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    New Holland EC240 Excavator SN 724002-up Excavator-301-330

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    55 views30 pages

    New Holland EC240 Excavator SN 724002-Up Excavator-301-330

    Uploaded by

    leogerguz

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 30
    Bypass valve (22, Fig. 12)... Fiter contamination switch (28 (S18) Fig. 12). ‘Thermal sensor (24 (R14), Fig. 12) Right servo control valve (80, Fig. 19) Lett servo control valve (31, Fig. 13) Travel pedals (92, Fig. 13) ‘Servo-control valve - adaitional equipment (32, Fi. 14) (option)... Solenoid valve (34 (Y113), Fig, 15) Solenoid valve (35 (¥66.1) Fig. 15). 6-way control block (50, Fig. 16) Valve arrangement within 6-way control block (50. Fig. 17) Primary valve with pressure cut-in stage (51, Fig. 18) and (A, Fig. 17) ‘Shuttle valve (63, Fig. 18) Boom shut-off valve (55, Fig. 20). Emergency operation (55 (1), Fig. 20) Pressure switch (59 (S74), Fig. 21) Valve assembly (60 - 65, Fig. 22) Solenoid valve (61 (Y95), Fig. 28) Solenoid valve (63 (Y39.1), Fig. 23) Solenoid valve (63 (Y21.2), Fig, 23) Sealing plug (62, Fig. 23) Diaphragm-type accumulator (65, Fig. 29) Shuttle valve cascade (70, 71, 72, Fig. 24) and prassure switch (36, 37, 38) ‘Switching valve (72, Fig. 24) Rotor (78, 78, Fig. 25) Travel gearbox (100, Fig. 26).. Hydraulic travel motor (101, Fig. 26) Travel brake valve (101, Fig. 26) Boom cylinders (201, Fig. 27). Stick cylinder (208, Fig. 27) Bucket oyinder (205, Fig. 28).. “ Restor check valve, adjustable (206, Fig. 28) Ballcock switching TL - Grab (207, Fig. 28) (option) Description of system sections Load limit control system Unpressurized oil circuit of pumps Oil circuit pump 1... Oil circuit pump 2 ... Servo-control system Servo control valve (80) boomvbucket Servo control valve (31) stick/swinging ‘Servo-control valve (82) Travel Servo-contol ave (82) Adtonal hydra. Working hydraulic system... 53 54 on 82 soo 82, 92 33 33 33 soo 84 soon 88, 35 36 38 40 son 4 42 42. 43, 44 45, 45 45 45, 45 46 46 a7 48 48 48 49 49 . 50 50 50 51 81 soon 81 51 52. 52. 52. 53 Bucket parallel connection... Travel hydraulic system ‘Additional hydraulic ‘Swinging system ‘Swinging mode activated (LED on): Swinging mode de-activated (LED off) Neutral position so Counter-clockwise swinging Clockwise swinging Braking the superstructure Checking and setting pressures Safety instructions General Pressure settings Tools Big leather test case with contents. Pressure gauge ‘Stroke measuring device (Fig. 3) ‘Servo control pressure: Working hydraulics with power boost function Setting up primary valve Secondary valves for cylinders. Secondary valve in boom shut-off valve. ‘Secondary valves for travel motors Setting/adjusting secondary valves Setting/adjusting primary valves. a Pressure and stroke measurement on control spool Max. control strokes for: Pump control through proportional demand signals. ‘Swinging system ne Feed pressure and zero point ‘Swinging power (swinging mode) High swinging pressure and safety valves Safety valve ‘Swing pump legend (Fig. 5) Changing the braking torque Installing the hydraulic pumps ‘Components Installing and dismantling the hydraulic pumps. Dismantling a pump Installing a pump 61 61 74 on 58 87 59 60 60 60 60 6 62 63 63 64 65 66 66 66 er 6 68 . 69 70 n n 72 73 74 74 74 75 75 76 7 7 7 Hydraulic cylinders Safety instructions 78 General eet sonnei sow 79) Boom cylinder (Fig. 1, 2) 81 Bucket cylinder (Fig. 1, 2) 83 ‘Arm cylinder (Fig. 1, 2) 85 Disassamble oylinder 0... a soo 87 Disassemble boom / bucket cylinder . 87 Disassemble arm cylinder... sonnei a soe 89 Assemble Cylinders 90 Tightening tourques 20 Assemble boom cylinder 1 Tightening tourques a ae soo 2 Assemble bucket cylinder. 93 Tightening tourques 94 Assemble Arm cylinder. 95 Special cylinder tools EC 240, 96 ‘TROUBLESHOOTING ... ‘Troubleshooting, instructions Layout of the troubleshooting table Troubleshooting guide 99 SERVICE MANUAL EC 240 HYDRAULIC SYSTEM Foreword The "Technical Specifications’ manual contains important information for personnel servicing the machine, Machine specifications listed elsewhere in the machine documents are not always re- peated in this book. ‘The documentation includes: + the operator's manual + the parts catalog ‘the dimension table with the technical data of the machine. ‘The present brochure does not contain the speci- fications of auxiliary units for the operation of additional or optional equipment or the specifica- tions of individual machines. ‘The refiling quantities specified for consumables are approximate quantities which are intended as {help for planning consumable requirements. Each unit is equipped with a suitable checking devices, e.g. dipstick or checking plugs, permit- ting the operator to check proper filing of the units. Safety Instructions Danger in the event of non-observance of the safety instructions A WARNING This hydraulic excavator has been built in accordance with state-of-the-art standards and the recognized safety rules. However, operating the machine when a fault is suspected or has occurred, or car- rying out repair work inexpertly may = endanger the lives of persons In con- tact with it + damage the machine and other prop- erty. The hydraulic excavator must be stopped immediately when any damage is suspected or occurring, to ensure that the safety of the operator, other persons at the place of use or other material property is not compromised. All components are carefully coordinated. Trouble-free operation and a long service life can only be achieved with original spare parts. 73179387,00 us SERVICE MANUAL EC 240 Rules for safety at work A WARNING Personnel ‘The machine must not be started by un- authorized persons. It must therefore be secured. Observe the accident prevention regula- tions. ‘The hydraulic excavator may be operated, serviced or repaired only by specially trained and authorized personnel with the appropriate technical know-how. If such know-how is lacking, meticulous instruction must be given by experienced personnel. ‘The personnel must have read and under- stood the operator's manual and in particular the chapter "Fundamental Safety Instruction: ‘Only such persons may start up the ma- chine during assembly work in order to adjust the attachments. Incorrect operation of the machine or the attachments may give rise to life- threatening situations. During all works, always observe the start-up and shut-down procedures pre- scribed in the operator’s manual. A WARNING Personnel Personal protective gear and working clothing: Wear a safety helmet, safety footwear, gloves and safety glasses. Wear closely fitting working clothing when working on the machin Loose, wide garments may catch on ma- chine parts and result in injury. the work to be carried out requires aux- 6, @.g. operators, the competences of each individual helper must be clearly defined beforehand. The idual responsibilities must be meticulously observed to avoid unclear ‘competences endangering safety. Tools, hoists, slings, stands and other de- vices must be in a reliable, safe state. Metal splinters may cause injury when at- tachment bolts are being driven in or out. A brass or copper drift should therefore be used for this purpose, and safety glasses must be worn. For climbing onto or off the machine, use only the ladders, steps, platforms and handrails provided for this purpose. ‘Always keep ladders, steps and platforms in a non-slip state. Remove any oil, grease, dirt, clay, snow, ice and other foreign matter immediately. 73179387,00 us SERVICE MANUAL EC 240 A WARNING Securing the working equipment Before carrying out assembly work, the machine and the attachments must be secured against inadvertent and un- authorized starting, e.g. by placing chocks under the wheels or tracks and by setting the working equipment on the ground. Set the working equipment on the ground in such a way that no movements can be made when mechanical or hydraulic con- nections become detached. Secure any equipment or component which Is to be mounted or dismantled or whose position is to be changed using hoists or appropriate slinging/supporting devices to prevent them from moving, Systems and units (e.g. pipes, accumula- tors, etc.) must be properly depressurized before being opened. Protective devices on moving mact parts may be opened or removed only when the drive unit is stationary and pro- tected against inadvertent starting. Before recommissioning, all protective de- vices must be refitted. A WARNING Hydraulic and lubricating system ‘Always observe the safety regulations ap- plicable to the product when handling oils, greases and other chemical sub- stances. Unused but open bores, pipelines and hose connections must be closed in a pressure- tight manner. Refill collected hydraulic oil back into the hydraulic system only through the return- flow filters. Dispose of waste oil without pol environment. Observe the correct working sequence when fitting or replacing components or equipment. The working sequence has been specified and tested by qualified experts. Replace defective, mechanically prestres- sed units only as an entirety. Never open them. In exceptional cases, open only when the system and the operating sequence are precisely known. The Technical Manual contains no information on such work. When the machine is at operating tem- perature, the consumables are at least at the same temperature. Precautions must therefore be taken to prevent burning or scalding. Be careful when handling acids, e.g. bat- tery acid, Acid splashes may injure the eyes and the skin. Do not smoke when handling flammable liquids. Be careful with open flames and unprotec- ted light. Not only fuel but also other consumables often have a low flash point and catch fire easily. ing the 73179387,00 us SERVICE MANUAL EC 240 A WARNING Conversions or modifications to the machine Unauthorized conversions or modifica tions of the hydraulic excavator are for- bidden for reasons of safety. ‘The nominal pressure of the pressure re- lief valves must not be modified. Do not remove the lead seals from pressure-relief valves and pressure accu- mulators. A CAUTION Recommissioning Prior to recommissioning: = Grease all lubricating points. = Check all oll levels and make the nec- essary corrections. = Carry out function checks of all re Paired components. = Check all functions of the excavator including the brakes during a test run. Release the hydraulic excavator for re- commissioning only after all functions have been found to work perfectly. 73179387,00 us SERVICE MANUAL EC 240 Depressurizing the hydraulic system A WARNING Hydraulic systems must never be opened unless depressurized. Even when the ma- chine is parked on a horizontal surface with its working equipment set down on the ground and its driving motor switched off, a substantial amount of residual pres- ‘sure may still be present in parts of the hydraulic system: ~ Primary pressure from the last hydrau- lic movements prior to the machine be- ing stopped. = Secondary pressure resulting from the tare mass of the excavator or of in- dividual components of the working equipment. Secondary pressure is present until the pressure-generating ‘components have reached their resting position, e.g. by being supported me- chanically so that the supporting func- tion of the hydraulic system is super- fluous. = Precharging pressure in the hydraulic system, resulting from structural mea- sures. Residual pressure is reduced only gradually. If work is to be done on the hydraulic system im- mediately after the excavator has been stopped, the system must be depressurized: * Isolate system section to be opened. + Depressurize system section to be opened, if necessary by combining more than one of the described measures. + Open depressurized system section carefully. System sections are + working hydraulic circuit + servo control circu Depressurizing ) working hydraulic circuit (Fig. 1) ‘+ Immediately after stopping the machine, actu- ate all control levers in succession in the preci- sion control range. Proceed purposefully, as the diaphragm-type accumulator which is now pressurized has a limited capacity and the Pressure drops due to loss of leakage oll For 'b) Servo control circuit * Shift control lever repeatedly to limit stop in all directions. After ca. 30 shifts - residual pres- sure down to ca. 2 bar - the servo control system can be opened. a 73179387,00 us SERVICE MANUAL EC 240 Venting the hydraulic system Reason for venting Hydraulic pumps, motors and oylinders must be careful vented after oll changes, before initial commissioning, and before recommissioning after major repair work. Otherwise their intake and op- erating characteristics are severely disturbed. Hydraulic oll is simultaneously the lubricant for these units. Allowing them to run dry will result in a complete breakdown after a short operating Period. It intake conditions are not in order, a gas-air rmixturo is formed. A rise in tomporaturo and pros sure results in spontaneous ignition in the gas bubbles: diesel effect, Diesel effects damage seals and guide compo- nents. They also reduce the service life of other units substantially. Venting Hydraulic tank The hydraulic tank is under slight precharge pres- sure. When working on the hydraulic system, measures must be taken to prevent the entire contents of the hydraulic tank from running out. This is done by unscrewing the pressure com- Pensating sorew plug (1, Fig. 1) before starting work. Top servo control caps + The boom cylinder must be actuated several times to pre-pressurize the reservoir before shutting off the engine. + The screw plug of the pilot-control cap (Fig. 2) to be bled is now tumed out The oil level which has risen on account of the pressure in the pre-pressurized reservoir is now Visible in the bore of the pilot-control cap. + As soon as the oil spilling out of the pilot- control cap is free from air bubbles, the cap must be closed again. This terminates the bleeding procedure for this pilot-control cap. Foe 73179387,00 us SERVICE MANUAL EC 240 Hydraulic pumps and hydraulic motors Dual variable displacement pump: Vent dual variable displacement pump after each cil change or pump replacement. Unscrew sorew plug (1, Fig. 3) and wait until bubble-free oil emerges at the driled hole of the sorew plug. Then screw in screw plug again. Fas ‘Swing pump: Vent swing pump after each oll change or pump replacement. Fill in clean hydraulic oll through the T-connection (2, Fig. 3) after removing the line. Then install line again, Vent feed pump by loosening the suction line when the engine is stationary. Retighten the suc- tion line when the oil is free from bubbles. Gear pumps: Vent gear pumps after each installation by slack- ening (engine stationary) the threaded unions on the suction side at the grabrotation pump. When ‘bubble-free oil emerges, tighten union again. > > Fea 73179387,00 us SERVICE MANUAL EC 240 Hydraulic motors: After each installation, fil hydraulic motors with ol prior to commissioning by unscrewing the top leakage oil connection and filing in oil up to the bottom edge of the drilled hole. Driving motor: leakage oll connection (1, Fig. 5) ‘Swing motor: leakage oil connection (1, Fig. 6) Fa Fa6 Hydraulic cylinder * Before the cylinder is filed with oll for the first time, the piston must be in one of the two limit positions. The piston rod must thus be com- pletely retracted or extended, * Only then is it ensured that = the still empty cylinder compartments are filled almost completely with cil ~ no combustible air-oll mixture can be formed on a hazardous scale. + Always fill frst that cylinder end where the piston is located, i. the piston surface connection (Fig. 7) when the piston rod is retracted; the ring surface connection (Fig. 8) when the piston rod is extended. The same applies if the piston rod of the cyl- Inder has to be brought into a central position for installation purposes. 4] |-aL Fo? 73179387,00 us SERVICE MANUAL EC 240 lio. |_| -— Fa + The first filing must be done with a reduced, controlled oil flow, So retract or extend piston rod as slowly as possible. + After installation, the cylinder or group of cyl- inders must be retracted and extended to the limit stops at least 5 times. ‘= If the wearing parts of hydraulic cylinders are to be replaced, all sliding components, guide belts land sealing elements must be lubricated with ll from the hydraulic system. Never use ‘grease for this purpose. ‘© During oil change, repairs or replacement of units involving the unscrewing of threaded hy- draulic connections, care must be taken to en- sure that the quantity of oil in the cylinders is not reduced, If this has proved unavoidable, the affected cylinders must subsequently be vented again. After venting Start up motor and check hydraulic system under load. Pay attention to any pump noise. Jerky movements are an indication of residual air pock- ets. These can be removed by actuating all hy-

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