305 Mhexmod

Service Training
Course Materials STUDENT

MATERIALS
COMPACT CONSTRUCTION EQUIPMENT
MHEX MACHINE SYSTEMS
MHEX MACHINE SYSTEMS - 2 - Student Materials
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STUDENT NOTES
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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
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COURSE DESCRIPTION
MHEX MACHINE SYSTEMS
Course Length: 1.5 Days
Course Ends: 12:00 P.M. Second Day
Class 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, and
vehicle operation and maintenance for Mini Hydraulic Excavator in the
Compact Construction Equipment product line. Students will be
challenged to demonstrate their understanding of course material and will
be tested to monitor their progress.
Various labs will be conducted to allow the students to become more
familiar with the iron and to put into practice those skills of testing and
adjusting learned in the classroom. Major systems to be considered and a
brief description of lab exercises are as follows:
Machine Orientation - Students will perform a daily walk-around
inspection and operate the vehicle noting the characteristics of the:
machines hydraulic systems and controls.
Engine Labs - Students will identify engine components and
perform tests for high idle, low idle, and engine oil pressure.
Electrical Labs - Students will demonstrate their ability to use
electrical schematics, locate components on the machine, and
determine if key electrical components are functioning properly.
Hydraulic System Labs - Students will locate the various service
points and perform the systems tests as described in the service
manual for the hydraulic system.
Students will receive copies of service manual modules pertinent to the
vehicles and systems being covered as well as related handout materials
used in the classroom.
Class size will be limited to 8 students maximum.
CONTENT
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DIAGNOSTIC TESTS
SKILLS TAUGHT
Upon completion of this course, the student will be able to perform the
following diagnostic tests:
check engine high idle and low idle,
test the hydraulic system
check the electrical starting and charging system
COURSE PRE-REQUISITES
Prerequisite tests should be administered at least one to two weeks before
students 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 this
course.
Multimedia Course "Fundamentals of Mobile Hydraulics"
TECD9001
Multimedia Course "Fundamentals of Electricity"
TECD9002
Multimedia Course "Fundamentals of Drive Trains"
TECD9004
PREREQUISITE TESTS
PREREQUISITE
COURSES
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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
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STUDENT COURSE BOOK CHECKLIST
Description Form No.
Binder SENR2910
Fluid Power Graphic Symbols SEEV0529
301.5 Service Manual RENR2800
Optional
302.5 Service Manual RENR2840
Reference Materials
Parts Books
301.5 Mini Hydraulic Excavator SEBP2820
302.5 Mini Hydraulic Excavator SEBP2819
Specalogs
301.5 Specification Sheet AEHQ5301
302.5 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 STUDENT
MATERIALS
K
STUDENT REFERENCE
MATERIALS
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MODULE: MACHINE ORIENTATION
The purpose of this module is to make you familiar with some of the
service requirements for the machines. The module is composed of one
lesson 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 quiz
for the hydraulic system, and electrical system.
For the following objectives, use the Operation and Maintenance Guide as
a reference during the lab activities.
2. Perform a 10 hour/daily machine inspection for a CCE mini hydraulic
excavator.
3. Identify the following CCE mini hydraulic excavator controls:
Implement control levers, travel controls, keystart switch, warning
indicators, and accessory switches and controls.
4. Locate machine warning labels for operating and servicing the
machine, on the ROPS, use of jumper cables, steering link, and
accumulators.
5. Demonstrate proper machine starting and stopping procedures for a
CCE mini hydraulic excavator.
6. Perform the provided machine operations and answer the questions on
the handout.
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Lesson: Machine orientation
This lesson will help you gain familiarity with the correct machine
maintenance and operation guidelines, plus, machine features and
benefits.
Perform a 10 hour/daily inspection before starting and or operating the
vehicle:
_____ 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, governor
controls, keystart switch, warning indicators, and accessory switches
and controls.
Perform startup and machine shutdown procedures. Operate the
machine - If feasible, move the vehicle, noting operating
characteristics, travel operation, implement control function, etc. Use
the 301.5/302.5 MHEX Vehicle Operation Worksheet.
Operate the Implements (optional) - note the operation of the different
functions. Operate two circuits simultaneously
Refer to Operation and Maintenance Manual for the characteristics of
the coupling feature.
_____ Specalogs (for the machines used)
_____ 301.5/302.5 Machine Operation Worksheet
_____ Operation and Maintenance Chart (for the machine used if
available)
_____ 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)
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BACKGROUND
INFORMATION
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 the
blank 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
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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
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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 two
speed switch.
Did the machine slow down? _____ Yes _____No
5. When driving forward at maximum SLOW SPEED, and the governor lever to the rear, depress
the 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, release
the 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.
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MODULE: ENGINE SYSTEMS
The purpose of this module is to have you locate and identify engine
components. 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 modules
locate the following: fuel filter, fuel injection pump, fuel shutoff
solenoid, priming (lift) pump, water separator, oil filter, engine oil
dipstick, 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 idle
adjustment screw, and fuel injection pump.
2. Using the handout provided and the related service manual modules
locate the following: engine oil pressure test port, plug for checking
engine 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 pressure
and, engine oil pressure. Optional additional checks may include fuel
injector testing, full load, injection timing, and cooling system tests.
4. As a homework assignment, read "Know Your Cooling System" (form
SEBD0518) and answer questions on the Cooling System worksheet.
The answers will be reviewed.
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K
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Lesson: Engine Systems
This lesson allows you to become familiar with identifying engine system
components.
This lesson allows you to become familiar with identifying system
components.
Use the Engine Systems Checklist to locate the engine components on
the machine. Put a check in the blank next to each engine component
located.
For homework, review the cooling system material in the O&M Guide
to complete the Cooling System Review Worksheet.
NOTE: The instructor will identify key tests to be used when
identifying cooling system problems, discuss the need for coolant
conditioners 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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K
K
K
BACKGROUND
INFORMATION
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 as
a 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
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COOLING SYSTEM REVIEW WORKSHEET
Directions: The following are true or false. Enter T for true and F for false. If false, circle the word or
words 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 radiator
and 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 top
tank should be below the coolant boiling point.
_____10. The temperature of the water pump outlet must be approximately 80 to 20OF above the
temperature 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 operating
temperature is below 1750F
_____13. Caterpillar Extended Life Coolant (ELC) or a commercial ELC that meets the Caterpillar
specification (EC- 1) is the preferred antifreeze to use in Cat engines.
_____14. Commercial coolant/antifreeze that only meets the ASTM D3306 specification is acceptable
for 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 a
Supplemental Coolant Additive (SLC) only an extender needs to be added at 3000 hours or
every two years.
_____17. The effectiveness of the Caterpillar Extended Life Coolant (ELC) is reduced is it is mixed
with other types of antifreeze such as Caterpillar (DEAC)
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Lesson: Engine System Tests
This lesson allows you to become familiar with typical engine system
tests.
Perform engine tests for engine high idle, low idle, and engine oil
pressure. Enter specifications on the worksheet in the classroom before
performing the tests.
_____ Engine In Chassis Test Sheet
_____ Related engine specifications
NOTE: You may have to refer to the Hydraulic Systems Operation
Testing and Adjusting module for engine specifications..
_____ 1 - 6V3121 Multitach Group or 9U7400 Multitach II Group
_____ 1 - Mechanic's Tool Box
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BACKGROUND
INFORMATION
Shop Lab
Materials Needed
K
K
NOTE: It may be necessary to remove the engine oil pressure switch and install a pipe thread
fitting and test nipple to check engine oil pressure.
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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
NOTE: It may be necessary to remove the engine oil pressure switch and install a pipe thread
fitting and test nipple to check engine oil pressure.
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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 identify
electrical system components. Students will also learn how to use the
electrical system schematic to locate components and to trace the starting
and charging circuit. Systems tests for the electrical system will also be
performed by each student. The module is composed of two labs with a
review quiz.
OBJECTIVES
1. Use the electrical schematic and the provided handout to locate (on
the schematic and on the machine) and determine the part number of
the following electrical components: starter motor, alternator, battery,
fuse panel, engine oil pressure switch, coolant temperature switch and
sender, fuel level sender, fuel shutoff (shutdown) solenoid, key start
switch, starter relay, start aid switch, coil (start aid).
2. Using the electrical schematic and the provided handout. Identify the
numerically coded wires and components of the starting and charging
system.
03/00
K
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Lesson: Electrical System
This lesson allows you to become familiar with locating electrical system
components on the machine and in using the machine electrical
schematic.
Use the electrical schematic and to locate and identify the listed electrical
components on the Engine and Electrical System Checklist. Record the
schematic coordinates, part number and machine location in the provided
blanks.
NOTE: The instructor will discuss how to use the electrical
schematic for troubleshooting (color coding, switch specification
chart), and how to locate components on the machine.
Use the checklist to locate the engine and electrical components on the
machine. Put a check in the blank next to each engine component located
and circle the electrical component location letters recorded previously.
Use the electrical schematic and the Starting and Charging System
Worksheet. Draw and numerically code the wires to correctly connect the
components 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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Classroom Lab
Shop Lab
Classroom Lab
Materials Needed
BACKGROUND
INFORMATION
Electrical System Checklist
Directions: During a lab exercise, use this sheet as a checklist when identifying components on the
machine 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
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MODULE: HYDRAULIC SYSTEM
The purpose of this module is to have you locate and identify hydraulic
system components. You will also learn how the hydraulic system
operates and the function of the components. System tests for the
hydraulic system will also be performed by you. The module is
composed of two lessons, two case studies, and a problem analysis
worksheet.
OBJECTIVES
1. Locate the hydraulic system components and service points on the
machine: main pumps, pilot auxiliary swing pump, swing motor,
travel motor, main control valve group, pilot valve joysticks, pilot
manifold, hydraulic oil cooler, hydraulic oil tank, and hydraulic oil
filter.
2. On a schematic of the mini hydraulic excavator, identify the following
hydraulic system components: main pumps, pilot auxiliary swing
pump, swing motor, travel motor, hydraulic oil tank, main control
valve group, pilot valve joysticks, dead engine lower valve, auxiliary
valve, 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 record
the correct part number and the parts book description for each service
manual component description.
5. Using the appropriate service manual module and the "Hydraulic
System Testing" reference material handout. to perform the hydraulic
systems tests (as described in the reference material) on the machine
to determine the machine is set to specification.
6. Using provided reference materials and handouts identify potential
system problems caused by malfunctioning components during a lab
exercise.
7. Using provided reference materials and handouts identify potential
system problems caused by a improperly operating hydraulic system
during a case study.
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Lesson: Hydraulic Component Identification
This lesson will help you gain familiarity with the machine and locate
components and service points.
NOTE: Before operating the machine, a 10 hour or daily inspection
should have been completed which includes checking fluid levels as
specified in the Operation and Maintenance Guide.
Identify the components on the Standard Hydraulic Components
Checklist 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, pilot
actuator 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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BACKGROUND
INFORMATION
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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 lab
exercise, 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 Components
Identification
This lesson allows you to gain experience using the parts book to identify
with the hydraulic pump and motor components.
Use the checklist provided and a parts book to locate pump and motor
components
Write the correct part number next to the component description
_____ Hydraulic Components Checklists III
_____ Parts Book
_____ Student Notes
03/00
BACKGROUND
INFORMATION
Classroom Lab
Materials Needed
K
K
K
Parts Book Hydraulic Components Checklist III
Directions: During a lab exercise, use this sheet as a checklist when identifying components from the
parts 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
03/00
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 to
specifications.
NOTE: Before operating the machine, a 10 hour or daily inspection
should have been completed which includes checking fluid levels as
specified in the Operation and Maintenance Guide.
Using the appropriate service manual module Record pressure
specifications from the service manual before going to the shop.
Using the appropriate service manual module and the "Hydraulic
System Testing" reference material handout. to perform the tests (as
described in the reference material) on the machine to determine the
machine is set to specification.
Install test nipples and perform system pressure tests as per the service
manual 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 material
handout for needed tooling
03/00
BACKGROUND
INFORMATION
Classroom Lab
Materials Needed
K
K
Shop Lab
K
K
K
K
K
03/00
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.
Oil
Temperature
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 for
each cylinder in the appropriate space.
03/00
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.
Oil
Temperature
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 for
each cylinder in the appropriate space.
Lesson: Hydraulic Problem Analysis
This lesson allows you to demonstrate your ability to identify components
which could cause the machine to not function correctly.
Analyze the problem and circle the appropriate responses. Record the
reasons for your selections.
_____ Standard Hydraulic Reference Schematic
_____ Standard Hydraulic System Problem Analysis Worksheet
03/00
K
K
BACKGROUND
INFORMATION
Classroom Lab
Materials Needed
Standard Hydraulic System Problem Analysis Worksheet
Directions: Circle the correct response(s) and then explain your reason(s). Use the Hydraulic
Schematic.
1. When moving the 301.5 or 302.5, the machine is slow in both Reverse and Forward. Which of the
following 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 the
following 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 in
both Reverse and Forward. Which of the following may be at fault.
Why? _____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
03/00
Case Study: Hydraulic System
Use the provided service manual modules and notes to answer this case
study.
The customer complained that his new 301.5 mini hydraulic excavator
was much slower than his current 301.5 mini hydraulic excavator while
working on the jobsite.
The service mechanic decided to perform the hydraulic tests to determine
if the machine systems were operating at the correct specifications.
The mechanic satisfactorily completed the tests and found the machine to
be in specification. The customer repeated his complaint that the machine
was still moving slower than the original machine. What should he do
now? Are additional tests needed, if so which one(s) and what type of
results would you expect if the test(s) identified a suspect component or
components?
List at least two other problems that could be preventing movement of the
machine. Describe the tests and the anticipated results. Use a Student
Troubleshooting Analysis to list and describe your actions.
03/00
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:
03/00
Case Study: Hydraulic System
Use the provided service manual modules and notes to answer this case
study. A Student Analysis Sheet should be used to record your
conclusions.
The customer's 301.5 Compact mini hydraulic excavator has 704 service
hours on it. The operator says that the machine is not as productive as it
was.
The mechanic performed cycle time tests and checked for maximum
system pressure for all implements. Maximum system pressure was
incorrect for the lift circuit only. He decided to adjust maximum system
pressure.
Did he make the correct decision?
Even if he did make the right decision, what else should be checked? List
at least two other problems that could be preventing movement of the
machine. Describe the tests and the anticipated results.
03/00
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:
03/00

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