mA E-2 P2-PSV 770 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
shipping. shipping.

C-1 P1-PRES 7.0~13.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 0.2~2.0 M C-2 P2-PRES 7.0~13.0 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
21-39 299
The mode is already "S" mode when power is thrown.

Table13-1
NAS 9
Class
or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23) °
C — Atmospheric temp
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — 50°C~-10°C (122°F~14°F)

Engine speed
not required
Adjustment
Measure the engine
B mode Hi idle 2100 + 30 - 70 Perform all
A mode Hi idle 2100 + 30 - 70 measurement with
the gauge cluster.
Decel 1050 + 25 - 25 the air-conditioner
S mode Hi idle 1900 + 30 - 70 "OFF".
P1 a1
valve pressure
ATT MR1 Boom up

Main relief
34.3 (4970) + 0.7 (+100) - 0.5 (-73)

P2 a2
P1 a1
Boost 37.8 (5480) + 1.0 (+145) - 0.5 (-73) MR1 Boom up
P2 a2
R 37.8 (5480) 0 - 4.0 (-580) OR4 Boom down
Boom a1
H 39.7 (5760) 0 - 5.9 (-855) OR3 Boom up

R 39.7 (5760) 0 - 5.9 (-855) OR8 Arm out

Main pump
Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
Bucket a1
RH 29.0 (4205) + 6.0 (+870) 0 OR6 Swing RH
Swing a2
LH 29.0 (4205) + 6.0 (+870) 0 OR5 Swing LH
FW —
RH a1 35.8 (5190) 0 - 2.0 (-290) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 35.8 (5190) 0 - 2.0 (-290) RH and LH
RV —
13-4 300
Standard
value
1st speed 34.3 ~ 31.1
Track link revolution STD
2nd speed 20.4 ~ 18.4
(RH,LH) sec / 3 rev
1st speed 36.4 ~ 33.2
(H mode) LC
2nd speed 21.7 ~ 19.9
Up 2.7 ~ 3.3
Boom
Operating speed
Down 2.1 ~ 2.7

Operating time of
In 3.4 ~ 4.0
cylinder Arm sec (At no load)
Out 2.9 ~ 3.5
(At no load)
Digging 2.7 ~ 3.3
Bucket
Dumping 1.9 ~ 2.5
RH
LH
Amount of travel
2nd speed 0 ~ 240 mm / 20 m
deviation
Performance
58 ~ 98 degree
parking brake
ATT amount of drift Boom cylinder 4.2 mm / 5min (At no load)
Arm cylinder 6
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in
advance.

13-5 301

1) Outside view
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
CN101 1 GA 0V
6 GA 0V
7 GA 0V
12 GA 0V
13 GA 0V
18 GA 0V
21 GP 0V
22 SHG1 Shield GND
26 GP 0V
21-47 302
CN102 1 GA 0V
6 GA 0V
7 GA 0V
12 GA 0V
13 GA 0V
18 GA 0V
19 GA 0V
CN103 1 GA 0V
6 GA 0V
7 GA 0V
12 GA 0V
13 GA 0V
16 Reserved
21-48 303
CN104 1 GA 0V
6 GA 0V
7 GA 0V
12 GA 0V
14 GA 0V
16 GP 0V
18 GA 0V
19 GA 0V
24 GA 0V
25 GA 0V
12 D1- -0~800mA
14 D2- -0~800mA
16 D3- -0~800mA
18 D4- -0~800mA
20 D5- -0~800mA
24 D6- -0~800mA
26 D7- -0~800mA
28 D8- -0~800mA
30 D9- +0~800mA
21-49 304
2 SHGF Shield GND
8 OILG
10 D11- -0~800mA
12 D12- -0~800mA
14 D13- -0~800mA
16 D14- -0~800mA
19 D12- -0~800mA
21 E1- 0V
22 SHG3 Shiled GND
17 Reserved
21-50 305
19 Reserved
20 GP
26 H2- 0V
28 H2- 0V
15 Reserved
21 SHG2 Shiled GND
21-51 306
SCHEMATIC NOMENCLATURE FOR JAPANESE HARNESS
SYMBOL COLOR W BASE COLOR WITHE

B BLACK
G GREEN
L BLUE L STRIPE COLOR BLUE
R RED
W WITHE ABBREVIATIONS BZ Buzzer
Y YELLOW SV Solenoid valve
P PINK SW Switch
O ORANGE SE Sensor
Br BROWN M Motor
Lg LIGHT GREEN R Relay
Gr GRAY L Light
Sb SKY BLUE PSV Proportional solenoid valve
V VIOLET D Diode
E Electrical connection
307
A B C D E F G H I K R Z
CONTROLLER LOW PRESSURE HIGH PRESSURE PROPORTIONAL PROPORTIONAL SOLENOID VALVE SPEED SENSOR POTENTIOMETER COMMUNICATION BATTERY RELAY RELAY OUTPUT ENGINE
MEMORY SENSOR SENSOR VALVE VAVE
P1 Unload PSV- Power boost Wiper arc Common Rail
01 Engine adjust data Boom up SE-3 P1 Pump SE-22
D
P1 Pump PSV-P1
SV-2
Step motor Throttle Battery relay
prevention Pressure
Torque adjust P2 Unload PSV- Swing parking Step motor index
02 data
Boom down SE-4 P2 Pump SE-23
B
P2 Pump PSV-P2
brake SV-1 point
Wiper CW
Unload adjust Boom head for Travel straight Travel speed Engine speed
03 data
Arm out SE-8 overload SE-26 PSV-C change SV-3 sensor SE-13
Wiper CCW
Selector valve Angle sensor for

04 Arm in SE-7
SV-13 showel & ECU
Windsheld washer
Bucket digging Bucket stroke

05 SE-1 limiter
Bucket dump Arm 2 spool
06 SE-2 PSV-A
07 Swing SE-5
08
09 Travel right SE-9 Fuel sensor
10 Travel left SE-10
Selector valve
11 SE-29
CAN Communication
12
13
14
15 Travel alarm relay
P1 side option
16 SE-20
AIS 2 stop relay
P2 side option
17 SE-11
Engine stop relay
18 Lock lever
19
20
Adjustment data
21 sector 1
Safety relay
Adjustment data
22 sector 2
Hourmeter sector
23 1
Hourmeter sector
24 2
Proportional valve
25 adjust
Cluster
31 communication
Larger than Larger than

0 normal range normal range
Abnormal
Transistor OFF
1 failure/GND short CAN Error
circuit
Transistor ON Transistor ON
2 Wrong output Wrong output
failure failure
Over run
Transistor ON
3 Disconnection Disconnection Disconnection Disconnection failure/ Disconnection Disconnection Time is over
disconnection
Power source Power source Power source Power source
4 short circuit short circuit short circuit
Contact closed
short circuit
5 Abnormal data
Z010 ABNORMAL DISCHARGE COMMON RAIL PRESSURE
308
22. HYDRAULIC SYSTEM
22.2 HYDRAULIC CIRCUITS AND

COMPONENTS
STD. SCHEMATIC HYD. LINES LQ01Z00052P1
Item Component name Part No. Model No.
LQ10V00018F1 K3V112DTP (STD : without PTO.)
1 Hyd. pump assy
LQ10V00019F1 K3V112DTP (OPT. : with PTO.)
2 Control valve (main) LQ30V00024F1 KMX15YD
3 Swing motor unit LQ15V00021F1 MFC160
4 Travel motor unit LQ15V00020F1 MAG-170VP
5 Boom cylinder (RH & LH) LQ01V00028F1 ø95×ø135×1235
6 Arm cylinder LQ01V00038F2 ø105×ø145×1635
7 Bucket cylinder LQ01V00030F2 ø85×ø125×1200
8 Swivel joint YN55V00053F1
9 Pilot valve (ATT) YN30V00111F1 PV48K2
10 Pilot valve (travel) YN30V00105F1 6TH6 NRZ
11 Inline filter YN50V00020F1 Y-457400
12 Suction strainer YW50V00004F7 Y-501400
13 Solenoid valve assy YN35V00047F1 8KWE5A-30
14 Return filter YN52V01008F3 FZ1F183A012A
15 Air breather YN57V00004F1 AB0210GA008A
17 Restrictor YN21V00005F1 07381-00000
The part numbers may be changed due to modification,

so use only the numbers for references.
22-4 309
22.2.1 STANDARD
Ps Pm2 Pm1 Tin

SE22 SE23 4
P P SWING
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
P1 3
R/G
P2 P
PSV-P1 PSV-P2
Av
P2
R/G
P1
1 RIGHT Tin Pm1 Pm2 Ps LEFT 28.5MPa Dr

TRAVEL TRAVEL GB
BDEEF FCA GA
8 B Mv A
a3 a4
Dr
5.0MPa
M
a5
136kw B1
/2100min-1 B3 Dr3 A3
PTO
(OPT)
2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL
BL
12 CT2 CP2
BOOM SE1 SE2 SE3 SE4 SE7 SE8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1 SENSOR P P P P P P
BLOCK 1 2 3 4 5 6 7 8
BR CP1
AR PCa
PBr CCb 1 2 3 4 5 6 7 8
PAs
Dr SE5
LCb LCs Pss
BOOM SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 17
T2 P2 LQ01Z00052P1 01
13
310
22-5
22.2.2 N&B SPECIFICATION (OPTION)
N&B specification YN01Z00162P1

NO. PARTS PART No. MODEL No.
50 SELECTOR VALVE YN30V00104F1 VBY-174B
51 STOP VALVE 24100P3133F1
52 PILOT VALVE YN30V00080F1 16030-00000
53 RELIEF VALVE YN22V00002F1 KRX16EK22
P2 P1 T1 T2
NOTE:
PTb 1. THIS HYDRAULIC CIRCUIT IS USED TO ADD TO STANDARD CIRCUIT.
TRAVEL 2. SELECTION CONDITION AND PROPORTIONAL VALVE COMMAND WHEN ANY OF NIBBLER SINGLE & CONFLUX FLOW OR BREAKER IN SERVICE.
P1 UNLOAD PRIORITY
PCb
COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE
SELECTION
(W: , W/O: )
M CONFLUX / SINGLE FLOW ELECTROMAGNETIC COMMAND SIGNAL P1 P2 TRAVEL
P2 UNLOAD CHANGEOVER SWITCH OF SELECTOR VALVE (ITEM 50)(W:O,W/O:-) PUMP PUMP STRAIGHT P1 UNLOAD P2 UNLOAD
MAIN PUMP CONFLUX FLOW OF NIBBLER CONFLUX "ON"

PCa SINGLE FLOW OF NIBBLER CONFLUX "OFF"
BREAKER CONFLUX "OFF"
3. WHEN USING NIBBLER, ACCORDING TO SPECIFICATION OF NIBBLER INSTALLED,

CHOOSE CONFLUENCE OR SINGLE FLOW BY CONFLUENCE FLOW CHANGEOVER SWITCH.
4. ADJUST OVERLOAD RELIEF VALVE OF OPTIONAL PORT TO CUSTOMIZE SPECIFICATION ORDINARY SET PRESSURE.
51
LEFT
NIBBLER
NOTE 4
HYD.TANK 53 RIGHT
BREAKER
PBo 52
OPTION
PAo NIBBLER & BREAKER
PILOT VALVE
24.5MPa Ao
Bo T
P
24.5MPa
B C1 C2 A
SOL/V BLOCK LEVER
A1 LOCK P
SE-11
50 SV-13
Ps C PL
P
SE-29
YN01Z00162P1 01
22-6 311

Training Manual 20-30 Tons BJ Series - EN

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Training Manual 20-30 Tons BJ Series - EN

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Training Manual 20-30 Tons BJ Series - EN

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CRAWLER EXCAVATOR

20-30 tons BJ series

Torino Training Center

MECHATRO CONTROL SYSTEM

Turin Training Centre

MECHATRO is the link between electrical system and hydraulic system.

LOW PRESSURE SENSORS

Low pressure sensor block located on the

THE LOW PRESSURE SENSORS ARE POWERED

IN THE OUTPUT THE ELECTRIC SIGNAL MOVES

VOUT OUTPUT SIGNAL

INPUT PRESSURE FROM 0 TO 3 MPa

HIGH PRESSURE SENSORS

Input pressure from 0 to 50 MPa

The signal from engine speed sensor SE-13

ON-OFF SOLENOID VALVES

SV-1 SWING PARKING BRAKE N.O. type

SV-3 TRAVEL SECOND SPEED N.C. type

SV-2 POWER BOOST N.C. type

Fuse directly powered through switch on the left armrest

SV-4 PILOT CONTROLS ACTIVATION N.C type

PROPORTIONAL SOLENOID VALVES

PSV-B P2 UNLOAD , PSV-D P1 UNLOAD , PSV-C TRAVEL STRAIGHT fitted on the

Due to PSV-A, arm 2 spool is controlled by MECHATRO, regardless the secondary

From joystick arm

Solenoid valve block location

DISPLAY STANDARD SCREEN

SELF DIAGNOSIS, FAULT

AFTER KEY SWITCHED IN ON THE SCREEN FOR OPERATOR IS

S standard max 1900 rpm E 265BJ

S standard max 1800 rpm E215BJ

H WORK MODE S WORK MODE

B WORK MODE A WORK MODE

BRAKER 1- WAY NIBBLER 2- WAY

From this screen press enter

Adjust the correct flow rate by using arrow up and down

When target value is reached press enter

WARNING ICONS when the machine works in a dangerous state

IN CASE OF ELECTRICAL FAILURE DETECTED FROM THE CONTROLLER,

FIRST DIGIT SYSTEM

From base screen press SCREEN CHANGE BUTTON

This screen display the remaining time to the end of

One by one the display shows : ENGINE OIL, FUEL FILTER,

To change the interval timing after carry out the maintenance

Confirm the new value by pressing ENTER

From base screen press ENTER

This screen shows SWITCH STATUS to enable or disable

AUTO IDLE STOP

CLOCK/CONTRAST to change the setting for data and hour

AUTO WARM-UP function :

OFF function disable

Press ENTER , and with arrow UP turn it in ON and confirm

AUTO WARM-UP FUNCTION

1. Engine running at 1050 rpm for 3 minutes without using pumps

AUTO IDLE STOP function :

OFF function disable

With lever in neutral and armrest in UP POSITION after 1

If equipped this function enable and disable the alarm for

From the cluster the serviceman can: