Section E Hydr. (E171 To E342)

i) Section E - Hydraulics Cushion Valve Operation “Tm icing datas io custann mason sar up. Tha Itong desrtes ely the “Opper r uncon Di Dope au, Boom in and Soom out aes epee teeane ay. wat L 4 1 i ‘Sma /netra . ‘tom ne pressurised of cok io, eter pot Ret tho cation veo, Bough the cuter spel ‘Sound te ina spok wa the galores E ard ‘Sound tw rida cater vagabond ‘tung th ka pon 2° Cashed Nose - Hand contoler st Dipper in Petes ner por cfc ae tan ne ‘pens move rere he Ox penton ADE fe gator an Rowson tthe pot spat be hin conl vee Reuning a fon tbe ala fente! vale era pot Dad pasos hg ale Jota pr. Te movonort he a rtetannana ter and over epoteut gatos E.G andi, Ths allows hat ot Fo port to pass ‘hough galery F. tough the canal one 2, va m7 aS ot Bethe dyprhand contol whic thnwarms & Ccuoned Mile = Hand contotee moved om ‘ipporinonaural Fi (TVET) nan be nan conte Is sso ef tad Inter ahd oct spoots move roo back Ins te nau pation. Plt eken of fom He al vale ars via por then pases Breath ‘Rovers omen Z trough ie cone of be er ‘ool Duet ie reaticeofe tesippr cores eal nha man cont! ve vata sow han ‘eel he ara top poston ot eataton os supped tom te T pon he hard coat tough port 8, trough he cee of he rg hand ooo ard galery K. ve pot Dw the Cusnen Cont ot 2 Fig 6 (96-179), inn th eosin se is Huma he cuson ‘len sevoged ae pl presi fost port Stone custom vate Tho oir oan shlon cpt re bom pushed eee fe ‘Sine son wo athe ues ates Xan {te actson ve spose are open t lew be lat ‘us ton he hand corr wp ro te the spr hander is operatoa pt eas fromthe eer prt A moves he ava spl otne tabard pt pesurlsfoctothe dope soa nine {nel vaho, pe. tho corcusonf heared feneter opoaten, to retringplct Ok gone Stalgt boat te ovr, wth ro rticn. Tas ro cusionng wfec. Hota fom por R ross {ant wa he apse hand cont 36 es he ‘taming ret nthe nel poston EArtCushion Valve ‘Operation WB Section E - Hydraulics pel | | Fig3.Cusloned todo - Hand controler at ppm Eq —aasamees SCOTBw Section E - Hydraulics Cushion Valve ‘Operation Fig 5. Cushion Control ff ew CT® Section E - Hydraulics ‘Cushion Valve Removal and Repacement Removal and Replacement A WARNING Hydrauie Pressure Hydaute id at ‘ystem prosture can injure you ‘elore connecting or removing any hye hore, ‘esi! yale pressure tapped nthe saves owe line must be vented Maks sure the hose eves tes ak ie he eget be rec we Removal 1 Tun of onan, Operats to cone joys back fe ae ie to fo verre press. Replacement Repacerert isa reorl ft romora sequence A WARNING Fine jts of ida igh pressure can penetrate the ‘hn ep face‘ hands well ler ffl under (ronaure ar wearprotectve glasses, Hold specs of Carcbord ele to suspected lene an thon inept {ecardboerdforstgns ofl Wud penetrates your ‘tn get aca np nmediay. Note: tyes tater tet ore nae eget wth {bended satin weer mus also have JCB Treactan) 12 Deconest at hyerute hoses tom he vane lack apple ih aes he caper ‘plug nt scs fo prevent npn oft The femee shoud be Idee, fn. bel 9009 ‘etre decomecing, ths wil entre cores potion ttnen retin 2 Table. yaruhc Connectors hes Tablet Hyer Conmetons Pot ose Colour e = [lane 1 g Pi G = [tanec re ane Gren ie = [Rea 3 csr eave ‘nos orSection E - Hydraulics Ww cushion valve Dismarting ae Assembly Dismantling and Assembly Dismantling 41 Remove aepter 6-and Ong 68 rom yao. 2 Geel sping 66, 001 6D and png 6. 2 Remove adr 6 tom ve ae ropst tp 2 Inspection ‘Boor asebing the alee vahe make ue Bet tereuph naecton oa te component cared ou. Remeber tet ahooh fae smrponent mayb cay (eidoy the cae may betas ayo Wace ie oso ossive at falas component may have cased 41 Caely dean of componens using 2 subi Segrenerg ager 2 Carhy nse at earoonat for sls exossie ‘wear of ange. wear or damage 6 eve ‘engonois mus be ered Assembly -Assobly overs ote dgnarting square, 1 Lariat spt 6, prngs 2 ad wih lan roa ot Ea7s ‘sateen EATSB Section E - Hydraulics Cushion Valve ‘isantng and Aasebly Ea76 — ens agwB Section E - Hydraulics Slew Motor and Gearbox Removal and Replacement Removal ap a ene, Operate te aw can it erect pester von rng Remove tos 4X ard reference pin 1. wre sig sutabl iting omupment (602 wags In Teerncal Data arty slow meer tll roche Eq es EAT?A) Section E - Hydraulics ‘Slow Motor and Gearbox and Replacement Replacement Replacement veel of moval saquance, 1 Peso Slew eto tame by relerce pi 13 WARNING Fuld Under Pressure Fine Jats of id thigh pressure can panera the Shin. Roop face an hande well lao ul undo? prooure and wear protective gcse. Hol a place of Cardboard lose to suspected leks and ten inspect ‘hecerdboardfor signe of ful. Mud penatrtos our kin got moda hip nmedttay. Aer roplacamant cock he msn a ave MA) 8nd ‘ony re wake (AR) pressure ttre Torque Settings Tene Ka eave a ENSSection E - Hydraulics Bw ‘Stow Motor and Gearbox “Sow Noor Coniguaton Slew Motor Configuration [serve] oI, ‘rsa 2stage euston Gear | [ Snash Pt Type All ton Hyaute Meter Mechanic Bake By pss vahe Feiehaie Mako vive Ete sens E479B Section E - Hydraulics ‘Slew Motor and Gearbox ‘Slew Motor Reduction Gear ‘Slew Motor Coniguation NS, i Fs. my A Reduction Gear Structure and Working Principles Powor rans by the hau motor ott sha is ‘ranumite to socon sun ger 7 va is ea 68, Planar gear elder. Powers hentranamios {cpl sat 53 va sacond sn ea 7 anlar peat ‘Tana 76, Th cuts contd whan ogi pon arte epoted m ow ee 8 By ‘bute severe cording under utich be cpa shat ‘operate, anol sal tepid inh cn goa ‘lee ah poate temtnge em meal waste Wer fromtne gear Thabarng ncmanber Alibre wih ‘poral ae tang chore B ah ease E180 E180Ww Section E - Hydraulics ‘Slew Motor and Gearbox Toto Disassembly Motor Disassembly Dismantling Important Before stomping cement te sw metor ‘nd geabor cont Dena and et pars shout bo ‘anh end tho utr suraces washed down wth 2 ‘Sole sober remove a it and dst Diy Usk ‘compressed a 1 Remove motor fom gearbox Mako an aipent ne 4. aos he gear fra motor marang flanges, 10. poe ‘erence when rena Unscrew soctt hand scows 48, fing ne Stow otra goarbox ogee: 2 AntSwingtact ave Osan 1 Leosen he to antninaback wale pis 6A Seoung th atewagback vale fo te motor opie © Remove th anewngback valve 6 tom te ase ‘hoc 4-0 ava om he gerd Remo Be Omg s08 fom the sew mtar ‘owning ange 3 ig 8 (TNE 4 Removetta tro Oring seas Fombo asap Snr neWw Section E - Hydraulics ‘Slew Motor and Gearbox Motor Dassombiy K Fa? me 3 Rerove gs 15 Ramove an ingback vo ps Unscrew the to pigs BA tom the ant {2 Unscow teeta singback vale pg 1-8 ‘sungheck ave nosing Fs famplte wh sping 108, for To. ve rows. 1 Separate srng tom te pig and remove the (fang sol 0-6 om es, 98 bono th Oring stl om the pis. 4 Remove pgs. 2 Urecrw the Mo ple OM om the ant ‘sunginck ale hows 1b Remove the Oring ee tom Be ge.wB Section E - Hydraulics Slow Motor and Gearbox WotorDsaseembiy {© Roo the Ong sels fom he ant-avaton ‘ve poe. Fig tt {© Remove th chock va ssa fom tho vho Remove he ave lve on using 2A, Repeat tps ate dt damantohe sacondant- ‘raha ave asany 1 Unsoww me wo socket hod baselt secing scree 13 econ to tho arcaiston vee ge 138 1 Unscow hea ai.caveaion ae pins 13-8 ees ror}we Section E - Hydraulics ‘Slew Motor and Gearbox WotorDisscarbiy Fat. Pat |© Remove the et-aviaton hack aes x2 15-A 8 Base Discsoy. ‘rom te baspats 1 Unscrew the pug 1A fom be base 7 Rolo viv Asembles secon 1b Ranove he Ong stom he wo ip. 1 Unscrew and remove the to ret aie ‘sonbias fore capt 1. © Unscrew he tao fering octet heed Dose ecu sews 1 Ronove he Oy seals 0 end tock gt ‘EB ro sont te eat aes {© Remove the poppe 184. 1 Remove he Oving seas 1-0 te haat o ‘heroit aes eee SSWw Section E - Hydraulics ‘Slew Motor and Gearbox ote Disneseriy © Remove the two loosing pis 218 tom the fn Fig 8. Note Tae ar hen ramon the zo peo enzo Iho ocating pie 1A came comply oo he moe Foz, ous 10. RamovetteOrngses2-Aromhemetor touting (Remove the ve lle 20 an tae ot the pe 08, 11 Romore te srs 22.8 from he brake piso, (Uso pur and thao the banng 20 Fig. 9 Noter Stal and Cynder Blok Dissent. 3 Ramove he to plugs 21 fom Be mole rose Remove the Oring seals om he pas, meas roB Section E - Hydraulics ‘Slow Motor and Gearbox ‘Wolo Deassery Fig2s. 12 Remo pon bra. 12 Removethe fer Bock 258, Math patton of he brake itn 208 as cet wo At6 screws 26-8 su hee tt cute bra piston 14 Rameve he es pin 26. om he jeder lock {Remove he O-ing abl tom th bake pon E186 ‘ov0st63 E186WwW ‘Section E - Hydraulics Slew Motor and Gearbox Motor Disaster iz. Paz. 15. Desssenbis te poneetane pate ut 147 Remove the fst ple 3BA fom the melo eco. | Tht shia bush 27-8 a remove the (hepotonseinr snd pte 27-8 Remove the pions fom the reining ost Spe (ne Fig 1 Use aputrtoronovethe eke spacer 2-Aand brake es pack 'b Remove the Ong sl tom the bake spacer. ‘sNS E87Ww Section E - Hydraulics ‘Slew Motor and Gearbox ‘olor Dassonbiy Sraeatin ne mer havsng. 1 Use cotp pos and eovernacetp 31-8 ton ‘horn cho Note Orme te sot ing need tbo replaced ei abe Somoged i remaral ig32 Lit cut the cor shat and boating $2 ¥ig 92 (PME fom he motor mowens © Use a ple fo sparta the mator sha and testo a8 ‘eoneo E88B® Section E - Hydraulics Slew Motor and Gearbox Motor Re assomby Motor Re assembly Ro assembly Check st pats fore seseniy end renone sy fcrtces wits feof sone ot eatonncun pape, ‘Wouh wih sabe soetnd bow ay A caution ‘lesning Coaning metal parts wn incor solvent can ca ferroslon Use only recommended leaning opens Sra solvent “rane eve epic al sels wth new ones. ply chan tyre of Wa shting cee aung ena, 1 Rta new soning ng 3A in its ean Be eter oueg os Fase, 2 Psion the bearing 35-4 onthe mot shat an so ‘Shoat ands food haart sat ons ‘torah snosder 6, Ea9 F935 2a mos anaes ne ry eyeat the ousng chur Sige sea Note ote rasing the maar shah fo the moe Inuing ensure he soa rings wa ateBw Section E - Hydraulics ‘Slow Motor and Gearbox ‘Motor Re asombiy Ascentle ne plans In he rting pte ‘Dig a. (NE-00 fr caret aso, 5 oar = 4B te trast plale nto the motor hotng “ Bipa7 (e190) Pods Ascent cnder tack. © et he non any 0A os | Grease an athe nen the sel i the Sider Bock 38 1 Place me sper bush 36.8 onto he ence Fass. Note: Ensue be wo st of pine ar ales. 16 Buté piston asm, 4 Exeu atpston cries are opon and can.Section E - Hydraulics B® Slew Motor and Gearbox Motor Re aseerby Fiat Fae. et the ender ook seomty 44-A ote 8 Asembl bral pon. ‘oie Reusing #48 and ont Bo Ter ht ine 46. 1 Fine Og eal A in tera space outer 1b Fitna Ort set Be seats on he bak 1nd wth internal oo AA, Fe trata spaceto th brake psn, Note: ake care ne © damage the take piston seas tne with eral ae ADA, ‘ois gto spor kin with tera teh 4A East moe E191WB Section E - Hydraulics ‘Slew Motor and Gearbox WelorRe asienBy Figs, Fig 9 Fi the brake piston 45A over the yinsr Hock 12 nae i ns ATA no hare sats he rake Eesngibe Semen mets S55 soroe om sn 13. FuOAmge nd poe 10. Fite Oving sal 45 no the sat in te mote house | 12 FL now Ost sade he Wo motor Pousng Digs usng bat see Service Tots 1 inst the pgs it the mater housing 4B ad ‘oroe tn 388 9.25 Nm Fas. 11 ert the wo base pat cating pis 46 io te stots on te mor hag. Fie at 14 bate Pate Restor, * Savoia teadhanmes E92 awB Section E - Hydraulics Slew Motor and Gearbox Fata, 16 Aocemiothe tse too he mt essen. 1 Ft to soca hoa sows ino te Basie ‘Sathmant nee fatest suey tom to a= aviator se, mountings end Igy een been new Osta sol tho mo bas lat pls ‘s2Aushgbot se Sorce Tools. Pigs (© Fine page 2A to he basalt ae tre ‘hon 9688-25 Nn eo E93Ns) Section E - Hydraulics ‘Slow Motor and Gearbox ‘2 Usetoa se Service Toots ting sl 55 ‘tothe otcaviatn valve pops 1 rsa the sigs 55.8 an check vos 55.6 tothe pgs Foss, 17 Asses tbe Rae Ves Asante the new Ong sels ant backup 9s ‘Gone tn ae vasa ole © Use too see Service Toots thing sa 3+ 1b tstvave Orig en 598 © stows backup ong 3 asp ad tre tien 157/10 Nm ror poppet 89 1 Poopatbacp tg SE Poppa ing a 18. Father valve aes ino ha Boe and ‘ihiee tem Soe) Nm‘Slew Motor and Gearbox Metre ascarbiy Ww Section E - Hydraulics Fags. 21. Fe rmaiing bo socket Nand sro STA no ‘te baneiateaackmen: ae and true tote Scour i 2air 2l © net tha tt check ae assem tothe va rg i 38 (INE10) 22 Assemble te An Sng Ya, es 1 Use tal, see Service Toot ft row Orig Sci SA oo th wo che vale pe. (Seow be tt etswingbock ave pl ne a ‘ve nustg > Fig 60 (T3185) 1 sate apings 588 roe check vao pg. E195 ens E95Section E - Hydraulics Slew Motor and Gearbox ‘Motor Re asserly 23. FRptns ne hase. 1 Use too 80 Service Tools and ft rew Oxing Seal orto ee page LA md eA 1 Sc to pgsino the housing. 1 Assambla the slave 61:8 oto the 2nd check ‘ave 6-8 and insr he assomey ino He ve owsng Fig 2 (TNE 106) 1 Sco ne nd an-sngpac valve pg oth ‘ove hing Fig [716798 Foe. E196 eS E196Section E - Hydraulics ‘Slew Motor and Gearbox Figs. 24 Flantving back ve ascot 1 Pte now Ong sans 66 nto the sole a ‘hoheushg. Asontle the sn-eiegbck vate oxo tbe ‘Sept and inet the res scons © Targus tphan the theo scows Sahm Sigeninesn, Motor Re assembly Figo, 25 Teruntghon se wosnsewingback vate plugs 8- Roem Fig7. 27 Terquetghian he chek valve pigs TOA to B20B Section E -Hydraulics ‘Slew Motor and Gearbox ‘Gearbox Disassombly Gearbox Disassembly Important: Geos atenping fo cemanta ne slow miter 1 Make an aprment ne 4, ares te gostor Sef rnon ong foes pe + Unscrew scat head sce 4, fsening the Fart ‘oor and wat sutaie Ming cere the ‘Se mc 4-0 ay fo he gearbox Remove he 0-09 seat ram te slew matar Frouning ange > Fig 8. (TN) E08 Remove tstedsten sin gar 73.8 ‘© Remove he streduton pont gear set 76 E198Bw Section E - Hydraulics ‘Slew Motor and Gearbox ‘Gearbox Dieasconbly Fit Fa7, Tek oth ae redetn an ge 7A Remove tering ear 76.6 © Litand remove the goatboxtopsacton 748 4 amove te Oring sa! tom he underside of . sngoest Note: n etre reseed wth be gearbox dsssambh 13 Remove the O-ing wat 75: fom te rhggeer_‘IS now necessary oomov fom he mactireand take {le apropet opaeped wrthop 4 Remove gsarbachosina 1 leocet bx wrench 77. an raat ots 1778 200 Sovise Tools, eta ta mel TH Ba ngs ome muir (125) Sin 7a E20) unocew ne ig E99 easesA) Section E - Hydraulics ‘Slew Motor and Gearbox ‘Gearon Deassarbiy 15 Separate peor st rom bea, 2 Use uta iting ace oraz and prions angbearng U-Aand ha clr t- ‘Br separ to ae Srvc Tol, ve he 1 Potion the bua spot BC of seperation ‘al ee Ste Ton rn at eaing conte wi cle ero spac © Use rosso separate phon sat tom me ‘© Atach a putrocracar BOA tothe geuox housing #88 ané spy postr o spate the Dion she ond ower bearing fom the gearbox foiting Aor soparaon, Joo sub lng ‘Sei ase ane onove a gearbox Reus,Section E - Hydraulics Figee 7 Use separ 89:4 20 Serie Tol remove te fg salto geroox huang, E201 Tees E201B Gearbox Inspection ‘Rtpocton ofa te components scafad ot Reraber ‘stash ed caps Bosany Wy. Seas garbox camper hat te seo geet ee ete Boarngs Seas 1 Carfty lean at components eng suze Sroreaaes ent 2 Guay wept ages, bers an hate 3 tn tho caso of damaged goa, for example 2 ‘areay goa Got proceed 10 ropace te ‘nec gnr to nto ease. Ea02 onesies Section E - Hydraulics ‘Slew Motor and Gearbox ‘Gearbox mspecton E202B® Section E - Hydraulics ‘Slew Motor and Gearbox ‘Gearbox Re aseerbiy Gearbox Re assembly Re assembly Chock all pan betes assembly ant remove sy fcrices wits theo sone orextonndn pepe ‘Vian wi sue svt and ow dy Acaution —— ‘leaning meta parts with ncrrct solvents can cause ‘oresion Use only recommended leaning agen nd solvent place al aca nit now one 1 Rapoe ing sat at te iy Sea Be sean Be gee 1 Use te Fing Sea Tel BA see Service Tools ‘aint tho set shox Fats, © Tanth gntoxhousing over ard lhe bosing haber wih eae. 1 Paco nn ing 05. on neon sha 1 ayn ing wh ree 5-8, {© Paco the barn 85-C one pron stat. 4 Use tol, sm Service Tok nd press op spanstihe naar (© Aoly a coat reso, one bering 3 Rat pion shat gearbox hous, | Uso cute ting ato ao ans lover he Pilon stand beara athe tibuar son of {eo\00h oe Serce Toot E203 E203i) Section E - Hydraulics ‘Slew Motor and Gearbox (Gearbox Re assembly Pater 868 ana ace Ivete pon sha ‘Staplertet 688, s0e Sars Toalson tg tana ui true wench se 29m Use ao 08-6 ee Service Tool ds pres a ‘ra out pe (125), en to rg mat bush be oeatorhessingsoansibenon shit Biman esd w Sn equa Foe. Faso, 4 Pace te sain bang ce tpn thst na 2nd econ le gest A. toatconsiethe taming one sha angio De Dpearorhusig 87-8, 1 Asply C8 THeealoker ono the treads of = Figo. 6 Rott rng goa | Ins a NEW Osrg sal 1A ints sotin be goear 13. E204 E204wB Section E - Hydraulics ‘Slew Motor and Gearbox ‘Gearbox Re assery Figs, Place the tho gear 9 1 fang wh te Og wigite & Roflgratox wp secon 1 Fino geatoxtop socond4Acro hing sar inst socket nen ote S48 ard re / © Inset a NEW Ong son 92A i eat ne a top oine ing ge 8258, Fe 9 Pete ttresction pant gor sl 8, 17 net th ng reucton un gear 8A oa E205 ng iWB Section E - Hydraulics ‘Slew Motor and Gearbox ‘Gearbox Re assembly Fig 95 ron 10 Fine tt recon wn gar 95.8 1 patie ya rer ent gst ‘Smerson 80x i schved:ndestng, coe ‘Senay ofte peotox Use sulting tate tao and owe ho Io eno th gearbox. neu ego by (hing mans Fa 96. Fig. 12 Inara NEW Ong sal 87 to Is Seat ine Saar wth socket hea sree 98 and re au ma Shon ah E206 wees E206Bw Rotary Coupling Operation ‘Te couping it lsstad inthe conte of te machine ‘een ower and upper secons and tate round {ewe cae. The spend etn of te ‘uplg pes tom Be vero th net Sct, hat Socted by be ronal movement ane alows th machina few 60° bth rectors “Theron coupra cane of he ie ie A an oute ‘oor Bw aching ings, Ose, us pt an cover Inte avo end rotor Bore ae pars of pars an Dassgos cach fae bang seated fom fe oes Oy rola ringe and O-ring. Bat he si ane roar an Foe and ol can ow Feely rough heal rare, E207 eves Section E - Hydraulics E207i) Section E - Hydraulics Rotary Coupling Removal and Replacement Removal and Replacement 11 Poeiton each anniv grnd Extend he ‘per uly and hen oer no Som fly. Sth ot teenie an emove he aaray 2 Release haul yo poss, soe Releasing Tank Prossure In Seton yar Hydrate nu at System pressre can inure you Ettore connecting or removing any hydrate hose, ‘esidiol hydraulic proseure tapped inthe eames hove line must be vented. Make sure the hose eves line has bron verted before onnecting or rerving hhseo. Mako sure the engine cannot be started whe A warning Take care whan disconnecting eral hores and {ngs 35 theo wi be HOT. {3 Atach neato gs he tay eouping owas ‘rd onda conmochonforrecanecton panes ‘Remove netoes ana rt bind pug ad eae preven conamnton, 4 Renovethe mounting bots Aand washers Btn ‘oaycupingassonbiy cls te lowar tame. Replacement Instalaton ne eves of emors. Ens anitoaon racket © i asd cree ae secu ory cup ssa. ‘oxy JOB Treacher ond Seater to bts Aan que ‘ght 10:26 hm (0004 Bt. A WARNING Fld Under Presse Fine jos of tid 3 igh E208 E208Bw ‘Section E - Hydraulics Rotary Coupling ~ Dismantling and Assembly Dismantling and Assembly Dismanting 7 6. 5 5 4 = g 4 AS ty |G JOH 4p Joe 0 5 « 2 1 : ‘0 3 Fa, ‘Te mma seguir sow gue odmaog. 2 Remow fos ad wats & etch hog 7. Seaineae Siovtat eco 1 onc th cto drat ss 2, sds Ramon steal coms 3 an pl ce Somnocase Snes ey 2 Remove fing screws andthe anolston becket 4 Exact tho ne ale 10 and nsec tho sas and : ree E209 E209B Section E - Hydraulics Rotary Coupling 5 Remove te sea! 1 and yong 12 om te ao Note Do ot ase tome 8,9, 1 ana 12 6 Renae e019, an pcg oe 1 on ‘Note: 00 nt euse ‘eng and te packing toe. Assembly Inspect te pans fr sine of wear, pling, sting, ‘Jeeoourton ee. Ptah out scnches ung fine rads ‘stone etre ses, teroughy clean of pare sing « ‘ube seven: DoNOT use salves on Og, bastup figs ad ele Ft now 0"sngs back tng on sae Lutte ‘ings, ack ing and os, wih ean yer he bole ting, 1 Chan the ee 5 th elnino compressed ‘Aer door. check ste tae ae ay sachet ‘rromnens onthe ier ade for ergoove * Stn iene on bala bac €Satone packing ng nach groove staring rom the 2 rove em hop. Sette ‘O-ng inte op goon, 3 Atrisaingte Ong packing igs and pactig, rack wn 8 mir to s08 toy or eno ‘Aer tacking, cost wih grease ten cs one ‘noel ny posi, singe 4 Instn saa 12a myn ra 1 onthe 10ane (geese aceite, Take cae to pent onarintono he grease by water ot 5 Indl he we 101 the or 15 ‘Noe: Sale stl 1200 halite cit sotto Disranting end Assembly {Ina row sal 9 to housing 7 ane food otic ‘he hough Fea 10. 77 Install fe fo rg 8 an sce ung 7 ng ‘nas ard bat Note: Tore tighten Bots TON (SH {rt encatin brackt 5 sing sro & rela mitt asa! 2, conection 3 E210 E210Section E - Hydraulics Drive Motor Operation == Under nomalronincined rod coon, oes ‘ons Aan (pans on these tecton) At por A i presaure ves shuts and ot fowe af yom fetereo ot on he tveshaa aio. The ls sow {ges ough hemetor and back a ak (ts vat he tako spa sete. The owe dad ‘ded a check vv, ls raat a opt ee Wore slots a spat Of postestwaugh Be he: heck ve wher ladosd ended by Be slate poo. ‘perten changes Ol i flows frou emo {ho prossu ars bul up forthe othe ne, ‘hs pressure sorts bo faa CVE whi lows a fo oss, at CV2, whch coos of, te supp to he, ‘rough ee ries, vos he sooo, Nox pod MP Flow is fh pie. Tho pst as Max pee, ‘The rors fate spooled uth pao des ot slot asthe sping peste det sana. fom Theoer sxe ofthepon open lark Aste pressze eos mich ant overcame the sping. Poses (tees reste ne pot wilt talc ‘Theol arash spol anges docton fed he iti poate to aie ft ton, la mov De [iso ihe oppote Graco rg ha erat ange © (ve manu equ. The max fe ist en Ean Eani) no tr The soa shes to match rq weh oad senders en the machine travels down Ni he mata open ‘teas puro, tho ol sup’ afl fo prveré ‘avatin win tho mot Nepabve pressure can Ht Be ‘Stock van tow oom nia ke up epee ‘avant vets wn hse 00 gree ‘Rib eg oe yang las reso Ports on Motor Body x ug Po. Serv Pon Pressure (lx Spleen) x Cage Par Seo Pon Pressure ‘Splcarent 99) mu Cage Pe. Seno Susp Pressure (Bare Ones xs ‘age Po. 536m Possue Ports A and B ‘Tho tosbld pressure can be aust oar pit wns maxmun and miiman esplscomert takes Foon. Tho edusmant sw gos 0 Be’ meas! fecucton per ene complete tum. Atari tb vests Pressure wit ve varying suns of tro ahd epead tht wi foc he meshes rood speee ons aco Me rachis ably to cimb hile. Thar Is m0 oxo ‘igiseront on tho delat ior sro, eu ‘Sauron tl postle, Re doe by tho aon ‘enor of shin, eral Ea mS Section E -Hydraulics Dr Motor ‘Operation E22Section E - Hydraulics Drive Motor ‘Deseipton Description rm . a4 SH OFS é i eens 2 Gauge pat X1 = Seno pin presime (nat, 8 ‘Seplacenen i) + cna ‘Ses re 5eaeR a 7 Nake w p(s) Eas ‘Safty ae (8) ‘att Vas “Tost rear agus srw euge pot XS ot proteus EzsB Removal and Replacement ‘The ported level of senicng f liniad to the ‘apace seal, Orgel get ‘Teunt must error om ha machina or seg, Removal 1 Satchote engine an peat ie conto relee system presaue 2 Tlng stops caleh ay of apitge dasa be Roses te ave aie erty be hose wi Pre oestn replace Cape ows ends ord ug mar pons. 3 Remove e fur bots secant dive mata oe ive geortox anata Note: ro eve motor fe heavy Ung sutad ing fooke, mote sure supeoed whan tho bats are remove A WARNING iting Eauipnnt ‘usa be nd yu se aly ing ean ‘Ma sur that ng equipment sn good co Repacanent isthe rovers of ameva Ea eS Section E - Hydraulics Drive Motor ‘Removal and Replacement rrWw Section E - Hydraulics Drive Motor Dismanting and Assembiy Dismantling and Assembly Dismantling 1 Ramee he x hexagon sco scat he orto ‘noma 4A. Un he conta mad. Important tb contol mde verte epwarte so tharte 2x chacessve bts Ado natal Sonn tre Note The 2x gue 8 canbe oso, Es ‘seas E25Dismanting and ASSO, {© Remove te gpa support pin (nt shown) fom etecn tech barel od eat shat. 3 Remove the 4% hexagon seems securng the Fae. rman moaie 6A and IR COMET Ra yeah a Nese: Mok sur tat of to ot shat rs camo cut ‘wen sore sa & 8 Remove he er supp pn OA Hom beeen he 5 Lote ene tare 7-8, Jorhat and te gute pin 88 ote: The spper upoot pin (tot show) assed 9 Removethogul pn 8 Seto tt Bare ad he sak gh at E216 a E216Ww Section E - Hydraulics Drive Motor Dismaniting and Assembly 10 Ramov he compresion png 10. Fat onthe normed roving 100, 42. Remove the etang i 1 11 Ramo to peton 1-8 anh "Org 104 fd ‘oe: Tests shout tenth same bal soe 44. Remove th sel carer HB ac sha seal fat {roetae you dotanerd to sung the fone Ste) ra ho sn fe 12. Remove Be needing 10 Garner norms Rereeset enti eee Ea E27Bw Section E - Hydraulics Drive Motor Dismanting and Assombly me 17 Uso a tyra rss © remove the shat. Pace ee meting so care ea ts eamageng 48 Lite ostorboning 154, 16 Romar te retaing rng 1A ond spare washer ae 19 Uso a wera toto reve he ner beareg ‘rome shat E218 enw E218w Section E - Hydraulics Drive Motor Disrarting and Asconbly area 4 Presi ctr bawing 7A enone sat See Sates Reno Pe te ‘te: Be ct whan using te prose. You must aco ine conect beang eating, no bash and 2 ow rng Note: ac the stat on 2 space eon E29 eT E2195 Assemble the spacer washer 188 and tho retaining Asset cari 20.8 wih pew sha aa 0 8 Assemtothe tring ra 20, 7 ubicate he sang sue whl one sh Figat 10 Aesorie he cepresson sing 2A or E220Ww Section E - Hydraulics Drive Motor Dismanting and "Note: Uso reason toot shat soa teers dot Note: Asem ta roles te chanfr vas. Foz, 12. Assemble toad housing 2-A 12. Aesonbi the pistons 22.8. Be pons have not tion reac assomile hem ie fe same Sal Piss ‘osha a etre 16 Asconbie he poe upp sn 25. in fe oyindor 14. Assomte the loner suppor pin 2. ‘are Ema a EzB® ‘Ne: Us ease a he in 2 that ae nf Sou Inthe assay won assanbing e cinder bare 17 Aesomble te oyindor bare 26A and te sng pine 265. Note: Tho sng pale must be second wth tho sos! ‘ise towaris tender bare! andthe oe 00 ord eves sonar Em Section E - Hydraulics Drive Motor Dismanting and Assomby 18 Mato cure bw tbe suppor Is ne comet besten by us athe pancetta tn cack gen. The. suppat pm must sand Wp Big (ean ornare ssa wine & x hago cove Sentient 108s 20 Nm EmWw Section E - Hydraulics Drive Motor Diamanting and Asser) Note: Be very care not tap your figs 20. hesomble th 2x check vate balls 2-4 Mate se (ate 2c ude pn 298 ae pace 21, hasomble 8 contol modse 208, the seing ston am 30.5 noe va sare 204. 22 Secure te cant mode srg th 6 x hoxagon ‘soe and true egon 18 20 Nn, Ems E23Bw Section E - Hydraulics Drive Motor ‘ismanting and Assony Control Spring and Filter Fast 41 Rese he seal mt 3A 2 Tube ajusinent sro 31-8 camo close 31 Remo the sping bt Change the pn). 4 Poston he raw sing tad tum the adstnaré {ew doce un he sig prose 5 Teen the seal nt Fost © Remove th er 32-8 17 Ptac th nar vat a oundednesehsutace ‘awards (some waa tb Row) ‘Note: Won the Mor hasbeen easton # mtb hana Ene aan E224i) Section E - Hydraulics Steering Control Unit General ote: Me soos ted below a non sonia Brig r(DE226) Should they be” svipected of imatunctino damage the cme staring ear unt ‘rou bo change. 4 net chack vate Proven fom returing tough the staring unit stengreisrnonte race sere ‘heel ce 2 et Led Sensing Rae Vave Limits axinum presse to he stetng unt posing te sleedng cet 3 Ofindor Por shock Vahes C(t and Lo Protas hoses asinst pressure supe costa by (Found fees one stowod se 4 sot Cvtaton Vv for Cynder Pons Bot ar tae Potts seeing cet age acum (avian) Dismantling Before cammenchg demartng, separate te seg tant ar the owning pony wae (50 Staring Prony Vive, Removal ard Repiacoer) ‘The rumerical sequence town pu to damian Sign anes 1 foie ng atu SCY na ae 2 Remove te capstan 17 of nde washers 2 2 Remove cst endeap 3 ad pacer Ems 4 Remove and decerd'0"¢ng 8. 15 Revove tha geo and dive sha 7 ogee mth ‘Spacer pe wove nd dlcad'O age Bend 15 Rano he cont slowe 11 conto spot 12 ‘tery tome housing 18. Die ouentg pn {1 Pul cartel spoal 12 up an eat of core sore ‘Hts eet ect ha ong seg 18 7 Remove the cating spas 15 om coal eect ie 1 Remo and deca ta 16, Remove retiring te Ir Sai or acs fog 9 Remove ny 19 a ea 20, des 10. Donetremovebearng 2 nests dmeged 11 Ramova set sew 22. Tis wil nate th check ‘elvo@3, 2¢ ond 25) 0 bo Yomoved. Dear" ge 26 20 21 12 Clean al pats 9 sible stent a How ‘Stamina pats or wear nor damage epic Assembly ‘Assay ia eval of te demanting posse. Use wr els," gs taining gs ‘tor asabig tho stosira corel unt (SCU) det their sna appratmatty 10" a han rane The ‘of ohods rare wanoit heaton Repent fis [Recacre mtbcpystedrocton. Rote he SCUIn both ‘actos 'o eur feedom of movement and ret he conting sping 18 robe changes hay must be hongec asa st E25Ene Section E - Hydraulics ‘Steering Conta Unit E226wB Section E - Hydraulics Steering enirl Unt ‘Spring Instalation 12. For arangement of the coring spigs. She? (ez ‘ign te sing sts of sove 4 and spool 12 Shia Ryser roca flows Mak sr tat he etna does X 1 te spngs are donner 4 rset spa a stn ott soo 12 (Rao poo ‘Soh fom lave for more sig ares). 2 nsot sping ae sue the bowed cane sectons foo Spgs ae pete Fos 3 Puth sping and baran te two orgs a ant pus spings and fbsteeen sae bad 4 Path spect 12 ro deove Hf uit he epg st ‘us wn ep and cn thew Emr ean E27BW Section E - Hydraulics Steering Poy Valve Priority Valve Removal and Replacement ‘wen Assembiing 1 Remove he wo socket ead sree A. evow Ongs 2 a 6, lahty smentng wih ean al of bt tg. 2 Soperata seeing pray wave B fom soeene ‘Seu. rong ew Flv poston “obi Torque Setings co Karm e 2 check Ovings Dan ae enew damaged. x Beas ata 4 Repacamen ithe overes ofremova o 35-85 [25-40 5 5-55 [25-40 Dismantling and Assembly “The nmol sequence onthe station I @ gue © Semantng, ‘lanat prsinasutatosoentend iw ry wth eon meres ar Assembty isthe roero of mantis, =aB® Section E - Hydraulics Hydraulic Rams Precautions During Use Installation 1 Precatons when ting foramen he machine. 2 When nating and removing om tho moc, Stspend te ra say, ‘Suspending the ram by he png isnot ony angus, bat con in une drage toe inaee Socio te piston fe wth 9 bard 07 tanger fh od enfant unary. Ae, the ted can be damaged and become unstable. 2 Wang terse team mayest in damage 2 elec wing is doe even at point aay ‘tom fe ram are maybe spuing ele a ‘am ad wt Bocoma necessary elo the 3 ven pinting te machin, mash am, 1 si adhe tothe rsa orth pe tig asdharam persed he mer ing ul at funn prepay eli ater apt ck nly earth rm. wt ose drags To soas, rasteaty Shonen bette erm 4 rt tora ony when ts cla Caution During Use 1 hytaue of omer than he designated ot Uso he seats qu dager tnd besos ‘omige te ele vaio ela ave ghee ‘han sped itmay ease ar damage ane ange. Inia tomporatire envionment (prox O'S {nt stow) oF low tampa eneoninnts (Gein 20°C), seals qty become damages. ‘Spec sod mati are necessary so cook © ‘stoi atyouare using slse or {© The ruber oe cute fam ol ekags 8 danapn Se cr nto damage theo, Yar sco tlorsbegring work Ira oper al mani prose Pscnun sped Sell be damages “Theta ea age amount atin anew amar one hh i own a frog rs he rail ‘otoperat smoot. Asi pescure is appod Swocory bout” Bowding eat gh {pert wl be generated duo tobe ‘amprosly en tho sols ay bum. ‘efor Sephing work, ays move to ram at fl ota nth no lod and ga fam he ‘indo en egg tig Jo a 9 ses es oan ang ped of ne because the {rico to om may Took and tho fyeraute ot ‘oume devoases as cols. Sop” str te ‘rath ns al ands poston. Maintenance, Inspection Points 1 Cary cut diy marenance ana napocn, The hoy goto caectong tam rem non it iy ranance ‘nd specter Cary out Imartenance and pecion so tal the tam {inet ty ata mes Aaya reve sry ‘rae water Sst orl finan eroded (ening their ing an sas co nat ge nam Wet win wor bu we len wo aap To Droventrustoming dung stage De ara ipord ram psn ro stone hap 10 EzeWw Section E - Hydraulics Hydraulic Rams Precauions Daring Use Inman if tang for mere than one neck, Sy a ght coateg of sub grease oF Bethe 0 eos at fe van 2 Use ganune spats when roca pats. «pas oar Nan genuine JCB pas ae vod. the dosredresusts ey sb cine Us ery ‘eine 205 par, 3 Caxton surg marin and roassorbh {smarting he am whe ts stint on he ecie a be_SNNSONS 98 nec ‘eran fem he machine an then Gea, bi roscembld with diy hands, frign maior art: ramus a sori Ke span a feo to or hyerule equpment mayo ‘omogod Rosssemble na Goan io © Flow te insractons ne doors rearing [Emu tgfienng beacon pre inet {potiph orto l san sais smage E230 Tn 8w Section E - Hydraulics Hydraulic Rams Removal and Replacement Removal and Replacement ‘Typical Bucket Ram Removal WARNING yeraui Pressure yeaa fl st Bystom pressre ca Ine you ore connecting or removing any hyrause hose ‘til ya presaiee Capped the sae tne hasbeen vend Dore conmecing or meri owes Make sure the engine cant be started wie the owes ar open, A WARNING iting Eauipent You cn be jure if you ue folly Hing eulpment. Make sure that tng eoulpment sin good conton. Nake sure that fing tac compl with al loca ‘equations ands suitable fr to ob, Mako sure that Iiting euipmentis strong enough forte 1 Loworthe aaa ote grou Fiat 2 Pace wooden Hock under th back am. Et Fas E21Section E - Hydraulics Hydraulic Rams Removal and Repaceront AWARNING tata Spits an bo injure by fying meat spintrs when sot fecad hammer ‘ond mata pins. Aways Fas. 1 Restaln ne ee ent a he ram piston roo he am ‘finder prevertine psn ro fom extending. Ea2 7 Remove the ram hoses and ntl pigs o ap 0 ‘onierrason Ach sng tsp een Remove the it aba en Be ered of tna Pah epi ng 8a rhe WARNING et Spiers — ‘You canbe inure by fying meta splints whan ‘vin Fou. Utes sf feed hammer E232WwW Section E - Hydraulics. Hydraulic Rams Feroval nd Replacement 2 tt tart nn Figs. Rplacoment 41 stacy sings ram ane open ont ever E233 ‘noes E233wB Section E - Hydraulics Hydraulic Rams. Removal and Replacement 46 Hott ne am alg ek neta ep, bt and us Note Stoke te ram to ree enbapped ai. Ate eosin teak obeck or eatags ( E34 aaa E24i) Section E - Hydraulics Hydraulic Rams. Typical Boom Ram Removal A WARNING Hyarale Pressure Hyerauite nud at Systm pressure can nur you Before connecting or removing any here hose, reside! hyraule preseure tapped In the series ows ine must be vented Mae ere te hose servlon aa sure tat fing eauipment en good conten. Mako sr that tiftng Tale compo with a tea {ogulatons ands sutable forthe Jo. Make sure that Iifeng equipment strong onoush forthe Jo. Figs. ‘Sop ne eng, renovethe ky. 2 Remove be gene te sd tach tgs oe E235 ‘Removal and Repiaceront Fa 3 Remove the ns, bt ans cal, A warninc ‘Meal Spinto ‘You can be injured Oy fying metal spire when ‘ving maa pein oro ced hammer ‘or copper pinto rmove a metal pins. Always tear eae geste. Push ct epi, using a bar an han. Pat 4 Lower ram an place on a an E2355 Resa to ey ond of to pln fet he rom fort proton movonart of ood Section E - Hydraulics Hydraulic Rams Removal and Replacement Prosser bat Ato rss he tank pressure, A F920. ~ 7 Remove the hes, and intl pugs o cape to Float {8 Remove he nan te an push othe pn wh 3 WARNING ‘Yu canbe injured by fying meta eplintrs when ‘ving meta pina oF out Use» sof faced hamat ‘o remove and Mt metal pins. Alvar ea poy E236B Section E - Hydraulics Hydraulic Rams Removal and Repacement Replacoment 1 Asan ang wine ram. ‘ign be am its rts poston. Foz, 2 Ina pe pn an thon te bo ane us A WARNING tS ‘ving moa pins or Use a sof faced Ramm fr capper pinto move and ft metal pins. Aways E237 voonnsies ERTB Section E - Hydraulics Hydraulic Rams Removal and Replacement Figs. —~ 4 Utne ram ane agnor ey end wth he on poston’ Note: Viton checking or rttng JS macine pots, Sergi toot es ‘othe pe bos bu must have aproxmataly instal he pi wih abarand hanno {2 athe pis tea tom onsen WARNING 2 Instat he noes oc. ured by ing tal ini wn ‘meal pins. Aways E28 sro E238wB Section E - Hydraulics Hydraulic Rams Removal and Replacement te: When hosing a lets, ‘erating ns ar bats shat not be fastened iP (ein toss bast have ‘ray Fig2s. E39 ne E239B Section E - Hydraulics Hydraulic Rams Removal and Replacement ‘Typical Dipper Ram Removal WARNING Hyraune nid at system pressure can injure you. ‘tire connecting serving sy tase Pose, on ine mnt be vented Moke sre the Dose sans toa nen ban verte before comectingorrmring sweat iy he eget be rnd we A warnine ‘iting Equipe ‘You canbe injure you se faulty ng equipment. Make sure that ing eaulpment sn good condition Nake sure tht iting face comphs with ail nel {eguations ad issuable forthe fot Make sre that Iitng equipments strong enough fo he jo T Figs. 4 Remove te sand tos em he rod end of ne E240 a E240Ww Section E - Hydraulics Hydraulic Rams emovel and Replacement 16 Rosanne ae ad of ram pn ro he am na to pretrt helston o tom xen 15 Push cutie pn, uso bar andhanmex rose -_ 17 Ramone har hes, nl igs or apo proventcodammaton Ean a EaWw Section E - Hydraulics Hydraulic Rams. ‘Removal and Replacement A warning You can be injured by fing metal splines when deving meat pns nor out Use aso faced hammer fF copper plato rove and metal ps. Maye 41 Ata sings nit tram ono ne boon. Fo 38 9 Ramove te nas an bts fom the inter of Seton pane epg abarenshanne ma BO E22wB Section E - Hydraulics Hydraulic Rams Removal and Repiscement 2 nate pi, bots and us. A.warnine Wet Spiers ‘You can be injured by fying metal pints wher ving met pne io ott Une ao facad hammer 3 ntatthe gore ed anract he hoses. rr E243Foss, 4 Holt ho rato ante piston od aye ond wth ‘Speer pation 5 Ina he pin, bot anus ‘Noe: Stoke the ram to rieaso enapped at. tor WARNING Meta pte ‘You ca be injured by fing metal pte whan {ving meta pin in or ot Use as fced hae ‘or coper pinto remove and Mt metal pins. ANaye tear sae also, Eze Section E - Hydraulics Hydraulic Rams. Removal and Replacement Note: wan creck o” etn JS machine plot ps eetaning nts ant ots shout not bo fastened pth [bimepot boss but mst have sporxinte Sr of ay ‘Sate pin Fee rem inser. ERM®B ‘Typical Triple Articulated Boom (TAB) Ram’ Removal Awarnine “ung Eine You canbe rd you enna emer tat sr tat ing een | fmolaton aa tel forth bake soe tat Ing equipments strong enough fore job. cet ord per rams fy vated ado TAS ‘an arly onerded, ewer he stacner 0 e ‘Sp he enge an rove ky, 2 sae satan ting goat he TAB am sn jst Eas Section E - Hydraulics Hydraulic Rams. ‘Removal and Replacement ek cute pot pin using bar an hamme.Section E - Hydraulics Hydraulic RE27 EarwB Section E - Hydraulics Hydraulic Rams Removal and Replacement 5a he et pin and ela ba and us WARNING Ene eae E248wB Section E - Hydraulics Hydraulic Rams: ‘ismanting and Assembly Dismantling and Assembly ‘Typical Boom, Dipper, Bucket and TAB Ram Eng 08 rrB Dismantling ronove th yer pes 2 Pcetheramharzonal ona dsmantngessniy ‘ae and oer try. 3 Remove en ap 4 by removing retaning scons 2 ‘ing nln ay 4 Uae singe to supper th woh oto pston ro SioenBy 3 ad pl he asembly dear of rar finder Use @ sill eentanert cach sn ‘etal au ad apace. Note: may b6 necessary t ape ao” haute essu 10th head st oft ram nrcr tac he ton ved assem rom to eae A warnine ia or hyraule pressure is used te free out the piston sesembly, ensure thatthe end cap secutly fa. Sovere inary cam bo exused by = susnly released piston od A.warnins {iting Equipment You cn be inured you use faulting equipment Nae sure that fing oaulpent sin good conden. Niskesure tht tting face comple ith a Ioesl ‘egultons ands stable for theo. Make sre tha ugh othe Posten the ston rod eesty one ram pon hea omatiglasamy tn fe on rod Fosing on support Bok J s08 am Piston Head Nt, Removal en Fting, Remove gr cow ter iting athe stating, Femove sl at 6 7 Remove ton nut? a tao nam ison Head It Removal na Fn, 1 Remove shi stn oad 9, ution 10 ae ‘sngcap aes mone, rom pon ro E250 Section E - Hydraulics Hydraulic Rams. Diemariting and Asso 9 Hold pion net Bina so james vice and prose Seton 1 Remove ura lower side teat ge 2 nc 13y Pad ' citand remove pon hea ain sea 14 king ‘Sxeratio cage a seal ore © Remove 01g 18 10. Reroute an cap esl 16,17, backup ngs {U Ghapod sel an wpe ss 20, Note care must be taken not © camage any sash ‘1 Remove gondatanal'tnge 22 nbac-p gs a 12 rtieracosan to remove tush 24m orca Teme sup tg 25: Push cul the bush wih SRS ro tte Oca er Ps Assembly Sere assy, make sure all compares ae ‘torch esa i staan slvr men eas ‘Uso naw’ ngs, sas ndbock rs. hy grasa bere, ‘Sa ng rs oa cap 1 2 Feber asleep 1 oe cap 1 Sendo oa Gini U' step (end rats tr an 8 (0.24) to vo nig) and neat fs pore Theopa end le shape mst oo two paso se 3 Intl anew bap Ag 18. shapod soa 19 {Usha tc pon neg). Make sure re sro sing and hg of teen 1 oe ol 1. {5 nal pow gland etme‘ ings 22 nd bcksp ‘ge 28 (gs sat oh paston he) 16 FLO’ mg Sino ite mie groove ofpsion head, ating suet et te. E250B 7 plan hand sea! 28a feta tstaton ‘nfotoung p99) 12 Sarto wurfoo of npr guise X wih reaeo andi sa 4 oto in hoon postion 14 lower side boar rings 12 and 13 othe ‘on nead by hae, © Fhe tn ond of ine pid X over he upper ‘Seton olson hea 4 enn cto oie Xs ut + Un mi se oi nlf eat se: rss cae 0 ensure ta tho soa fs sagt ‘te ine gue Xan three sary seve ‘Oreo rosin stars do nt sop mis ave os Se ‘become eames Use bodng Ja Z afta oer tat ison 12 Sarthe pra seten ajo Z wih roses 1 neti piston a aes ej Zn Ung he nytaute pes, psn the pan head Eas Section E - Hydraulics Hydraulic Rams Dismanting and Assembiy sett strap he Sp to press for 3- ‘tends ste buen pt W. {© Gontnu topes the peton had tough az 9 FL mo upper ede beng rps 12 and 131 he 10 lest end cap asamtly over pson ro Note: tis aaisate tape the piston ro tad 0 Proven domage ona sole Ramo the ape aor ‘rattan, 11 cushion ng 10, psn ad aston 8, new fen @ and pla has retain mut ton ro 12 Palo the pion rod asset on We rm piston aod damani(gasertiy (2 Ram Peon Mu, Forcast Fn wth et a ego 8 suppor blk, 13, Pecee ae desctbed in Ram Piston Nut Removal ‘2a Ping, que tohenig he ptn Pea NU ‘hotoruospotea Toe Stas 14 sat sol bat ane gr sre 5, Tan ih ab ‘row foo brq apoaed Tous Sang, ‘Sika ee gu eo a apne 18. Using sings reve th seers fom te i snd Ineo in ror soa 4 Ener that ange do rot move out pace by teepng the piso ro Ssieralysquneta esas 16 Fond cap othe cynde and soe ftowng ho Sequence 2 Fig 63. End Cover Tightening ‘Sequence (e252, Tae eaning scene 210 ‘etorquo spect. E25B Section E - Hydraulics Hydraulie Rams Dismanting and Asser Fig 63. End Cover Tightening Sequence Tobe 1 Torque Setings Tam] Dimensions | — Pier Paton Rut Co Location | BorexRod | Nut A Torq Torque (oom) (om) Ne ern) Nn ore Bean | is 80 = 0 GRR) | SEO TOT aT THT Depa | 005 es oto un | sageeio7 aasar79) ut | 105475 % 0 car | 515150 @aawte) meus | 00475 6 200 mm | atsrsa eaasraay a porn) | 190x00 100 5500 v2) | sesr107 _aasee79) Note: For piston rut ave pressures soe Ram Piston Head, Romort aed Repacernont Eas2 ‘soos E252Disrarting and AScontlyB Dismantling ‘The numotel sequence an he Muang ‘onan 1 bina nye ns om am 2 Pace e am orzo ona damantigneensiy fire and sce fry. 3 Rana od ip 1 td aw pon ad 2 naar 22 Frese ote alse tbr tte ton od essay hm fe cine A.WARNING if aio hyaule pressure I used to foros out the ‘ston assemay,eneue thatthe end cap ls securely 4 ict at sa, "orgs, taceup rg and wee te. Assembly For assombly revrso the amar soquonce onthe "maton, beaingin min he fbwna pas 1 Chan at components heoughy in a. suitably ‘Sivort Use now sons, baorop ngs and {pny ree soi tbls ng. 2 Aegy JC Aro he ret of pon ad § Suing 08 Mewar and Soa 3 Aeply JCB Tveatocer ant Saale to ead of ton fou 2 Ft ana pon pon oa Sto the ferue Shown opponent Ye poaon ofthe palo ha 0 tat eave ol js wth Bi ot tn ros2.Ovehome onal 4 ly 308 Tvoodocar an Sater he toads of ‘ns cap 1 Ftend cap 1k lnc 22 and an {othe erie shown epost Ease Section E - Hydraulics Hydraulic Rams Disrantng and Ascombly ote: 108 Teaser apd Seale snd JCB Acar ‘mon lente soe, beep gs Orgs ‘ote: yuo ceists vcured Tcedlcter ant ‘Seat @ weakening of the Bond wi rau. When ung ‘etter aw amu cag se of a te Teg Stings eee YG o re | s00 [oo 5 CnB Section E - Hydraulics Hydraulic Rams uot the high ston nut hing tos used on he ‘ast recs vs a pocal (ols ee ‘paca ol row he Tae) fram pon Padma ‘rg and remove see Section 1- Service Tools ‘As shown nhusratons Aan B th i uses 2 mesa {ram acng en shady ng spanner Do asen ‘rte ton nt Hyarauipoma opr oi tay be cbiod fom a suabe yas power pock {raram roasre routed 150 bar 2175 a} fom {Mo uelny erat 9 ICS mac equpps wr que ‘lees coos meet case smal bre Moses E Pat No. 92001372 of most bo ued bcontet a © ‘no power sources inte spoof epraton ot rom Iodaton ot puint Part, 6920282) ond posoue {ige (Poe No. 8201278) sau be ted nto re {Ro pln sie fhe rom fo esse to Sheng Dossure beng apples. ‘2 Table 3._([YE287) for dole of tho prose ecasar achive he roqued ightanng ries For ‘eruo stings, so Ram Torgue Stings In Techical Date Section Nut Removal Imachin, Pau png removed and Be pion fod ‘Seemby seperated rom he ine Note: Batre using tent ranovattting operate te "9 ender overt a range fr 8 6 stokes remove ta tom ne eae: 1 Intl pon ro assomby in tho dsmantn! _ssemby wih epson ot suppeod by oc 2 Soci te ojo ond of tho piston of he rs at poston Gung a sulabl pet pn. the oy oe fram Ca potion 4 Power the ram snl Suma ttn the fitn .Th pressre shuld be 1D 1015 tos {he tihoing reset pvieus a) 5 Remove the ton mt (6 Remove the ston rod assay tom he gan Sen pcan carer soe xr ‘Ram Pleton Head Nat Nt iting oor secamby anne tat sl crgenats have been {torotiy seared sr al ow si basing ngs ad ‘Suing ar avait, Ser al sel wih Myre ‘i 41 Assenbe the pion rod conpenens as deled (otro eau rar 2 nate pon rod ane ine nut moral ‘Sing ig wth pion ro pred by kJ {Secure the eye endo he ptr rod ote gat pain ua ase pat pn 4 Fa rg span eps ut ad enna to be eye en aan € a potion K 15 sng te i, sn th ptr Deas ru 10 torus spear nd rane by Powetng he ‘aml omar The run, requeo! Indeed by gga Tables. (70-257) 1 Remove te pon fod assonbiy rom the are Feat io he fam ender ce dad wae or E256 E256Section E - Hydraulics Hydraulic Rams ‘Ram Pston Head Nat Requied Tgitaing | Necearany Gauge “Torque Preseure aR |e wo | a | a e 400 | toss | 88 | 90 470 | Tot | Tox | var [reo | ~isa0— [es | 8 Tea 1387 | a7 | 8 1900 | a0 | 13 | 900 a0 | es ta |e a0 | 1696 | 189 | 20 20 [ 78s] tet | ‘te | 2567 | ana | 8 ‘a0 [2601] 207 | 9508 Ea a0 | —35 | at | a a sa —arer | aa | wa —ear7 | ea | 70 wo [eae | ea | 989 Tor00 | — rasa —| 738 | Tar T2700 | wae? | —a78 | Taro T7169 | woe | are | —ars ooo [1265 | 85 | —e60 “7700 | “T3085 | wo | 70 7a5T5 | tase | 952 | Wor EO “Te torque i determined by ean te pressure on niga Fin thei et th he pera 50" othe ip ‘endand conarg according tte tle bore, ewe: Me press nthe above abe assume at ey {2 sed th spanner having 00 nent E257 aoe ESTwB Section E - Hydraulics Tiare Rae ea Reconditioning seo ae oes emcee wire eee arigres chains ee D Rests on lt ep Procedures for eertng ed bdeng the seal ring. = 41 Oring intalsson & 4 SN ‘opty 2 thn cat of uta to ner gio 8 Mako are at ny oon the at, cp Ieteland nt gona atere ewe oer sacs he a6. ‘rar us i. Sroch ‘ising A by hand and tine we pion A Ole ude rng Be ro ett he Ong Atwised Ong may ount cua ae E ovr ner gude fo 8 and sir ste F Gitostr paige acter al eng. cry iran Xf ogi a 8 ne reuionorpean eet et he sal ng eur nth er ans ie maa E28Section E - Hydraulics Hydraulic Rams. SPs ing Fim. Corte ops ite F on outer gue fo by rau press ul sel ing ts ee grove ‘Se ureto ros the lt cay otha seaog 9 ‘sii syarely ov be bre gute a an Pio be feo. Cony ous apc sasty 6 Removotia ‘tor contig ha ea np = compo os fxote pon grove, ems te gente oon 1b Romo pat F Remove er ue a Remove nar taf 8 “Thong othe seal ng icone ti sage Next, comet te ing of he sa ag using the bei ‘Recendtoring grt. 7 Beng i seprton a wh vite ==. coprmnyeens Be carl tha ro ek, chipped melt nd St E289 sens E259Hydraulic Rams ‘Recondtoning Ww Section E - Hydraulics 1 Inserting te piston ees oO moire Fig7. ‘Ta conslotete ing artbeddng ofthe el. P97, crouse pon Cito boating ig une sal ‘Dist crt wih beading ce 10° Removal of badge ‘Ate: compen ef De bag sea 9D, renove he pote tlowng ode Roache pes od Remove beng io. E260 ‘oS E260Ww Section E - Hydraulics Hydraulic Rams Recenationing Bushing Removal 3 Sing he hud assony 1 liner at sting Craduty nsee cuckessonbly T8A to eer aod we deen oes bushing era THK oat hus essary TBA tocar oad 736, ain cow Bat prs ote Bade 6 nat awe eet Watse (1203 Taner | bar Ea [om done Ratot 7 ska Por Raia OpeiCans [350 Bar GOTEEAT [Busan TP [> aura Rel vats (1 oper Pex Rae [Cun | 58a GOTT per Rat rear | auxin Reet a (Dot Gabe Dose | TPH ‘Stabtzore (E28 para Serer “bar (oe eH Brae Sane Brae |e Ada Pressure E200) [seer Sar eS br ET ‘ir Sal 5 Steer Sal [TPT ‘System Pressure QE201) (1) Themain roasting mus be nase aig esting Eare Tae E276WwW Section E - Hydraulics Service Procedure Prateure Ree Valve Location Pressure Reliof Valve Location Fi AS or Harmer (Opn) oper Rate vate Doze Up Rott Yo> 00m Down Ral ave ‘ustat Open Rat Yao ‘Boom Up Ra Vane Sipe Out Rata ave "AB oc Harmer (Optom) Main Ret Va (A) Bo eeveweun i’ ear een Ea?Ww Section E - Hydraulics Service Procedure Main Ree Valve (MR) Pressure Main Relief Valve (MRV) Pressure 1 Prepare teaching 2 Cyst dpe ot nvr te oma at Fos = Mako the mochine ste, fort» Seedon & tl 90 400 bar (0 6000 pressure gaigein TP ortha, 4: Surtne angie an conti that the ergo at {emanmum noead speed ard icine = oe Set sind pes on Lose et 1 Richa beam end hen ops he spp ou antl re he pressure gouge wih he Spat ‘am slag athe ond of se. 1 Htc th ents sop trong ard adit «Remove seo ote Ea pla hos, the he btw . © State enja, and caren at he erg at ‘Not: For sccunta sating, the pressire should bo {maximum noted spect ant ‘tos op toe quod oe ‘mote 2 Hh Presi Setig (Powe Bos) | sane ape (Hoi ut dress ck mt Band sero ha Tow prosuasting nA doce ae way Hot nt and slacken rut. Ser mut 12 Iereaso pros or uti cece rosea 1 Once roqund pressures achloved on fe sso gape, hed nat Cand ook rt back 3 Lem Presse Sting (Santee) E278 meses E276zt that tb agra at is maximum noo ‘Speed anditisintba mode lh pp. Hotdra¢ and siacknlokritB Sow nit Aout (nce roquted presse is achive on the prossure paugo, ook na B apart ret. ako the machine sal, refer to Section E, ‘Serves Procedures, Re-stachthe se hoses MR 4 Chockina posses Section E - Hydraulics Service Procedure Tan Roe Vatve (ARV) Pressure E270B Servo Rel 1 Prepare tte Mectine a {Oporto to cpprout ae onrthe boom sat Fas. ‘ Mako te mscrine se, rer 10 Section E, 2 Beore esing tho Plot Relef_ abo ‘Digs (REZ cornet a 0-10 bar (1501 in prone page tts pit TPS Section E - Hydraulics Service Procedure Sere Rel Pressure Pressure ‘Sat the engin and con tat he eng a 8s rnin notes! speed andl te E mode. Pressure gnuge redig shoud be corpares to {Senile ate sot oft econ Haisouee ‘hens aus ne ple eet ave as bow. Loosen the ack Bo it Re ave. Theva is acute by turing ree vale asin tere A (one nf he acre! sew equ S02 bar 668510, “Titan lok ru Bo 17 Nm (12.1) che ne tat pressure span E280B Section E - Hydraulics Service Procedure ‘Siew Motr Pressure Rit Slew Motor Pressure Reliof Prpare ne mactine 1 Oporto te gps ota ner bom ost tebadat on te ene, Make the machine Sle, ‘ter 1 Section &, ‘can 0400 br (0 6000 ai pressure gouge Sd adapt tt pa 2. 1 Ramove the watsroofcomodr on the sow [ee sents at. res the lack owen wc eon ta ight nd conss nae heb an cof at oe ‘ew teckaymtl spear on he mostar & ; ‘Sat the engine, (ano codes may appar or Sisoomeced sobre) and penta he engine st ‘ound 1000, ten operat ho sow vet Stony Liston fo com tthe ree sound rd ant ths machin dae ntl Ran te enge minimum o-eed speed and ‘hee maa {© Operate sow over, “The granu gauge rating shouldbe compres (ho tcc dat ate st hi acon Ft ‘se teins ast slew mote rove Ear coed terpenes Ife readings ae cui he tnt, corte 25 © Presse Agutment 12 Mote tbe nochine sal, rr © Section E, 1 Romov ele vane: ads {© The torre botwoon ost presi an te Devon pressure ctormines the mambar ors Erogured br aesimert 17 Reno the mle vabe assay fom te iw ote: rele ves ae moves the same tne, ‘nar hm ot ar tf ate reassen no arecpason | © Oisasemty ‘Reson a Suien saga rst ee ote ‘ton no B pppat spac, sims ard Ec py Add she news pressure, Ramove shi io doceosa posse. E281WP Section E - Hydraulics Service Procedure “Slow Motor Pressure Rett © Roascamble lef vave ssonbly 4. Fictneslone to avi endian cap Ath Storgn a G69 Nm (8 17 © tal terol atsonby nt slew moar nk (hd cote presse E2a2 coy E22B General 1 Proper ihe mectine |» Operate cpp out ae onerthe boo se ‘tebe on fe gran 2 trereas MR Prosser Seton E, Service Proendures Teste AAs with the engine at Ke using He reopens. Section E - Hydraulics Service Procedure ‘nally Rote! ValesBw Boom Ram Boom Up 4 Papa the machine | Opera th spp out and owerhe boom sat ‘Sebiketon he grand 1 Gonrt 30 = 400 bar (0 = 000 Bi) ress ‘igen apa opr TP on yale pe. 2 inreae MR Presse felt Seton E, Service 3 Suri engine, ower th gua ck ver ondrun he fergne enim nolod speed nth = mode | Fuly eset boom nathan caren to operate ‘hori conol vor ast. Eee Section E - Hydraulics Service Procedure “slay le Vas rat > Topressure gauge rang shou be comes ‘Dito teseal aaa athe staf he econ Stee ten cht he AP Noe: er sccuae poss ating te pressure shud ‘be aed up te equted eel. loee ook mut X ‘eat ating sce Yo presue talow to eure ‘ett nd than try rua back wp a soy. Tonto eck na ig 4 Restor Onl MRV Presa, fro Section E, E284w Section E - Hydraulics Service Procedure ‘Boom Down 1 Prapare ne mace |» Operate cppr ct and arth boom se (ebalaton te grune Ga Figs ad 1 Make the machine sate, wert Section E, ‘Serves Procedure. © Canal #0 40 br (0-600 in) pressure ‘auge ad adore pt TP on to yaa pane. 2 ero yay posit uty ogo he boom fa, wibeut tra fo underage of roe “haere te ARVs must bs swapped oer 1 alyaisetne boom nhen contre to operate ‘poeeinie mode, Eas "Noaary Rett vaves b Thepresue gauge eating (800m down) shook {a cmpred De tec dla testo the sen Itt oases, oat Be Note: For cco sswo satig, bo prssure shod este up toe requoa fra Raa oc nt X ‘Aaja ating seen ¥ 8 presie bow be eae ‘rl an than ing pressure Beck pf fra sting Then ook nat Fats. {3 The rete vane fr boom up an boom down mast ecwappad ar rtured oe corel prs. 4 Rostov Orga MR Pressre, rer fo Section E, ‘Serves Proves, E285wB Dipper Ram 1 Pepe th Machine 12 Operate th dipper out ard ower the boom st ‘Me bucket one grad Fite, = 1 Wako te machine sale, rele © Section Semtee Procedures, © Connect 0-400 bar (0-600 fn) pressure ‘augo end adaptor epot TP2 onthe merle 2 locnose UR Presi rfrto Sacton E,Sarvice Procedres, | She theengin, worth ate ecklover ad the rgine stmnimum nolandspedinihe€ mode 4 Prose Aauetent 1 Rave te boom enaigh te alow he Dipper to trove tee Move te dpporuy cut nd ten conn 1” Section E - Hydraulics ‘Service Procedure "Anallry Rett Valves gt {© The press gage rang (Oper Ot should ‘compare nthe local dat ate tof the oclon Wm oe te hy, tne Move the dope fly sd then come to pate heceliover a5 eB "(Gtr att ate chal essen he Sar othe action is oui he iis am ae Note: For costs sting, te presi. should bo ‘ute up f© tho equ lve. loa bck ru X ‘aut soting sor one 9 possre bet he ‘oud ean her ig te presi ack Seng. Mion kt Fie 8 ‘5 Resor Orgna MR Press, raferto Secon E, Service Proceaires. ze sans E286B Section E - Hydraulics Service Procedure Bucket Ram Props te Machine ‘2 Operate gpa outa onrtbe boom se ‘feb on ground Fig. = 1 Mate tt machine ele refer Section Service Procedures. {© Como 0 400 bar (0-600 ie presse ‘pugs snd adaptor op TP on eae Inseace MR Presi reer to Seton E, Service Procedure Sint haere owe tego ock ve and un he ‘eng al mur robe 00d ne Eos Prone Aguseat 1 Open the buckt fully and then conn to ‘paras coe ver st A “ay Ratio vaves Fig20. ‘© The preseus gauge rena (Bucket Open) Sheu bo corgare ote tee da te Strtothsoton Fx ousce he ee ear 4 Cc the tute ty and en contre © The prassus gauge reading (Bucket Closes) ‘hou be corgre oto fines dt te “Ett hoe x ose it, curt ote: For esouste sting, the pressure shuts be ‘sted up to tne quod iret Roles ook ra X ‘aja stag sore V9 indete a easre bow ‘req ove ar thr bg topos back pf fl Sain. Tonk rt Ear ene E287B Section E - Hydraulics Service Procedure Option ARV (Monoboom) 1 Preps Mactine ‘2 Operate tie gpa out and overthe boom set thebukat on he ground rig - Service Procedures. 7 {© two cap B he opto ote an he pre 4 Camect a0 40 Bar (06000 Btn) presse supe oT 2 tncoase MR Pressure, refer to Seton E, Service Prooedares {Sarthe ange, lowe tho gto lak iver and un be lenge erm noload specs in he E mode “Auiiory Reet Valves 4 Operate tn ote by prossg he ot pal. Chack ‘eprossue one gate, agus ne AAV. Note: For accute sting the prssue shoud bo ‘sted up 1 be mguted lve Raeae eck nut X ‘ast sting screw ¥ fo dete 2 rosa Dl tho ‘equa evel andthe binge pressure Dock up oral ‘Seg, Then eck {5 Resor Orginal MRV Pressure, refer to Section E, ‘Senvce Proves, E288 E28Section E - Hydraulics B Serve recede DozerSabiers Dozer/Stabilisers 1 Operate the pyar ct and aerthe boom set ebueat on fe ground Fig2s, 1 Mako the mactine so, rr to Section E, ‘Somes Procedures. © Connact 0 = 400 bar (0 $000) presse ‘ue en adaptor po TP on the hyeraule 2 lnreas MR Pressure refer Seton E,Savce Proceaures ‘ron minimum noted speed in the E mode 4 Pressure Adustnont 1 ress he ai Ato acta he dozer bade oF Bort iors : alsa sty antes conte a opr ‘hecanel lever € 60-2 Big 9. (E209) © (Doetechncatans ate cata cocto nt ‘oui tote at 2 Lower te blade tty ndtnon contn operat (tocael iver CIDE 2 Fig (INE 200 © Te presae gauge reaang sou compared ‘oineteceal athe son otha stan, Teoutsde th ts, act AR. 5 Resor Ons MR Presnre, rete Seen E ‘SomiceProcesure. Em omnes E289Ww Section E - Hydraulics Service Procedure Brake Sonics Pressure Brake Service Pressure 41 Cenmact 0-70 na (-100 st prestre gre Tete tet pot on he eae lek the sven pa iy own © Fert dna st of soto (Siti er dt sage 4 Ero the pressure eens oO br when the pede 15 Ton ho locut and achack E200 ae E200Ww Section E - Hydraulics Service Procedure ‘Ser Stal System Pressure Steer Stall System Pressure 11 connseta 0-400 br (6000 ti presse ge teinotest pone TPH 2 Dcomoc and pug hose B rom he svn er Fiz. 3. Capos open parton toro. 4 Sane angie, ower tng ok ver ard une ‘Se strum noe pees in he Ease. + pmo premser ees Sen meses © ew ts pat cl age P venteugrananry dno pn mi, mewn ree rs ae ln acter os Beata apart 1 Repeat ta operation unt te reading icone E21 DS E21Ww Section E -Hydraulics Service Procedure ‘Sor Sia System P Page lt itentionaly bank E202 eT)B Section E - Hydraulics Fault Finding Hydraulic Contamination Hydraulic Fluid Quality Condon mctinay use alae vine ct ila he ‘meal syst for power warcnission,eupment [scan rit prvenon nd setng.Acsorang © & ‘voy conduc by 9 pur manufac, coven ot in te canes of probeme in hyeaue upment ‘tre strbuasce to hadequaa manance fh aly ‘te erate. Thro, lis cous hat orl of {he quay of ba hyezeule hid Rebs revert auc ‘aupmen! robora anc gresty erves sly and ‘olay Furhemer fom an econems age exons ‘hoe thyme fd gait e mainainas, Effects of Contamination (ce inside the syatim, nyse erat contaminants ‘rsty fact the pererrance and le of yale Supment For sxampl, contamina in eae on devstop neal eco one a leakage and Fores loner dactargee. Wer parle generat wi ree wih the yetaule. ful use, her ‘tarreson inte peromance of ths ard er ‘Saupment Contaminants seo ear pnp sing cons of te equprart can temporary atc ‘esting, slung td losage ard Son ld to mat pronona Te man contaminant bo csaed foe . 1 Sod Pacis - snd, es, mai parces, en Sag tos wear rca 2 Liguid- vsaty water and incompable ols ané geese 3 Gases - A sughur os oe. which can crate ‘Suroaiv compan econ a ‘These covlaminants can appear ding manacture seen and oper Cleaning Operation “The purpose of ean lito remove contrat of _Alypen sn se by Ming Myre Nu Brough 2 leaning unt. 2 Fig 4 (C9280), Goer Balen O11 Sores Connect th cleanin unt in plage of he hyerale ee ‘2g. (E29) in teste fe ult te fo ane ai ie frie ad trough to an Daconnest fhe lsrng unt md recom la Top up the "ptm loan hae als ae eau, E203 E293B Contaminant Standards tat damages your systom sn many cas0s'9 srat {oto oan wth oe. The poi a le moseiea h 1 meron = 0.001 rm (0000384) Usted blow are fow yal comparisons: ~ fa Blood Got = 8 micros (0.08 ran 000035 in Haman Hr = 70 icon (0.07 mn, 5027S = Gainer Sat 109 meron (0.1 mm, 0.90394 n) ‘Salat pal vile t he naked eye 40 ions (00157 apponnaty, Sanders wit oten be guste 16 190 (trator Sardar Organsoton) ‘or wich trate can be Filters “Te fit assembly ed al prosuc anges i eed ‘ote bo cortarinaton tats gente ough ise Se voit el of Gea, eer tt be To ensue optimum peormance and roby ls ‘gata ha he mochines yates 6 sons petetcly in acordanos” wth te. manufechres ‘queens E204 a) Section E - Hydraulics Fault Finding Tiveraute Contamination E204WB Section E - Hydraulics Fault Finding Main Conta Vave Main Control Valve Spiers Possible Causes Coantarmessuree pos sing [OTTenpartre is abnematy High | Renee ebercton fe eat oi iy Reps Peano SEB 5: Paranedarstptaed io much —|hen ba ere vate sh dlomed doe > |Laben eisai Baa Sh remiss Pras OTR [x pressure gauge pa por ane rom fron hack posse Cocoa [Repacete vae assenbhy 7 Return pg aap Repace he daraaed srs 8 Spia or cap roto araghd [Loose cp and aoa, a, Se ‘Spousal swake [1 vav Gagged nao wih ait | Rona he usa. Tost canat be maPahed — [1 Oleaage or ea Chesca 2 Olisbrpasang on fa vave spool _| Repco ro vave aSSOnDy. 5 Tosage fam fpr let ave | Reva tho pat el Fom is FOE snd one nshousng set andre vave [asta Fo te Tascvave | Dissanae a st vave and came Poppet ses and seev, la esate Feats darmans.ropace opel oop win teapots sloaes—|7-Faregnmatarinlasd ches vabe | Dsamerio the wc vate so Saar mre aise postion. Io: Shh vate poppet ot sat daraghd | apie he poppet op te papa and seat E205 ~ eases 295Section E - Hydraulics Fault Finding ole Vave Relief Valve ‘Symptons Possible Causes oe Pras dos i an aa Ti hppa slave SOSA sreotcng open orton materi 1 Dies wheter orn ators enporpe 12 crock wnaber cac pat isstang soon 3 ean a te pa iar pressreTeursiaie |i. To et poppet sau taaged. [Rela e comagod par [2th pen sen ein BORPR | Reis he Sra sores Cara ps Feta prove oat crea] Wear dm Toran mate epic a wa Fm Cock tend act ar om, Rosati rose and en Hak rat oT 7 Garage sata O76 Replace dargodarwor pare Chese | tte ech pti sang meh ( 7 Pais ae ibang dn to orn wat Soak for sates, cus or fron main [Gen at in pars E206ww Section E - Hydraulics Fault Finding Tau System Hydraulic System Simpions Posie use Coarse [she eto ienat | Pome ben ea peso os TE orang wel or at at Foreign ter cpg ie rll Diserle lnvaleaeean, Reis ae Ceeaazaang oa mavens poceares Rambo Ropar orepie, 5 toads to Foe Chek deat ee Rack te va Repl he wave ase Spat os vat roa a Chak pee vere dope Replat hyaauioae 8 Far rai rea wo ages Caan er Fraps Hse rnd E207 E207Section E - Hydraulics Fault Finding ‘Siw Moor Slew Motor ‘Sepom [Cane ral pean | — Comoe Tapa fwaordos [eral aonege OS [Mesure talc —|Eaheosavat [RA TOT cron | mo etme, Jorapetone srg |e 20 mh pe eto apres Soetoro Semone aoe naar ape Be [O56 nl | goby ior | Row Gavan praor Fr ctl pats ar apt 20 [serge wnt |r he mar romastetwebce " |rumesnosryseantee| ‘tse po yor [rss ane Stat wert | Samant Fpet Soon sesh ae s Raa ce! [eames ea — [Re ERT tere etna Eva | eso dae oh seis Oran — [Loins BDOWATS | FBT STH se” |rmor a atm [roo hammlona sees | (629) Cin potae sa Sinan tary Damar a Pec parmcrra mopar [oop Remy Tsamat| Sos sia SSrg_[ Chek any nase rte [Rapier rove cana psc rot Ino coertsinmstar seco rt i | dager Renew [Zeinctararin tte.” |snotdoesrtrans’” [remot ers ep 0 sve (2r |smanty wren ase (Sy pat possus >| spl re oh etre roseo pet [posliy tera iy ore sat |sonage one rt frnatoawt | anaes pect enone 9 me is asap [Danae awer oar Raa a fomel [esa sede [Donan awe othe Ripa be obra once reno te re ony a pee ae | ac pear he | She eae we | Renew ne Sa cane (ig nd measure he [eacrgtlow 3 lem |Ropatorronen he in volar tose) Damani an | semanas prt, Renew Inept Gran vue |e mata spe E208 ans E298Section E - Hydraulics Fault Finding Sew ir Srapon | cam arate | ear anc | oars mee faperoseretone [Horo Siena [etapa Sa fee [rasossuse |Cagsmacenya[tmarmtenart” long coanye reece |sostny ean States (ean =| cre mecae |ven tear aants jereeerey Pee [Cac loses roe fancfas 2 Cree [Sotoae rt es by Ra NET Resa TR TSS aceon os i car as TET aE — oro Ta [eT ea See ratramrnee [egret ene?” |oeareipne tree raaacca” [mater [teeta nonce i Seve are Ea aaa aaa Tar — | an a | eg TS ee aera oceans TSsegeae—| Soot revo THe Pw ime eraeen ts | ng cr Snags ST er mai saree oe tenet 8 R ee Sak SO RSTO | THT TST Serie We 7 im S| rerrme meg area toca at Rear at Se a es i eae Spe aT a oe 1 foes eng oer forte ae Ea mamas EawB Section E - Hydraulics Fault Finding ara Pomp Hydraulic Pump. ‘fn fe regulon an tind vahes or pump swe 2 Abnormal VBation and Sound. Check 988 ‘ombhed ch mates & very aio dacover te thereto shrormal vat or cunt pone ‘rani, repect tw lowing cawgas man tay. Clack see hho a "opdar stm coving th sborma pe equ. sou of re regu’ wating et ‘onde veel worn toy earl 41 Fit and Drala Inspection. psc th or ‘bration or sou, ts posable at eel darane ‘Sbment Gros 9 see aheher tee ‘Sbrornall irge amount gn mat Tor wit omamat amountatmaale power ovo webr ef 3. Measure Pressure of Each Part. Wont scar {hoshooer oyinderbulferebaleyeareantet probiom, co ot wnecosoaly open pat or ‘tall powcr ne Mr may bo uo rouble _—_‘ispocbongurpsee massurebeprossureloreach tive shoe. Aso check to ran ne pup sacle athe abnormal to ‘Taba 3 Prime Mover Overload ‘coe Treatment Tie Fa lstheregutor toque seting co | Rosnapect gusto ebro regutrnaructns er? sexe cr demaysofpuree items |Repoce damaged parts cack ne eo ano for sn ot pats [somal wes Wong regres conection, _[Goresthoe tas. ‘abe 4 When pump flows extremely lw, dalivery pressure des ot ineeaa area TERIOR Re Sirota rar cane! a crc ino Pump breakdown, Replace damaged parts, Remove pump and inspect shaft sani Incest one con | Gratton ns "ite. Abnormal ound nd bation saan Pet anoton crestor? — | Bantam NG Tramuicensumieansomg|arasicedy axson pe Scan fence ounageftescautingean, | rope pon sts sae oe mein cyan repae one Dotan pe. cores nn | rere tang. apr. et ae econ E300 —_ wees E300B Section E - Hydraulics Fault Finding THyaralie Rams Hydraulic Rams ya ram ole ard it mae. Ilene any ofthe part casing the woul. ne ‘har om, poste probs Tall. Ropar ‘Sects tlre estate cause on Hosen! ‘Shed fo rat nthe chart th gener pore, ‘cima caures an esimart ae shown. Howe: machin Youbet moet ten caused, ot jst ene {ay pate rotons th ther pat: Nat at De pein cueae a Yost ae tes ine chart Felon heros may to nove for tha porson Ir tp at tr Evin = SRT | Biteatage fon ton oa sta pat 7 [Oiteakage fom cynder ead maetg 3 [estan tm yn ad meet pa [Fou eveaon sor ‘sea E301Section E - Hydraulics Fault Finding ‘ysl Rams em Spins | Related Pas a Oni ang aura, hare Srtcos ant ton be et by te trgemal. ‘Vesa Sane andrea he as ‘nd ake a sidng sac soo (Goertan 185) ot eatagecontrues ‘ven tough te od sae race ‘teu to crash may eae damage {2th Utngand ober soa so ‘Seasonbl and nos. See, Soaetergertaee? Rueiresastroo cae vee fiesarras — ier oe eager recatamrs aL [ene ag TRS [Sterns feome mae i Sas a asanaatepae ee Lae aR ee TShccsGnel [Sipunkewmaaeytanre faiteresa acne ea ee [mnarone [aintemammnnane soem car. newt “sh 2 ‘ect th yea rere (Bolo 90 Cleaves) Choa tgh tamper cay [DPR ae a epics i posse Ba aol NaN PEROT wring onthe pers” ‘cect ne epratn pressure, custion prose Par ich state othe berg ‘yf stat apc ae E302Section E -Hydraulics Fault Finding Weraule Rams em Symptom | Relate Pare co “Teainant ‘ack oping he Pane e RTTRS [FESS OR eed pasa aT STE snaing exons, fhe, ince eae pos whch ae nce the buts gat he sae te. ‘Sposa tat abooma nigh pressures he vee recto sore on shove elo, eking peg). Foran nator bang HRS | Remove hoon maa grimy |. Tato edanoge Peon "9 Fines are loa aboomat_| Rese. + |statngparon mage es Weer rp anda deoraes | Rai triton resco “rau porate vue tushing | Retr miners es | fanart mssram oma me) Large ich on SRG A | RAGS, Ns Tape DTG. ‘yinder a | Seria, atone el | Ramve Se, kwh fare WEST secrert a se ropie oplca he pnderboed Fors mating an nar} — Rare in mar enor ameter plc ‘Ong it omape [ore damaaes Inepect nie ibe: ny sts or ‘a ate sro eth sone ong ‘yest srr ato acs Inet ackupng ry aefomaton st Fromelen, pace. Canin ts sbove ae ic a lonstae | Beakur | Dtomaion pein [Replace wn Ono. 2 rom oyinder Toseness ‘sasonbl cy had and epost renee “Orargandosceip secre hex ae a cyngor nes tease om ge ey domoge reece ‘te napecton ton pec tor ak] Tnoeres, retain, Baan | Relea Baad ion =SaReT tegue ‘inde | Aono Bae Repace wih naw prs, eakags For csnecie prs maybe cates snarl fressre retcirgevanon presur). rapect Ifstube t-buge, Selomaton and ost he crore E503 co) E308Section E - Hydraulics Fault Finding Sancho a Sas [RETR] —— Tes a Laer ears aS rete SEES cence cute omdormt 2 [een Sere ed a) oes angartp ened eo ae aT RR — a ae | ares [Setipean [emonmyna mete, ee ry an fame sees as ee a aT oR TS aaa | 4 [Abnormal weer, damage of ‘Replace with new part Sarone ‘ame neat het eg | ena eae a core | sae! lpsapramareaaeg—}— tor Sear actecowarseciae| sean rnaee i mdstig Se ene rr )Section E - Hydraulics Fault Finding Fyre Rams em Symptoms | Read Pas “Teanent Ie tmeral | Paton sal Sasa, woorare peso ube er utara pare it par nape eer Peons Saari anova te scathasiustby Toa ot lesen ‘nn an ol one snd make te sures laces or I esr doops ant bo Sr ‘epared ropce es ine eer epost a lao Fae at aaa [Tato apeted oe specie Insp a vale oan STOUT and we aes [Taare reat ae Speedin apart nd erie Recor Baar ase expands arth car be mistaken fra leaps. When pein fel akg, dos a se [Arvemaing wate Opwasonsunteaey Sewer ad comp as tea [Seer wear Fora Rado na ve an eccor porate bac ana th sovrl rs stow pene and speed obese a orrams han seeder rove he ad {sroaucethe presse en horen he a nse: The ram may expand is ogped ‘Segenh: Ts induce compression he yea. soci especay wh org Pinbania [Sap bowoan aan pat Teast pin apn Big an elas [apn besiegstootame |parsifmeaseroment exceed bo ectcare. ‘saps —rsuicer a nara Finbusig, Pi Satirg at coming part Replace wih now par and ala Note ie te tata ware operations poor ram i ro agar move and ater pas wi be afi ses nope’ arya can ou apbropte measures E305 E305B Section E - Hydraulics Fault Finding Fault Finding Tests Fault Finding Tests Slow or Underpowered: ~ boom up pean ~ bucket senoeoperaton ~ spe sens epeaton sew sores cperaton| CCanyout he ftowng tat: Test 001 Testng negative contel na Test 002 Tortngmaxfow ott conto gat Test 004 Tosing horsoponer cont “estO0S Tastes operon of mah hae pet est008 Tsing aperaon of pressure scree est 0O7 Testing engine speed stings Tect008 Testing machine cyl tras est016 Tsing Purp Fow Noe Operon sHECY eben ay Test 010 Testing operation farm HEC Harsh Operation When Selecting: = boom dom, = sow snicn Cory ot the fon oats ‘Test00t Testing negate canta signal Goan down ow) TestO11_ Teng operon of Slow brake (Sow on) Test 005 Testing aperan of res ewtenes Loss of Creep Speed Cary out te flonng os: ‘estO12 Testing max ow cut sonal Tes008 Testing Wack motor speeds Tet 008 Tsing posse eis E206 Additional information hon ep speodtacing selected Yole sybo (spayed on monte? ys! no Loss of High Speed Cary out to eon et “ast00S Testing operation of main yea spot est008 Testing ong seed sings TostO12 Tetng ack mtr ea vale seinas TestO1t Test rack Mtr spose ond presute ‘Machine Selects High Speed Travel ‘cry teflon ets Test 015 Checking Sere press an slot ‘Slew Bearing Faults Cary otto ote st TeslO1T Check Sow Being Vere! LA and E306Section E - Hydraulics Fault Finding “Test 00: Testing Negative Control Signal Test 001: Testing Negative Control Signal mS N= Piz 1 ett gauges (0-60 bar, 1 1006/0) to hose 2 vem up macineryraue omporaue to 50“ ‘Stnractone efor PH and PIB wn too ice (122) ‘apr 2 Bipecie Pressures Feat Pot PE [Wan max engine nie endro sos saad wcmdnapaive conoal | —_22-S5ber | 28-38 bar BS BO7 te? | 368-SOT RT ste ants toom up sere ocre pressure ae SS Fy Bae Do Ten SO PS We ania atesladad | —WWisrwhen fest | — 25-35 uer selects oO 80 OT wha at | ST 0-3bar cic Stet ane tl bucket open sani rea presse ae E307 ae E307A) Section E - Hydraulics E308 eam Fault Finding Tes 07 Tsing Noga Conta Siga pee ca oR volo va wud ae 33a | ae sal bakes le ess 0-5 Bie 174 aa sonnel dpa os cd ome aime eos ee or oa Sonn dpe cove even esse oe |} ee seston aw te mar pene cae aoe | — 0a Sontag lena coven ere oo |e seuctan ae sorcerer oe Set aed atv sevice bala ocr pressure oe ee ) a a Ta aN aE SRT TOTO E308Ww Section E - Hydraulics Fault Finding Test 02 Test Max Flow SgraiDeve Conta! Signal Test 002: Test Max Flow Signal/Drive Control Signal Pmt ne z © r a Pm ea 1 ritsigages 0-508 0-200mI hohe 2 Wom p mine me npr 20 Sculow's ate Pat aw cepace 7 Gah = ac ne) Fant Pon Pat |W ax ona wis an vo srr ISG ae ak OTE bar (0-21. 7SBIN | O- TS bar (0-21,755007| tow cat cont presure E mode 7 Seer made ae ocors press oer eaaTBeA)—_|__ Woar GOTRINT '3_ Remove conacterrom eve presse sh ane ‘Sm for cones emia ot homes sonmacor {ogee ha rer ong fw. (envied Pressures) Poa Pint PoP | Section apod oer fine on tar veardprnaue | aber GOON) | — ber 05 6 Set igh peed got ad ao slo dnzt made by wich [OTS bar (0-71 TsA)| 0-15 ber (0-217 tlt har ele bud ol peat gaz ecare esau E309 a) E309Fault Finding "eat 002 Tost Mas Flow Signalibrive Conta Signal Ww Section E - Hydraulics (epcted Prosar) PoP? Por Pa Sac nai spd goa (avow on mono )recard proseus | — War (620.wIR) | bar G06 Sate medion speed peat and ao sl ner rev 6y [0-1 Sbar(O-21 75H} [0-15 bar (0-21. 7A) schon Rare controle bu do ot operate doe, rar Soc esp opaed gers on nla recor passe [0-1 Sear (O-ZiTBin] | — aba SHORE Steep peed ard es scl doar made record [0-1 Sbar(0-21 786i] | aD bar S07) E310 E310WB Section E - Hydraulics Tests Fault Finding Toating Main Pump Pressure Test 003: Testing Main Pump Pressure Eapaced Pressures i aie Ts estes rca perp 25 aebar | 25-6 359-7969 - Te lp sons ca presse Seba and wa bat [Soe santo oor aa | Oe “ea ei] STO SSB Sete and aa bude ae out src reco 4 tiatgeuges 0-600 ar (@700 Ito pone te | RESEE aise | sae mate Sele and STS [aoe sven eon 2 um up machine hyo mperaure to orc [presi ea | Sa “eet in | aaa ca, Selecta eat awich serce roca prem | Semerand aa aor ot soien cor 25-tar | SOB 5-57 | BE BS in? | BOOS i Soe ad waa Tere | ae Sete anda ba | Sear sect and tal boon op sree an reco OE in | BOIS i speed | Ti presario apes and egine Ean Eo) EstSection E - Hydraulics Fault Finding 31004 Testing Horsepower Conbol Test 004: Testing Horsepower Control Fig iow tom underside of Hara Pump Ft gauge 0-60 bar (0-000) ro proportional Serle secondary rossi moesuromor prt A (Sg stale apo (prteade 4 BSP tg ‘tera ‘Separate proputoal seni ales! canner Ung senoe consodar fem ele tal Shae (Des © Bruna 6) oR Brack 8) sig Ink wo, connect ke meter in cones Pimpsisehanece igs (DES. Fe ‘Warmup macsnenytauitnparateta 0°22 7 [Foneton ‘ipocied PSV | Expecie iiamps Pressure aon? | 145 | T80W | T7SW "Wa a ergs RP Tanda aanicn Ear [TET EMA SSA | SSO [ ASOT operates SalectAmote, mess ad Yom "hs stn ers RPA ard per aes sled ad | bar (18) esa san Sa aso [STN HOR SORT SON Wier mann gina RPA slid and vo sevice] ba (Sr [rst gine RPM alae and no sans Dear cpus. Sint Pate mess on ca DAR] ORR OR Oa ncease engine sped tou aximan engine sped win tats on party sauce | (Ear TARE) Ea aes EaBw Section E - Hydraulics Fault Finding Teal 008 Tsing Horsepower Control “Toschi he above vais teflon conn have 11 Feed pessue ipo" ofthe solrad be Sober 2. Back presue tte 0 ore than 10 bar 3 Oltampratie ob 6509 Hi 10 Eas sees EstsB Section E - Hydraulics Fault Finding Tet O05: Checking the Opeation ofthe Nain Hyarouke Spl Test 005: Checking the Operation of the Main Hydraulic Spool Fig 8 Sectional vew of valve block showing soo! andplet ports nso ples eft coun wee (oprosinay 2m (0.08 15) sonater) shroug he sper the port nt eng ‘Sleigh pet nde fe oytrderpo 8 Cykrderpo A Petpota i oe Msn pen Protponb ent wich is man doctoral spel er sanice bing tésod, and when io ofthat spel supped pt enor when senses oprte ened croton Ft presse omigs 0-60 bar 10008) fhe pt sd ats tpt on eppoete endo spol War phat o 0° (122°) Remove the hake fom he spon pat at ot Eos selcd aed pig te tose ero he hone fom te sos edb eect nd plug he hove. Cou & hand pup (coe Seve tel) wt pressure 80 bar (0 1600 ome ‘Rint anual nay Sosmady eetg be oerord Pressure gauge actu, bt be aca an Seah 8 so a sp can re Eat ‘Sli seat the =p fom te saat end using he ptapower pace mur the Sean the spl moves Suen Saye EIS, fing he aecumater pressure, tn on the machines Igor lowe leer ockand sole De bene Note: he secure may requ recharging by ng ‘te engne fra shor arog) omove Spool cap for the man wae Beck ene wonsaw Be. spen ehscang” for any sro Ingerecions, ony ss of sckng. Sloe to oan {tout ef fo vate tock, ong at Be same tne roc er smote. Est‘Section E - Hydraulics B® reat ‘Test 005: Checking tie Opeatin of the Maln HyerauleSpoo| 8P00t STROKE im) 2A TAD ONG wf Va SERVO PRESSURE (ba) tm Figo. Presse a apo por WHER | Provera apoo por WHER boing select Tera boing elcid TWapaiodpreanra) (expected pres) Wi axa risen no cane eosod_| _0-soe (aa Tae 0- seers Wit sore tay asics ‘aU bar (622 SDTaN_|—_O-Bber BSA eS Ess EatswB Section E - Hydraulics It Finding Tei O06: Tsing Pressure Switches Test 006: Testing Pressure Switches 1 Sart a engine 2 Prse te eet and made butions tgeter for S 3 Use the Up & Down sow bts out he Plot ‘SW appear onthe seen 088 . vere sae Suna nc OBO “ Bonsae ” . Fanon — aaa Baa a Tava | Upper [Boost [oe Davina —_ | Ta Dipperin | ore | ore | ore | ore | FF | ON |aumppresuois | EUs om, jseove 296 ar lig above 20 bar : ve | ore | ome | ome | ove | ow [Prete pene jsbove 296 bar | above 20 bar ti lewatinsou| ovr | ore | oF | ort | ort | ow |peprreanont fre eed Sewer ane| OFF -O [on oor [ono oF Tam arr | onF [or | or | on [or fon oF [emer [oor [on or [orn ore ca Ene amas Es16B Section E - Hydraulics Fault Finding ‘Test 006: Tesing Pressure Suc ‘Symptoms of Pressure Switch Failures Prssre ants at cod be Sond WSN TUGHE, OH Ha TOE RSTO ‘Tpperpiot | Tevet | tomese | Goes |—Vanmer [Sew rato oa err wi ot rr fal [Rein sare ssecea [Cased whan | Cased whan | Clost wher locas soncee | sons Tt na age oatunen Soom er per fa hy secs ‘Sow spond aval eis) soos nt wor [Cos when 2rd Sage RV ower Beet osx weet Auto| rece Foresing ove! Boost 9 Test 03 Testing isn sain Pum Pressure (DESH [csed wan Cake Sw sist up anew door vey erat oe eng Saaaa (ceaaeren [eae seloces ‘Note: Se Man Conta Valve and Shuto Valen Creut Deseraon for caton of Poss Sues, ET Toes Es?Fault Finding Tost U7 Tosng Engine Speed Speed Settings Bw Section E -Hydraulics Test 007: Testing En Warm Engine water operate above 80° (122) Pres Set + Magar sosonds (On the EMS). seta up and dou aro sate the RPM al Pres ACK to view engine ped Ft, WH 1 Ato Power Boost Presire Sh ECOG st: aa Coc Bd we 1 61% 9. a1 as we ADTOD Ene eesSection E - Hydraulics Fault Finding Tea U7 Tetng Engine Speed Satings ae Expected RP Wo Service Selected [Expected RPW Dipper Expected RP Buctat Clee sales (hve sale Pardew a [2060 RAAT 50 2 Paso ato ressre seach Fa me wie —|0OOW2ORART ae SOTA ao ressre wich arractes moo SOFA 602 SOT [a Pie [1050 2 RN aso TSO “abe 7.381450 peas Exposed RP Wo Saves Sood | Expected RPM Diver [Expected RPI Guchet. Chone sate (lore sales Farman ie — | TSOTBTRART 0720 zea au ressre wach shored at Far mode win he —| 10007 DRPAT roa OTR comet mode aa a0 aoa ROT Para nee [0507 RM 05720 ome Formed asa 20 cs a able 8.816001 [Especieg RPA Wo Seve Selected [Expected RP Dipar —[Expacnd RPW hat [Glove ste Eizo ses zo RT con 020 TOOT ATR OT ae SOTERA oO eos 060-20 RPM aso v0 eo Prose [5020 RP ta Nk ‘abe. ss1750 eae psi Sos ec exec DG [Exped PTA. Px rose in he TOD RAT S028 Faso san esr och Ese a) E318B Section E - Hydraulics Fault Finding Tost OT: Tostng Engine Speed Stings We [Expocea RII Wo Savice Selected [Expected RPM Dippxr —[Expedied APH Buck [Gove wae (Gore sated "arate wana — | 00+ DORA 650 +20 750+20 |auoproserswich re made [e807 20 RP ome ree 70 [erro HO 720 RP Nx ca Es20 em E320B Section E - Hydraulics Fault Finding ‘Test 07: Testing Engine Speed Satings Pressure Switches vs Engine Speed ‘Ths flown grap hows he reson betwen ‘2 mode, operand ve presi ses an re Example: 1 The tol pedals opr, the tava posse ‘htc sacle ane eg spend Yes on 100 rr (co ute 2250. 2 The tel pedal ia oid he can pon the tel presure sch dence el ge ‘pce emai 32250 pn ors utr 3 secs Sheet ao eam MS Siosecon 4 Teg soot cops to 1000 ps) Esa E321Bw Section E - Hydraulics Fault Finding ‘Test 007: Tesng Engine Speed Setings Coo Die “ato Eeonomy[ Ttermedite |e S00 Wa oearem | —T60rpR | _165579m_| TOOT TW Bao | —2soep | aterm | —738.mm | TOO em Jem Zao —| 201 | aise | 1895 %9n | —ToO0 em EW Boedrem—| 0D re | TSB | TSE roM | OTE Fags Description a ods Pra SET Upper Pressure Such ve Prose Swen Fura | o| =| oo» >I EaB Section E - Hydraulics Fault Finding “Test 06: Tetng Machine Gye Tes Test 008: Testing Machine Cycle Times Warm phrase 80° (122) Sect Ames nly ‘Oprate serves 10 teen ener warm hae een reed rough a tho sons. Use a spate to measure the tine i hes fr the ‘race Sonpate on eo wth Be he cole ay peat ue esa ae the sveape ne meparaing Sepa thane HOGY rt ed ‘nyavand ten epee [Sorves operated | — Tine (secon) sane 3iao Dip 2-6 Dip Oa aaa Bock Opon TH-30 Siow (irevehon)| 52-87 Eas a Bucket Ram speed. toe: essen of ie kes he back fy Foe, b Dipper Ram speed “Tocantins fr cng arth te Dipper shoud bo Measrement of he reas the Oper to open ae E323B ‘© Boom Ram speed “The cantons fo checking are fat he Dipper and the Measurement ft tne tak fr he Boom 6 90 fom {fay raed ly lowered potion te: Paco a wooson oc worth ipa wut mato Cont i th ground. sf prover sok eeay ‘Tie Dipper, when ts ower. Slew Speed ‘The conitons fr enecking ae tht the statment Tocing owas nt tha ¢ vera Ines chahad oe {utube booing and Tower hg, ten ce De ‘sachantin ie msmum slaw oan. ott the upper framework and ar one completes ‘anon, en mesure thine take fo not ‘ston Ea weaaos Section E - Hydraulics Fault Finding ‘Test 008 Testing Wachine Ojle Times E24Section E - Hydraulics Fault Finding “Teal OT Tstng Swing brake pressure Test 011: Testing Swing brake pressure Fatt ‘presets ome 0-60 br 1001 Rose omecionontose Aan te Sow Naor Mam op rate sytem 120° Presureatpot (eroeced pressure) an esr tans Jnosevens soloed ter 0 Bin rds Sega ave “er (20) Dessectsonsover recescenichcbeed, | “0 G80.) fect presse Seec TO0% sw oak | —aerS wes Sbar record presue erratiny E25 Sones EsswB Section E -Hydraulics Fault Finding “Tost O16; Flow tenng Myre Pumps Test 016: Flow testing Hydraulic Pumps lnstal fom mele a oa vale a dose a8 posse to ‘mp oetinane tthe pone ines. Ft posure test gauges 0-600 bar 6700 fo main ‘um est pon. ‘Serge ae warm up hal of at as 60 (122 * To Confirm Minimum Flow Setting ‘Setmacine io Arose ‘Sat boom up sic ane acer prose ac pp, Su on fo meter an engines (eco en set sted) To Confirm Maximum Flow Setting ‘lconnet nga ce pt hoss fom pup wks ring std pug tho ones and leave pore an me pono aostnes. Setmacine tomar engine resin Armed ith be Ate fon maar ty open and cont operat ny sons ‘Recor peesu on bon pump, fow on Now ma {the angina (aco hiro shel atch) Repeat sat rE mode, L mode and P mate ‘To Confirm Horse Power Control scone nogave contol ot ase and max aw ci plot ones fom bom pars. Pug the hoses and leave ports en pump open to ‘meeps, ‘Sarthe eg and et he achine max engine rts ‘mAmade ake surethe ba vale ly pen Record the pressure on bot pan the wo ow Iie, enge tps and peporional serad cunt (recs on eet aces) rae SLOWLY nase proscure using th od av wo Soper Record the presuon bob png, fow on ow me, ‘are oman roperional asenaideurent ecards ‘onstect ated) Inzeae the poss in tps of 25 er (982 5 roach tina recorng the ponsre on th orp ow oe ‘mao enge rpms and proportional sono cert (Voor on seat ches) 180 NOT increas psi sbov 30 ba (075i). sat te ed vale fy pen epost at for € mode an P made (cod ale on Stoo aac). Remove ow meer rom pun blog est and eo ‘Shcond pu ‘ary bu tse srt Mem No ‘rosa ow seep onl E26Ww Section E - Hydraulics Fault Finding “Tost 16: Fow ostng yeratic Pumps Record Sheet ‘Wana Flow Pane? Prsuer | Presawoin | Fow | Few ‘ini Fow Par 7 Mofo re Presarein | Pressuwin | Flow [Rem | [x Niode| et Pe e fe F t Paarer | Prsazsin | Fw | Pom Tarim Pow Pap 7 Mofe| Pe Presueim | Pressure | Flow | Pom Tmeponer Contal Pump 7 Made FranaGenPT [PrsrenP2] Pow [Rom | Pure orseponne Convo Pun 7 Wade [PaearaInPY [Prema P2] Few [Rem] Purp Ea eos EaWw Section E - Hydraulics Fault Finding "Teal O16: Flow tsing Hysraulle Pumps raspower Gaia Pump 1 Rode oaepowe Conol Pun TE Wade PrssareinPt |Presuein?2] Fw [Rom] Pare] |PressueinPt [PrsieinP2] Flow | Rom] Paro a un orsaponer Contal Pump 2 ode Fieseee nro Pa] Fw [Fe Pane Eas E328B Section E - Hydraulics Fault Finding ‘Test O77 Testng Slow Bearing Test 017: Testing Slew Bearing Checking Slew Bearing Backlash St tc ti 40) sore in we ay ‘Auch al et scat owe aff bearing and ‘tne tt head on op hae Sow boing. ‘Sep th machine. By hand push buck fly 0 ore se By hand push bucket fay to ater side and record ‘measurement on ds eter Aenatiaty Sot bucket mt 1 in} stove ground mn per ly ten, tap acne By and push butt ay oan sean nd whist ‘aris mode sons Ne ta halves slow barn. ‘err maton botom hat of berg (hs nine wt ‘gal aren tp na bean. roca mearamertand cock sot is bln ‘Slow Backlash Lins Takara aen 08H) rn 024) Es E329Fault Finding Test 17: Tesng Siew Bearing wB Section E - Hydraulics Checking Slew Bearing Vertical Lift Fit. Fig2t 1 Fiat ste Dern a pemandcuar rosin snd 3 slat te eginc andi emai by ith the bce, ‘stn ts but 200 (9m) save te ound, pen Stoo te she 100) bows op he ene. ‘he ground. na he eating a he a gauge. Tho ‘Ths vto becomes war ody oe rn Fam. 2 nal a dal gage and se tho not the Zoro Port Figz2 4+ Ton sata an ay 10 an apa ‘eval taeoree U3 E230 ae 85065 E330Section E - Hydraulics Fault Finding Fig2s. 5 Nox plao oc gauge on we ear of to veo ‘ha rope! te two oboe pecs To eban 2 6 Tae sirae lateral movements shown Table esl oft uate: keane Te ae Taal Tar 0057 eran (OTSA Eas 3stWw Section E - Hydraulics Fault Finding “en O18 Tsing Purp Mans Test 018: Testing Pump Milliamps Separate sopectona!slanoi ecticalcomeco sg save cannon fom lca! tec ‘Sig 95 (Nes on 2g 25.(DER2, eminent tne ertz2 © Brita 8) 2 Broiler Br) Pump sisonaness Fant Eapacioa ams vn air ange RP cle ano onic oped, Sane A mate, | REMIR [SNA | SSDNA ASD ase ong RN SRI SGP SSNS SORES HS SESE OR HOM SMR SDR m2 E332BW Section E - Hydraulics Fault Finding ‘Test 06; Testing Latch Brake Pressure Test 019: Testing Latch Brake Pressure ‘Testing pressure Adjusting pressure 41 Ft atow prossur gauge et prin Aon he ear ‘as ofthe machine (40. 4 loa ck at 2 Uangstenkaynrease or decrease nelenghotne 2 Run matin ad atch ha fot brake down cond «Dob oas0 Fo nigh to decease th rose. pressure 3 Sipe Brake Lath Prossuo 8S E33 os) E333B Boom HCV Installation ‘War uphyaul syst to SO andeprata boom Up aa dom several ms. Set pe ofl enor postion and loner boom ‘bch ress on he ground ‘Sette engine sped toile. Wis operator soy sls boom down. pan te ‘bed seem on oe of tho HBCV's (Ps i oats ‘toe P poton he vate) ‘ow ol © fw Bough bled sew unl a ar Calon ef of har boon seen fora fat oe Cle bla sere whi operate al anetng Repeat rooster ote se, ‘Arm HBCV Installation Warn up hyo sytem to 80°C and opeato ‘Spporn and oc several es ‘Set opto uly extn poston an ler boom (a tek ets on rnd ‘Seti ern speed ite ts cpcate sty select pr down, pen the teed screw on one oe HBC (he cad rt othe or one wa). ‘Aw ot fow tough ied seow unt 2 dear ‘aun of of hee been seen for st set fae (sels scow whist oprtor 6 sa soecing ‘ippor Section E - Hydraulics Fault Finding Tes (20 Testing fr Trapped A HEGY Piet Line Test 020: Testing for Trapped Air in HBCV Pilot Line E334B® Section E - Hydraulics Fault Finding Tes 0 Testing th Operation ate Am 2 Boost Soo Tost 021: Testing the Operation of the Arm 2 Boost Spool iar aie systmto So Ft prossregsiges (0 60 ba no post (bt for tale Bost pea) end pr ae (eo) ‘hanbee dain ot). Expected Pressures Fortat Porta i maa pis ad no sonics slog U:Tber 0-3ber Slt ata ese ecard presse bar 0-3b5F Stet an stam sane ert rose War 0 3bar Eas E335Section E - Hydraulics Fault Finding Tost 022 Tesing Ove Motor Treshold Pressure ‘Test 022: Testing Drive Motor Threshold Pressure xt Re oA = BA | fe a=! Fig, ‘Warm us hyetautsstn 250 cansve tos url th machine Mah Re! Valve Satin eos Rats th mati of to grunt ung dozer ate,” ‘Sale ager excita ond ‘oe: Batwoon 210 a 20 bar presses nthe gauges ‘may Rosie ate etm moves fom mira Int 400 bar gaue io pois XY and 2 ‘mowmom dplacornt Oras ani yom mle speed rave, 1 The seting canbe aed by ne ater tne eng he trothls xo A. One tam the srl ‘Sart toincreae te systom pressure by apoving te _—_‘ove I sting by 7 ba Never tthe earce brake som voor not nt Banana srw succes 230 ‘Sraura th i fara ein use ‘The gauge i pot Xt shold read etwoen the staring poss and 2b The gauge pot 2 ‘oul red nk pressure (0-8 ba nen the aytr pote eens mere the 220 Sarthe sje frsaute wl move the Bross ‘Spon. Gauge 1 Sus row cop t00-Sbar and te E336 a E336Ww Section E - Hydraulics Fault Finding "eat 025 Cecing Dive Moor Displacement ‘Test 023: Checking Drive Motor Displacement Figs “The motor Gepacoment ashi myst to change {ho minimum arg of sesh piste t rie the Imowmum speed of tierce 2 feet stings are used Fertomote One for Gonmany nd one rhe et othe wo eI 1 evra tsapscemodn eet Aon 2 Chacko langt othe busing ton te mime, Seplecanentscee 8 18 Ceman ve metas shadisbe 28mm. 1b Rastot tn wr ve motors sot be 18mm. E337 srs E37BD Section E - Hydraulics Fault Finding TEst 02. Tostng Props RPM Test 024: Testing Propshaft RPI 1 Warm up th au syetom 0 5% 2 alee he mactne ofthe god using zd, ‘Sailor lage omar ond 3 Slot igh gear are than sles ive forwards for 2 Smif flow fe syst 1 dau War ‘wosndina creat 4 Atach reflective. tape. to preps and ung {acheter are opt s ra a ato | gk gsr wih daze node Sced bat] 000 om zero cpr Meso gar ioe Mesum gar with doar made seca | 350 rp azz rt oprtag Cieep ar ae ‘Creep gear with dover mode ecod ba | 350 pe orzr rt opattesw Test 025: Testing Clutch Pack Pressure/Park Bral 41 iar up th yeu syste io 0 2 Fates gauges (0-€0 tr no prs At Ease Section E - Hydraulics Fault Finding ‘Test 025 Testing Gch Pack PrecsurTPark Brake Pressure Pressure FoR AT | PoRaT expected | expects [wimax engi risen] 0-Sar | tar ign wave gor sonctes cng sand [SE | 9-5 [wim max ania anvs and | —S@bar | 0-Tbar [it mx eine rms and | O-Sbar [Waar igh rave ger soci. ste park rao (in ab) E339Ww Section E - Hydraulics Fault Finding “eat 026 Tesing Ganditon of On Road Giach ‘Test 026: Testing Condition of On Road Clutch Tees na consion of he ss inte on roa eth pack, {any alte folowing aocedue 1 Pak the machine on frm eve rod, apy park rate and releae ress romero ane 2 Dacomest and pug ne hose A 3 Remove aptr fom Bona cth tet pt ond ‘ata part umber S160, ts gauge (0 ‘ie nanan pump. 4 seg puro, ul up pressure cach pakto S5iar han oak OF hard purp 1 hi resem. {5 Mentor pseu In cith foe any signs of os of No es of presi shoul be san one Sint any oso rnin soe he cach ant wa nave to ered fr menigatorteceaingB® Section E - Hydraulics Fault Finding Ram Grp Tess All Sevicas Ram Creep Tests - All Services \romcrepis uspectene long pecacres mise ‘aod atta cfr ne nsageis wn lance Ra {tee can because bya nae of reasons: Grind! Paton Lekage, ooo Leakage, ARV Leakage, Note:The sniceprocodreshube cried ut with 2 andr ety bucket oa Note: The proeaures nat spleale er re Mod ‘ut ase ret protection ves A Warning yan Prossure Hydrate nui at oye pressure can inure you Betore connecting er removing any hydra hose, ‘esldul hyraule preseur appa Inthe ores ‘ows tne must be verted. Nae sre the hoe service Ine has bean verted before connecting of rmoving hhtos. Mako sure the engine cannot be started while theses are open, Test for Ram Creep ‘Boom service 41 Operate he machin o brig he heute to 2 aml wong tomportre of SUC (22°F) wich {te measued wang hyeaute of terpestre probe (evisu 302028). 2 Roa ne boor Wis a neh 3-_Using ett pon and ror, mato amar 100mm (¢ Ina he ee oft wipe" sa on he ison ro 4 Measure be actual movement epson ed over ‘petod of omnane 5 Referte measured fur ots tbe, massed Sues ose th alowed Karan hen songs Dipper service 1 Operate he machine to bing the nettle @ ermal weang lenperatue of 50°C (1227) wreh Esa cen be meant ung © hyeraueo tangata rote eonea bt 0285 2 age the toum and mave the dipper 10 tly 3 Using et an andar, ak amar nm (¢ inom he eee te wpe seal on te pin r. 4 Reps te a:b rang te bom abd move te ‘appro ayepen poston, 5 Using ate on anu, make amar Od (4 ‘ne te ee a te wpa elo tho piso oc, {6 Measure the aul movanentt he pon rs over ‘peo 0meutoe 7 Rafr ne messed gio fo fhe tbe, messed furs oss te atowod rane ton compe ‘Gotasiccnecs he oo hs acon ‘Bucket Service 1 Operate the machine to ing the hyraule of @ ol wong tampa of 50" (12°F) which fanbe mensuvd vag ehstaute ol tmp pote (ono bet 9200285, {othe fly dood pooton 3 Using fal bp pan an nit, mae a mark 00mm ‘rome epee wiper seal on Pe po 4 Repeat he ay ang the Boom and ate (Spr ant butts ay open poston, 15 Using fet 30m re, ake & mak 10% tomb edpe oe wpe eon he pon 16 Measure tho acu movement fe pon rot over 7 Ror to maasod gu Table 14 (C.E-242)¢ Imecoud ur sous slowostaerarc ton Note: ho tbl nates Ye MAXIMUM pormited am ESatB Section E - Hydraulics Fault Finding Allowable ram creep rates “te 14 Boom am Dipper ‘ia Basie Checks (ater doting thatthe em crap le bute o te stabi trance) Awarnins Take care when dleconnoctnghyarullc hoses and Fins the wil be HOT. Ram seal bypass ream opis any ne arecton ofthe a nents Stay ote caused y fad ro eas, Pomever he ‘teepnexssavein bah aecsoncfne ran stoke on spose te eas hoe fle (hock rsa poss usng he flonng poco: 1 Pte oaain the bkefthe mace, 2 Lower ne stasimert tthe gun and vet yea pressure 1 Blank te prton eam, which wb upping ‘pantacnment| 4 Remove the hose ram eo prt on thee, ‘neh aoe ad leave Be pron he fom open sinoohere 5 Reteetne atactnentf ne pond ‘tert intial movementfne am wen rstraeed fom the gun 2 conn movorare of ofa of ‘nunsows ee ofa tom theape por he ram Woks Fett he a eas recur tor mepecon. Basle Chocks (ator ctormiing tht the ram crop Is ‘ui of oan ren) Ram Greap Teal Al Senveos Port rele valve (ARV) fluro the pola vse tae hd fae, contamination wos ‘Sick’on tha wove tet orf tho wave sua af was {hmge tho hs wuld low ot cot bypass a tare casing ram cee. ‘A lua check can bo made by ring the pt ‘hand checking fs condton of he ae sea nde Satine vave erg any damage of eer offs Wo ame weld requre netcaion or eplcarent| “choc or fale yor rl av, ose the user Iocan wind te terol pote! a ayn, ‘nt oe toll sneon. Rech ie am 9, 2 hanga nthe cep rte woud nate Dat uth Invetgpon of fe fot rei! requ thee ono ‘hang nthe reap mie he case may bene ARV seat intone sock (Quik hte Autry circuits scorman practice take ol om he excavator sence teoperte quest snd aunany cuts. Mbox ove hh uti Fem sees am eee Ras ‘Sy aa series cmmerte the bes ote Glormect to quck Meh ae sary cro an tet gan me coup ae Esa Eo

Section E Hydr. (E171 To E342)

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Section E Hydr. (E171 To E342)

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