305-mhexmod

Service TrainingCourse Materials STUDENT

MATERIALS

COMPACT CONSTRUCTION EQUIPMENTMHEX MACHINE SYSTEMS

MHEX MACHINE SYSTEMS - 2 - Student Materials03/00

STUDENT NOTES


TABLE OF CONTENTS

COURSE DESCRIPTION......................................................................................................4

PRE-COURSE/POST-COURSE ASSESSMENT..................................................................5

COURSE PLAN/OUTLINE...................................................................................................6

STUDENT COURSE BOOK CHECKLIST ..........................................................................7

MODULE: MACHINE ORIENTATION ..............................................................................8

MODULE: ENGINE SYSTEMS .......................................................................................13

MODULE: ELECTRICAL SYSTEM ................................................................................20

MODULE: HYDRAULIC SYSTEMS................................................................................23


COURSE DESCRIPTIONMHEX MACHINE SYSTEMSCourse Length: 1.5 DaysCourse Ends: 12:00 P.M. Second DayClass size: 8 students maximum

WHO SHOULD ATTEND: Training Instructors Technical Communicators Service Technicians

Classroom work (approximately 50%) will cover machine orientation,systems operation/testing and adjusting of the major vehicle systems, andvehicle operation and maintenance for Mini Hydraulic Excavator in theCompact Construction Equipment product line. Students will bechallenged to demonstrate their understanding of course material and willbe tested to monitor their progress.

Various labs will be conducted to allow the students to become morefamiliar with the iron and to put into practice those skills of testing andadjusting learned in the classroom. Major systems to be considered and abrief description of lab exercises are as follows:

Machine Orientation - Students will perform a daily walk-aroundinspection and operate the vehicle noting the characteristics of the:machines hydraulic systems and controls.

Engine Labs - Students will identify engine components andperform tests for high idle, low idle, and engine oil pressure.

Electrical Labs - Students will demonstrate their ability to useelectrical schematics, locate components on the machine, anddetermine if key electrical components are functioning properly.

Hydraulic System Labs - Students will locate the various servicepoints and perform the systems tests as described in the servicemanual for the hydraulic system.

Students will receive copies of service manual modules pertinent to thevehicles and systems being covered as well as related handout materialsused in the classroom.

Class size will be limited to 8 students maximum.

CONTENT


DIAGNOSTIC TESTS

SKILLS TAUGHT

Upon completion of this course, the student will be able to perform thefollowing diagnostic tests:

check engine high idle and low idle, test the hydraulic system check the electrical starting and charging system

COURSE PRE-REQUISITESPrerequisite tests should be administered at least one to two weeks beforestudents take the course. Students should pass the following pretests with 90% or better.

Successfully passed the Basic ISO Pre-test VEBV0556 Successfully passed the Basic Hydraulic Pretest VEBV0557 Successfully passed the Basic Electrical Pretest VEBV0558

Prerequisite courses should be completed prior to participating in thiscourse.

Multimedia Course "Fundamentals of Mobile Hydraulics" TECD9001

Multimedia Course "Fundamentals of Electricity" TECD9002

Multimedia Course "Fundamentals of Drive Trains" TECD9004

PREREQUISITE TESTS

PREREQUISITECOURSES


COURSE PLAN/OUTLINE

GET ACQUAINTED

MODULE: MACHINE ORIENTATION - Lesson: Machine Orientation

- Slide presentation- Shop Lab

- Module Summary

MODULE: ENGINE SYSTEMS - Lesson: Engine Systems

- Slide presentation on engine systems- Shop lab

- Lesson: Engine Systems Tests- Perform engine tests

- Module Summary

MODULE: ELECTRICAL SYSTEM - Lesson: Electrical Systems

- Electrical schematic discussion- Identify electrical components

- Module Summary

MODULE: HYDRAULIC SYSTEMS - Lesson: Implement Hydraulic System Component Identification

and Tests- Slide presentation on the hydraulic systems- Identify hydraulic system components - Perform diagnostic tests

- Module Summary

COURSE WRAP-UP


STUDENT COURSE BOOK CHECKLISTDescription Form No.

Binder SENR2910Fluid Power Graphic Symbols SEEV0529301.5 Service Manual RENR2800

Optional302.5 Service Manual RENR2840

Reference Materials

Parts Books

301.5 Mini Hydraulic Excavator SEBP2820302.5 Mini Hydraulic Excavator SEBP2819

Specalogs301.5 Specification Sheet AEHQ5301302.5 Specification Sheet AEHQ5364

Compact Product Specification Sheet AEDC0584

Laboratory Requirements

Mechanic's Tool Boxes with hand tools (include metric)One or more of the following machines

1 - 301.5 Mini Hydraulic Excavator

1 - 302.5 Mini Hydraulic Excavator

REQUIRED STUDENTMATERIALS

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STUDENT REFERENCEMATERIALS

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MODULE: MACHINE ORIENTATION

The purpose of this module is to make you familiar with some of theservice requirements for the machines. The module is composed of onelesson which includes a quiz.

MODULE OBJECTIVES

At the completion of this module you will be able to:

1. Using the appropriate specalogs, identify machine features on a quizfor the hydraulic system, and electrical system.

For the following objectives, use the Operation and Maintenance Guide asa reference during the lab activities.

2. Perform a 10 hour/daily machine inspection for a CCE mini hydraulicexcavator.

3. Identify the following CCE mini hydraulic excavator controls:Implement control levers, travel controls, keystart switch, warningindicators, and accessory switches and controls.

4. Locate machine warning labels for operating and servicing themachine, on the ROPS, use of jumper cables, steering link, andaccumulators.

5. Demonstrate proper machine starting and stopping procedures for aCCE mini hydraulic excavator.

6. Perform the provided machine operations and answer the questions onthe handout.


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Lesson: Machine orientation

This lesson will help you gain familiarity with the correct machinemaintenance and operation guidelines, plus, machine features andbenefits.

Perform a 10 hour/daily inspection before starting and or operating thevehicle:

_____ Check engine and hydraulic system oil levels.

_____ Check cooling system fluid level. Check fuel level.

_____ Identify service points.

_____ Test for proper function of indicators and gauges.

_____ Locate warning labels.

Identify the following machine controls: Implement control joystick,travel control levers, boom swing control, cab swing, governorcontrols, keystart switch, warning indicators, and accessory switchesand controls.

Perform startup and machine shutdown procedures. Operate themachine - If feasible, move the vehicle, noting operatingcharacteristics, travel operation, implement control function, etc. Usethe 301.5/302.5 MHEX Vehicle Operation Worksheet.

Operate the Implements (optional) - note the operation of the differentfunctions. Operate two circuits simultaneously

Refer to Operation and Maintenance Manual for the characteristics ofthe coupling feature.

_____ Specalogs (for the machines used)

_____ 301.5/302.5 Machine Operation Worksheet

_____ Operation and Maintenance Chart (for the machine used ifavailable)

_____ Operation and Maintenance Manual (for the machine used)

_____ 1-Mechanic's Tool Box

Complete "Quiz: Machine Orientation."

_____ Student Quizzes handout

_____ Specalogs (for the machines used)


BACKGROUNDINFORMATION

Shop lab

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Materials Needed

Quiz

Machine Walk-around Checklist

Directions: Use this sheet when performing the machine orientation lab exercise. Place a check in theblank if the fluid level is acceptable.

301.5 302.5

_____ _____ Engine oil level

_____ _____ Hydraulic system oil level

_____ _____ Cooling system fluid level

_____ _____ Fuel level

Place a check in the blank if acceptable or after task was performed.

301.5 302.5

_____ _____ Drain water separator

_____ _____ Check seat belt

_____ _____ Check air filter indicator and precleaner if equipped

Place a check in the blank if the indicator, switch or control is working correctly.

301.5 302.5

_____ _____ Keystart switch

_____ _____ Turn signal

_____ _____ Tachometer

_____ _____ Engine coolant gauge

_____ _____ Fuel level gauge

_____ _____ Horn

_____ _____ Running lights

_____ _____ Front work lights

_____ _____ Rear work lights

_____ _____ Windshield wipers

_____ _____ Heating controls


Machine Walk-around Checklist - cont'd

Place a check in the blank after locating and reading the following warnings label on the machine..

301.5 302.5

_____ _____ Before operating

_____ _____ Use of ether

_____ _____ Accumulators

_____ _____ ROPS

_____ _____ Use of Jumpers

Place a check in the blank after locating each of the following controls

301.5 302.5

_____ _____ Governor lever

_____ _____ Release lever

_____ _____ Two speed selector switch

_____ _____ Travel levers

_____ _____ Dozer blade lever

_____ _____ Boom swing pedal

_____ _____ Boom and bucket control valve

_____ _____ Auxilliary pedals

_____ _____ Stick and cab swing control valve


301.5/302.5 Machine Operation Worksheet

Before starting the machine: FASTEN SEAT BELT.

1. Put the console in the DOWN position. Start the machine.

Did the machine start? _____ Yes _____No

2. Put the console in the UP position. Start the machine.

Did the machine start? _____ Yes _____No

3. RAISE the console and RAISE the boom.

Did the boom raise? _____ Yes _____No

Drive machine along test range:

4. When driving forward in HIGH SPEED mode, and the governor lever to the rear, release the twospeed switch.

Did the machine slow down? _____ Yes _____No

5. When driving forward at maximum SLOW SPEED, and the governor lever to the rear, depressthe two speed switch.

Did the machine speed up? _____ Yes _____No

6. When driving forward at maximum SLOW SPEED, and the governor lever to the rear, releasethe travel levers.

Did the machine continue moving? _____ Yes _____No

With the machine in NEUTRAL, and the engine at high idle, operate the implements.

7. RAISE the boom and EXTEND the stick?

Which implement slows down? Boom Stick Neither Both

8. RAISE the boom and EXTEND the stick. Turn off the machine and raise the console.

Now, operate the implements

Can the implements be lowered? _____ Yes _____No

Return the machine to the lab starting point and shutoff the machine and raise the console.


MODULE: ENGINE SYSTEMS

The purpose of this module is to have you locate and identify enginecomponents. You will also perform various systems tests for the engine.This module is composed of two lessons.

MODULE OBJECTIVES

1. Using the handout provided and the related service manual moduleslocate the following: fuel filter, fuel injection pump, fuel shutoffsolenoid, priming (lift) pump, water separator, oil filter, engine oildipstick, engine oil cooler, primary air filter, secondary air filter,turbocharger, air filter indicator, start aid coil, radiator, water pump,temperature regulator housing, high idle adjustment screw, low idleadjustment screw, and fuel injection pump.

2. Using the handout provided and the related service manual moduleslocate the following: engine oil pressure test port, plug for checkingengine boost, plugs for checking coolant temperatures.

3. Using the handout provided and the related service manual modules,perform engine tests for engine high idle, low idle, transfer pressureand, engine oil pressure. Optional additional checks may include fuelinjector testing, full load, injection timing, and cooling system tests.

4. As a homework assignment, read "Know Your Cooling System" (formSEBD0518) and answer questions on the Cooling System worksheet.The answers will be reviewed.


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Lesson: Engine Systems

This lesson allows you to become familiar with identifying engine systemcomponents.

This lesson allows you to become familiar with identifying systemcomponents.

Use the Engine Systems Checklist to locate the engine components onthe machine. Put a check in the blank next to each engine componentlocated.

For homework, review the cooling system material in the O&M Guideto complete the Cooling System Review Worksheet.

NOTE: The instructor will identify key tests to be used whenidentifying cooling system problems, discuss the need for coolantconditioners and the correct water to antifreeze mix.

_____ Engine Systems Checklist

_____ Cooling System Review Worksheet

_____ O&M Guide for the machines

_____ Related service manual modules

_____ 1 -Mechanics Tool Box


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Shop Lab

Classroom Lab

Materials Needed

Engine Component Checklist

Directions: Use this sheet to take notes during the presentation. During a lab exercise, use this sheet asa checklist when identifying and locating components.

Location & Description

_____ Fuel filter

_____ Fuel injection pump

_____ Fuel Shutoff Solenoid

_____ Priming (lift) pump

_____ Water separator

_____ Oil filter

_____ Engine oil dipstick

_____ Engine oil pressure test port

_____ Engine oil cooler

_____ Primary air filter

_____ Secondary air filter

_____ Turbocharger (If equipped)

_____ Air filter indicator

_____ Start aid coil

_____ Radiator

_____ Water pump

_____ Temperature regulator housing

_____ High idle adjustment screw

_____ Low idle adjustment screw

_____ Engine oil SOS port


COOLING SYSTEM REVIEW WORKSHEET

Directions: The following are true or false. Enter T for true and F for false. If false, circle the word orwords that make the statement false and replace with a word or words that make the statement correct.

_____ 1. When the engine is cold, the temperature regulator directs the flow of coolant to the radiatorand prevents the flow of coolant back to the water pump.

_____ 2. An increase in cooling system pressure will lower the boiling point of the coolant.

_____ 3. Rate of heat transfer is measured by the specific heat properties of a given liquid.

_____ 4. Water with a high chloride concentration is best for cooling system usage.

_____ 5. Coolant conditioner is not necessary in cooling systems that use distilled water.

_____ 6. A 40% concentration of antifreeze in water will protect the cooling system to approximately -400 Fahrenheit.

_____ 7. When filling the cooling system, never fill faster than 5 gallons per minute.

_____ 8. An engine should never be operated with the temperature regulators removed.

_____ 9. When measuring the temperatures in the cooling system, the temperature in the radiator toptank should be below the coolant boiling point.

_____10. The temperature of the water pump outlet must be approximately 80 to 20OF above thetemperature in the radiator top tank.

_____11. The most common cause of engine overcooling is temperature regulators stuck closed.

_____12. High sulfur fuel will cause increased engine wear during overcooling when the operatingtemperature is below 1750F

_____13. Caterpillar Extended Life Coolant (ELC) or a commercial ELC that meets the Caterpillarspecification (EC- 1) is the preferred antifreeze to use in Cat engines.

_____14. Commercial coolant/antifreeze that only meets the ASTM D3306 specification is acceptablefor use in Caterpillar engines.

_____15. The service life for the Caterpillar Extended Life Coolant (ELC) is for 5000 hours.

_____16. Caterpillar Extended Life Coolant (ELC) does not require a frequent addition of aSupplemental Coolant Additive (SLC) only an extender needs to be added at 3000 hours orevery two years.

_____17. The effectiveness of the Caterpillar Extended Life Coolant (ELC) is reduced is it is mixedwith other types of antifreeze such as Caterpillar (DEAC)


Lesson: Engine System Tests

This lesson allows you to become familiar with typical engine systemtests.

Perform engine tests for engine high idle, low idle, and engine oilpressure. Enter specifications on the worksheet in the classroom beforeperforming the tests.

_____ Engine In Chassis Test Sheet


_____ Related engine specifications

NOTE: You may have to refer to the Hydraulic Systems OperationTesting and Adjusting module for engine specifications..

_____ 1 - 6V3121 Multitach Group or 9U7400 Multitach II Group

_____ 1 - Mechanic's Tool Box



Shop Lab

Materials Needed

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NOTE: It may be necessary to remove the engine oil pressure switch and install a pipe threadfitting and test nipple to check engine oil pressure.


Machine Model

Name/Code

Machine PIN (S/N)

Transmission S/N

Engine S/N

S.M.H.

Dealer

Customer

Job

Application

Date

Serviceman

Engine In Chassis Test Sheet

TEST SPECS ACTUAL COMMENTS

Engine rpm: High Idle

Low Idle

VISUAL CHECKS:

ADD. CHECKS:

Fuel Level

Coolant Level

Oil/Coolant/Fuel Leaks

Fuel Type

Antifreeze Protection Temp

Battery Voltage

Starter Cold Cranking Amps

Engine Oil Level

Power Train Oil Level

Air Filters and Precleaner Inspection

Engine Oil Type

Coolant Conditioner %

Alternator Output Voltage

MODULE: ELECTRICAL SYSTEM

The purpose of this module is to make the student locate and identifyelectrical system components. Students will also learn how to use theelectrical system schematic to locate components and to trace the startingand charging circuit. Systems tests for the electrical system will also beperformed by each student. The module is composed of two labs with areview quiz.

OBJECTIVES

1. Use the electrical schematic and the provided handout to locate (onthe schematic and on the machine) and determine the part number ofthe following electrical components: starter motor, alternator, battery,fuse panel, engine oil pressure switch, coolant temperature switch andsender, fuel level sender, fuel shutoff (shutdown) solenoid, key startswitch, starter relay, start aid switch, coil (start aid).

2. Using the electrical schematic and the provided handout. Identify thenumerically coded wires and components of the starting and chargingsystem.


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Lesson: Electrical System

This lesson allows you to become familiar with locating electrical systemcomponents on the machine and in using the machine electricalschematic.

Use the electrical schematic and to locate and identify the listed electricalcomponents on the Engine and Electrical System Checklist. Record theschematic coordinates, part number and machine location in the providedblanks.

NOTE: The instructor will discuss how to use the electricalschematic for troubleshooting (color coding, switch specificationchart), and how to locate components on the machine.

Use the checklist to locate the engine and electrical components on themachine. Put a check in the blank next to each engine component locatedand circle the electrical component location letters recorded previously.

Use the electrical schematic and the Starting and Charging SystemWorksheet. Draw and numerically code the wires to correctly connect thecomponents of the starting and charging system.

_____ Electrical System Checklist

_____ Starting and Charging System Worksheet

_____ Machine electrical schematic

_____ 1 -Mechanic's Tool Box


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Shop Lab

Classroom Lab

Materials Needed


Electrical System Checklist

Directions: During a lab exercise, use this sheet as a checklist when identifying components on themachine and for recording information from the electrical schematic.

Location Part No. Coordinates Description

Starter motor

Alternator

Battery

Fuse (fuel shutoff)

Engine oil pressure switch

Coolant temperature switch and sender

Main breaker

Fuel shutdown solenoid

Hydraulic boom lower solenoid

Key start switch

Start relay

Cold start switch

Glow plugs

Disconnect switch

Hydraulic disable solenoid


MODULE: HYDRAULIC SYSTEM

The purpose of this module is to have you locate and identify hydraulicsystem components. You will also learn how the hydraulic systemoperates and the function of the components. System tests for thehydraulic system will also be performed by you. The module iscomposed of two lessons, two case studies, and a problem analysisworksheet.

OBJECTIVES

1. Locate the hydraulic system components and service points on themachine: main pumps, pilot auxiliary swing pump, swing motor,travel motor, main control valve group, pilot valve joysticks, pilotmanifold, hydraulic oil cooler, hydraulic oil tank, and hydraulic oilfilter.

2. On a schematic of the mini hydraulic excavator, identify the followinghydraulic system components: main pumps, pilot auxiliary swingpump, swing motor, travel motor, hydraulic oil tank, main controlvalve group, pilot valve joysticks, dead engine lower valve, auxiliaryvalve, pilot manifold, hydraulic oil cooler, and hydraulic oil filter.

3. On a quiz identify the hydraulic system component.

4. Using the appropriate parts book and the provided checklists recordthe correct part number and the parts book description for each servicemanual component description.

5. Using the appropriate service manual module and the "HydraulicSystem Testing" reference material handout. to perform the hydraulicsystems tests (as described in the reference material) on the machineto determine the machine is set to specification.

6. Using provided reference materials and handouts identify potentialsystem problems caused by malfunctioning components during a labexercise.

7. Using provided reference materials and handouts identify potentialsystem problems caused by a improperly operating hydraulic systemduring a case study.


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Lesson: Hydraulic Component Identification

This lesson will help you gain familiarity with the machine and locatecomponents and service points.

NOTE: Before operating the machine, a 10 hour or daily inspectionshould have been completed which includes checking fluid levels asspecified in the Operation and Maintenance Guide.

Identify the components on the Standard Hydraulic ComponentsChecklist I.

Locate the components listed on Hydraulic Components Checklist II.Record a check after locating each component.

Identify the pressure test locations: main pump test ports, pilotactuator pressure, Record a check after locating each test location.

_____ Operation and Maintenance Guide

_____ Service Manual

_____ Parts Book

_____ Hydraulic Components Checklist

_____ Mechanic's Tool Box and hand tools



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Classroom Lab

Shop Lab

Materials Needed

Hydraulic Components Checklist I

Directions: Use this sheet to take notes during the presentation (i.e. locations, functions). During a labexercise, use this sheet as a checklist when identifying components and pressure test locations.

301.5 302.5

_____ _____ Main hydraulic pumps

_____ _____ Pilot swing auxiliary pump

_____ _____ Travel motor

_____ _____ Hydraulic oil filter

_____ _____ Directional switch

_____ _____ Speed selector switch

_____ _____ Hydraulic oil cooler

_____ _____ Main control valve group

_____ _____ Implement controls

_____ _____ Hydraulic tank

_____ _____ Hydraulic oil filters

_____ _____ Hydraulic oil cooler

_____ _____ Implement pump

_____ _____ Implement valve group

_____ _____ Main relief valve

_____ _____ Tilt control valve

_____ _____ Lift control valve

_____ _____ Auxiliary control valve

_____ _____ Pump supply pressure test port

_____ _____ Pilot system pressure test location

_____ _____ Pilot system accumulator

_____ _____ Pilot shutoff solenoid

_____ _____ Dead engine lower valve

Pressure test locations

_____ _____ Front pump pressure

_____ _____ Rear pump pressure

_____ _____ Pilot swing auxiliary pressure


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Lesson: Hydraulic Pump and Motor ComponentsIdentification

This lesson allows you to gain experience using the parts book to identifywith the hydraulic pump and motor components.

Use the checklist provided and a parts book to locate pump and motorcomponents

Write the correct part number next to the component description

_____ Hydraulic Components Checklists III

_____ Parts Book

_____ Student Notes



Classroom Lab

Materials Needed

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Parts Book Hydraulic Components Checklist III

Directions: During a lab exercise, use this sheet as a checklist when identifying components from theparts book

Hydraulic Pump Components

Part No. Parts Book Description Service Manual Description

Hydraulic Pump

Main Control Valve

Pilot Pump

Pilot Manifold

Hydraulic Filter

Power Train Components Machine Serial number prefix:

Part No. Parts Book Description Service Manual Description

Travel Motor

Swing Motor


Lesson: Hydraulic System Tests

This lesson will allow you gain familiarity performing system checks,using the Service Manual, and determining if the machine is operating tospecifications.

NOTE: Before operating the machine, a 10 hour or daily inspectionshould have been completed which includes checking fluid levels asspecified in the Operation and Maintenance Guide.

Using the appropriate service manual module Record pressurespecifications from the service manual before going to the shop.

Using the appropriate service manual module and the "HydraulicSystem Testing" reference material handout. to perform the tests (asdescribed in the reference material) on the machine to determine themachine is set to specification.

Install test nipples and perform system pressure tests as per the servicemanual for maximum system pressure and pilot system pressure.

Use a stop watch to perform cycle time checks.

Use a stop watch and tape measure to perform cylinder drift checks.

Optional:

Perform line relief pressure checks.

_____ Hydraulic System Testing and Adjusting Service Manual Module

_____ Hydraulic System Test Sheets

_____ 1 - Stop Watch

_____ 1 - Tape Measure

_____ 1 - Mechanic's Tool Boxes and hand tools

_____ Tooling- refer to the Hydraulic System Testing reference materialhandout for needed tooling



Classroom Lab

Materials Needed

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Shop Lab qq

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HYDRAULIC SYSTEM TEST SHEET

TESTS: SYSTEM PRESSURES

Pressure Spec. Actual

Maximum System Pressure ____________ ____________

Pilot System Pressure ____________ ____________

TESTS: IMPLEMENT CYCLE TIMES

CYCLE TIMES

Implement 1

Implement 2

Implement 3

Implement 4

1ST 2ND 3RD 4TH AVG. SPEC.

OilTemperature

Time

Drift Spec

Cyl. 1 -

Cyl. 2 -

Cyl. 3 -

Cyl. 4 -

Cyl. 5 -

Cyl. 6 -

Cyl. 7 -

38 to 48C(100 to 119F)

49 to 64C(120 to 149F)

65C and UP(150F and Up)

TESTS: IMPLEMENT DRIFT RATES

Enter the Times and Drift Specifications from the Service Manual. Enter the actual measurements foreach cylinder in the appropriate space.

Lesson: Hydraulic Problem Analysis

This lesson allows you to demonstrate your ability to identify componentswhich could cause the machine to not function correctly.

Analyze the problem and circle the appropriate responses. Record thereasons for your selections.


_____ Standard Hydraulic Reference Schematic

_____ Standard Hydraulic System Problem Analysis Worksheet


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Classroom Lab

Materials Needed

Standard Hydraulic System Problem Analysis Worksheet

Directions: Circle the correct response(s) and then explain your reason(s). Use the HydraulicSchematic.

1. When moving the 301.5 or 302.5, the machine is slow in both Reverse and Forward. Which of thefollowing may be at fault.

a. Straight travel valve b. Two speed valve

c. Travel motor d. Main pump

e. Left travel valve f. Right travel valve

Why? _____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

2. When moving the 301.5 or 302.5, the machine is faster in Forward than in Reverse. Which of thefollowing component(s) may be at fault.




Why? _____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

3. When engaging the two speed solenoid while moving the 301.5 or 302.5, the machine is slow inboth Reverse and Forward. Which of the following may be at fault.




Why? _____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________


Case Study: Hydraulic System

Use the provided service manual modules and notes to answer this casestudy.

The customer complained that his new 301.5 mini hydraulic excavatorwas much slower than his current 301.5 mini hydraulic excavator whileworking on the jobsite.

The service mechanic decided to perform the hydraulic tests to determineif the machine systems were operating at the correct specifications.

The mechanic satisfactorily completed the tests and found the machine tobe in specification. The customer repeated his complaint that the machinewas still moving slower than the original machine. What should he donow? Are additional tests needed, if so which one(s) and what type ofresults would you expect if the test(s) identified a suspect component orcomponents?

List at least two other problems that could be preventing movement of themachine. Describe the tests and the anticipated results. Use a StudentTroubleshooting Analysis to list and describe your actions.


DIRECTIONS

SITUATION

Student Troubleshooting Analysis

STEP 1 - MAKE SURE PROBLEM EXISTS:

STEP 2 - STATE THE PROBLEM:

STEP 3 - VISUAL INSPECTION:

STEP 4 - LIST ALL POSSIBLE CAUSES:

1 .

2.

3.

4.

5.

STEP 5 - DEVISE AND RUN CHECKS/RECORD DATA:

1 .

RESULT

2.

RESULT

3.

RESULT

4.

RESULT

5.

RESULT STEP 6 - ISOLATE AND ELIMINATE:

STEP 7 - REPAIR MACHINE:

STEP 8 - VERIFY FIX:


Case Study: Hydraulic System

Use the provided service manual modules and notes to answer this casestudy. A Student Analysis Sheet should be used to record yourconclusions.

The customer's 301.5 Compact mini hydraulic excavator has 704 servicehours on it. The operator says that the machine is not as productive as itwas.

The mechanic performed cycle time tests and checked for maximumsystem pressure for all implements. Maximum system pressure wasincorrect for the lift circuit only. He decided to adjust maximum systempressure.

Did he make the correct decision?

Even if he did make the right decision, what else should be checked? Listat least two other problems that could be preventing movement of themachine. Describe the tests and the anticipated results.


DIRECTION

SITUATION

Student Troubleshooting Analysis

STEP 1 - MAKE SURE PROBLEM EXISTS:

STEP 2 - STATE THE PROBLEM:

STEP 3 - VISUAL INSPECTION:

STEP 4 - LIST ALL POSSIBLE CAUSES:

1.

2.

3.

4.

5.

STEP 5 - DEVISE AND RUN CHECKS/RECORD DATA:

1.

RESULT

2.

RESULT

3.

RESULT

4.

RESULT

5.

RESULT

STEP 6 - ISOLATE AND ELIMINATE:

STEP 7 - REPAIR MACHINE:

STEP 8 - VERIFY FIX:


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