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0% found this document useful (0 votes)
216 views30 pagesNew Holland EC240 Excavator SN 724002-Up Excavator-301-330
Uploaded by
leogerguzCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
/ 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-
