Service Manual Elt 210 Colmbia

For machine s/n: 14-4507, 14-4508, 14-4509, 14-4510
ELT-210EJ
Service Manual
ELT-210EJ Service Manual
High Voltage Warning!
This unit is driven by an electric motor! This means that there are special
circumstances when it comes to operation and maintenance of this machine.
Never allow any personnel to be in the vicinity of the trailing cable when the unit is
running. The cable reel is designed to rewind automatically when the transmission
is put into the reverse direction range.
Be aware of the potential that high voltage may be present on the unit at any time
that it is connected via the trailing cable. Always use your worksite’s prescribed
lock-out or tag-out procedure when working on the machine to prevent potential
electrocution when the machine is being serviced.
High voltage is a severe safety hazard and only trained and qualified electrical
technicians are to maintain or repair the electrical systems on the unit.
Inspect the trailing cable regularly for damage and wear, never run the unit with a
damaged or severely worn trailing cable.
High Voltage Warning!
2
T ABLE OF C ONTENTS
Table of Contents .................................................................................................................3
Foreword ...............................................................................................................................5
ISO Certification .................................................................................................................................5
Serial Number Location ......................................................................................................................5
Serial Number Plate ............................................................................................................................6
Major Assemblies ...............................................................................................................................6
Introduction ..........................................................................................................................7
Terms Used In This Manual ...........................................................................................................8
Manual Objectives ..............................................................................................................................8
Service Technician Pre-requisites .......................................................................................................9
Safety Information ..............................................................................................................................9
Safety Signs ....................................................................................................................................9
Personal Protective Equipment .....................................................................................................10
Pressurized Items ..........................................................................................................................10
Hot Fluids and Parts ......................................................................................................................10
Wheel Chocks ...............................................................................................................................11
Accessing the Unit ........................................................................................................................12
Lifting Guidelines .........................................................................................................................12
Repair Warnings ...........................................................................................................................12
Fire Prevention ..............................................................................................................................12
Important Machine Operation Safety Procedures .........................................................................13
Undesirable Operating Practices ...................................................................................................14
Pinch Point Safety .............................................................................................................................15
Systems ..............................................................................................................................16
Power Train Systems ........................................................................................................................16
Transmission circuit ......................................................................................................................16
Drain and Filter Change Procedure...............................................................................................18
Hydraulic System ..............................................................................................................................19
Hydraulic System Settings ............................................................................................................20
Hydraulic Pump Description and Operation .................................................................................21
Flow testing piston pumps with load sense...................................................................................22
Hydraulic Reservoir ......................................................................................................................24
Return Circuits ..............................................................................................................................24
Pressure Circuits ...........................................................................................................................25
Load Sense Circuit ........................................................................................................................26
Pilot Pressure Supply Circuit ........................................................................................................27
Cable Reel Circuit .........................................................................................................................28
Pilot Valves and Functions Circuits ..............................................................................................29
Brake Pressure Supply Circuit ......................................................................................................29
Park Brake Circuit (Brakes Applied) ............................................................................................30
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Park Brake Circuit (Brake Test) ...................................................................................................31

Park Brake Circuit (Brakes Released) ..........................................................................................32
Brake Test Procedures ..................................................................................................................32
Electrical System ..............................................................................................................................34
General Design..............................................................................................................................34
Power Supply Circuits ..................................................................................................................35
Motor Start Circuit - Manual ........................................................................................................37
Light Circuit ..................................................................................................................................38
Monitor Circuits ............................................................................................................................39
Horn Circuit ..................................................................................................................................40
Warning Circuit ............................................................................................................................40
Transmission Circuit - Manual .....................................................................................................40
Emergency/Park Brake Circuit .....................................................................................................42
Brake Test Circuit .........................................................................................................................43
ABA Circuit ..................................................................................................................................43
Fluid Specifications ..........................................................................................................................44
Hydraulic Oil (15W-40 oil only) ..................................................................................................44
Transmission Oil (Hydra-Trans 30) ..............................................................................................44
Greasing Requirements .................................................................................................................45
Periodic Maintenance Charts ............................................................................................................46
Major Component Replacement .......................................................................................66

Safety and Working Practices ...........................................................................................................67
Changing the Transmission ..............................................................................................................69
Changing an Electric Motor ..............................................................................................................70
Changing a Driveline ........................................................................................................................71
Changing the Hydraulic Pump ..........................................................................................................72
Changing the Front Axle...................................................................................................................73
Changing the Rear Axle ....................................................................................................................74
Changing an Accumulator ................................................................................................................76
Accumulator Charging ..................................................................................................................77
Changing the Front Frame ................................................................................................................78
Changing Articulation Pins ...............................................................................................................80
Changing the Boom ..........................................................................................................................84
Changing the Bucket .........................................................................................................................84
Changing the Hoist Cylinder ............................................................................................................85
Changing the Dump Cylinder ...........................................................................................................86
Changing the Electric Motor Coupling .............................................................................................86
Optional Equipment ...........................................................................................................88

Fire Suppression System...................................................................................................................88
Ejecto Bucket Option ........................................................................................................................99
4
F OREWORD
This service manual was written to instruct the owner on the proper servicing
procedures for this machine. READ AND FULLY UNDERSTAND THIS
MANUAL BEFORE SERVICING YOUR LT-210. If after reading and fully
understanding this manual there are any questions, contact your nearest MTI
dealer..
ISO Mining Technologies International Inc. (MTI) operates a Quality Management

CERTIFICATION System which complies with the requirements of ISO 9001:2008 for the following
scope of registration:
» The registration covers the Quality Management System for the

Design, Manufacture, Sales, Service and Support of drilling and blast
hole consumable tools, and underground drilling, loading, haulage and
material handling systems for surface and underground mining,
construction, and exploration industries.
For certification details see the ISO Certificate of Registration.
SERIAL Always use the serial number of the machine when ordering parts or when
NUMBER requesting service information. Even machines of the same model may be built
LOCATION differently from earlier or later versions and as such may use different replacement
parts or different operating/servicing procedures.
The ELT-210EJ serial number plate (shown below) is located inside the operator’s
compartment next to the seat and steer joystick.
Note: If the decal is not found in the operator’s area it may be mounted in an
alternate location near the master switch on the rear frame.
5
SERIAL The serial number plate includes the following information:

NUMBER PLATE
» » 1. Date of manufacture
» » 2. Machine model
» » 3. Vehicle serial number
» » 4. Engine serial number (used for ordering engine replacement parts)
» » 5. Inspected by
» » 6. Ventilation requirements
Note: Some of these items may not be present on the serial number plate depending
on machine configuration.
MAJOR The following diagram illustrates the major assemblies that comprise the machine.
ASSEMBLIES Not that not all functions of the machine are represented here. For more detail see
the appropriate section of the Parts, Operator’s or Service manuals.
1 – Dump Cylinder 2 – Operator’s Area and Controls 3 – Bucket

4 – Boom 5 – Front Axle Assembly 6 – Rear Axle Assembly
7 – Cable Reel 8 – Articulation 9 – Transmission Fill Point
10 – Hydraulic Tank
6
I NTRODUCTION
This machine differs from conventional loaders in that its main power source is an
electric motor rather than a diesel engine. To accomplish this it is necessary to feed
the ELT-210 current via a high voltage electrical trailing cable. This design brings
forth operating, maintenance and safety items that are not considered normal for
this type of equipment. The high voltage feeding the unit and the trailing cable
itself must be considered at all times while operating and servicing this unit.
The unit features an all-mechanical drive, with a torque converter integral to a

power shift transmission, forward/reverse shift modulation that allows shifting
from forward to reverse without braking to a complete stop.
Safety has been an important consideration is designing the unit. Totally enclosed
hydraulically-applied wet disc brakes are incorporated on both front and rear axles
to provide service braking. Emergency/park braking is accomplished using a wet
disc, spring-applied, inline driveline brake unit.
This manual has been written in such a way as to give you a straightforward outline
of how maintain your machine. Improper operation, maintenance, lubrication or
repair of this product can be hazardous, resulting in injury, death and/or equipment
damage. Notice labels on the unit and in this publication identify potential
operating or service issues that may cause product damage.
Note that MTI cannot anticipate every possible circumstance that might involve a
potential hazard. The warnings in this publication and on the product are therefore
not all inclusive. It is still necessary to assess each individual operation contained
in this manual and satisfy yourself that the procedure is indeed safe, fits within the
scope of your individual operations and will not cause a hazard to you or others.
Also, if a tool, procedure, work method, or operating technique not specifically
recommended by MTI is used, you must satisfy yourself that it is safe for you, and
others. You should also ensure that the product would not be damaged or made
unsafe by the operation, lubrication, maintenance, or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis
of information available at the time it was written. The specifications, torque,
pressures, measurements, adjustments, illustrations and other items can change at
any time. These changes can affect the service given to this product. Do not operate
or perform any maintenance, lubrication or repair on this product, until you have
read and understood the required information.
7
Terms Used In This Manual

A few terms and machine features must be noted to fully comprehend the
information contained in this publication.
» Trailing Cable refers to the high voltage cable that supplies electricity
from the mine source.
» ABA refers to Automatic Brake Application. This means that the unit
will self-apply the emergency/park brake system under certain
conditions that are deemed hazardous to either the unit or the operator’s
well-being. This occurs without operator input and can happen without
warning.
» High Voltage refers to any circuit containing more than 24 volts. It
must however be noted that any amount of electrical current should be
treated with respect.
» Ramp refers to any incline or decline found throughout the working
area for the unit.
» PPE refers to safety clothing and/or equipment worn to protect a
person’s health. It stands for Personal Protective Equipment.
» Transvertor refers to the transmission with integral torque converter
(normally separate from the transmission).
» Ground Fault refers to an electrical protective system that will
automatically open (disconnect) the main high voltage system feeding
the unit when a short to ground is detected.
To properly orient to position references in this manual, we refer to the unit as

follows:
» The front of the unit is the bucket end

» The rear of the unit is the cable reel end
» The left-hand side (L/H) is the side from which you would enter the
operators area
» The right-hand side (R/H) is the side opposite where you would
enter/exit the operators compartment
MANUAL Upon completion of this manual you will be able to safely troubleshoot, dismantle
OBJECTIVES and repair the unit .The modules in this manual have been written in a manner that
will allow you to quickly navigate to the information you desire. This manual is
intended to only supply information necessary for the day-to-day maintenance of
the equipment under your control.
For detailed repair and system information on the transmission and axles please
refer to the appropriate Dana publications.
8
SERVICE The worksite where the machine is working may have pre-requisite training for
TECHNICIAN their maintenance staff. A certain level of competence and understanding of heavy
PRE-REQUISITES equipment repair practices are required to safely carry out maintenance and repairs
to the unit. The following is a list of basic prerequisites that are deemed the
minimum requirements:
» General safety knowledge;

» Knowledge of standards and practices of your particular company;
» Knowledge of government codes and regulations;
» Basic mechanical systems knowledge;
» Basic hydraulic systems knowledge; and
» Basic electrical systems knowledge.
Anyone attempting to maintain or repair this equipment requires the above skills. It
is the responsibility of the site management to provide the necessary skills
development.
SAFETY Improper operation, maintenance, lubrication or repair of this product can be

INFORMATION hazardous, resulting in injury, death and/or equipment damage. Notice labels on the
unit and in this publication identify operations that may cause product damage.
MTI cannot anticipate every possible circumstance that might involve a potential
hazard. The warnings in this publication and on the product are therefore not all
inclusive. It is still necessary to assess each individual operation contained in this
manual and satisfy yourself that the procedure is indeed safe, fits within the scope
of your individual operations and will not cause a hazard to you or others. Also, if a
tool, procedure, work method, or operating technique not specifically
recommended by MTI is used, you must satisfy yourself that it is safe for you, and
others. You should also ensure that the product would not be damaged or made
unsafe by the operation, lubrication, maintenance, or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis
of information available at the time it was written. The specifications, torque,
pressures, measurements, adjustments, illustrations and other items can change at
any time. These changes can affect the service given to this product.
Do not operate or perform any maintenance, lubrication or repair on this product,
until you have read and understood the required information. Safety precautions
and warnings are provided in this manual and on the product. If these warnings are
not heeded, bodily injury or death could occur to you or any person.
To identify our safety precautions, the words “Warning”, “Danger” or “Note”
will appear.
Safety Signs
Read and understand all warning signs on the product before operating, repairing or
lubricating it. Replace any damaged, illegible or missing warning plates, signs or
decals.
9
Personal Protective Equipment

Always wear the protective equipment
required for the job’s conditions or worksite
regulations.
1 - Hard Hat
2 - Hearing Protection
3 - Safety Glasses
4 - Reflective Stripes
5 - Gloves
6 - Safety Boots
Warning: Never wear loose

clothing or jewelry that could
potentially catch on moving
parts of the machine!
Pressurized Items
Carefully relieve all pressure in air, water or hydraulic lines and circuits before
disconnecting any hosing, fitting or related items. Drain hydraulic pressure back to
tank using the accumulator drain valve supplied.
Always ensure that all raised components (booms, gates, etc.) are correctly blocked
or secured against falling in the event of pressure loss during circuit repair. Be
aware that high pressure may still exist (or could potentially be created by a falling
weight) in components such as support cylinders that utilize counter-balance or
piloted check valves.
Be alert of possible high pressure fluids/gases when disconnecting components

from a circuit that utilizes pressure. Never ‘crack’ or remove a connector to relieve
this pressure. Loose or damaged hosing can potentially cause fires. Always check
tubes, lines and hosing carefully using an approved checking method.
Warning: NEVER use your bare hands to inspect hosing for

hydraulic leaks. Pinholes in the hosing can create fluid leaks at high
velocity and pressure that can be easily missed by the naked eye. If
high pressure fluids penetrate the skin, personal injury can occur. If
such an injury does occur, seek medical attention immediately!
Hot Fluids and Parts
To avoid burns, be aware of the hot components on the machines. Note that after
stopping a unit, the fluids remain hot in the lines and parts for a considerable time
afterwards.
10
Wheel Chocks
If your unit is equipped with wheel chocks, they should be installed as per the
worksite regulations whenever the operator leaves the unit and during repairs. MTI
recommends the following procedures if no worksite regulations exist:
» Park the machine as per worksite regulations. Ensure vehicle is not in

motion (engine off if required, parking brake applied) before exiting.
NOTE: When parking a machine on a slope, MTI recommends that the unit should
be turned into the mine wall or rib before exiting the operator’s area or installing
chocks. This prevents placing personnel into a compromised position.
» Exit the operator’s area. Install the articulation lock bar.

» For machines on a slope (1): Retrieve the wheel chocks from storage
and install them on the lower slope against the middle of the tire tread.
Some regulations recommend installing chocks on the tires bearing the
heaviest portion of the load (e.g. front tires for scoops, rear tires for
trucks).
» For machines on level ground (2): Retrieve the wheel chocks from
storage and install against the middle of the tire tread on the outsides of
the front and rear tires to prevent accidental forward or reverse
movement.
» Remove and securely store the wheel chocks and articulation lock bar
in their designated storage areas when the machine is ready to tram.
11
Accessing the Unit

Use steps and handholds when mounting or dismounting the unit. Keep your
machine clean from debris, such as mud on the steps or entranceways. Always face
the machine when climbing steps. For repair purposes use the designated access
provided. When this is not possible, provide a safe manner to complete the task,
such as ladders, work platform or scaffolds.
Lifting Guidelines
Use a hoist when lifting components that weigh 40 lbs. (18 kg) or more to avoid
back injury. Make sure all chains, hooks, slings and lifting devices are in good
working condition and are the correct capacity. Always be sure the hooks are
correctly positioned.
Repair Warnings
Although not within the scope of an operator’s duties, we have listed some safety
warnings below to take note of when repairing the unit.
» Attach the proper warning tag when working on the machine.

» If possible, make all repairs with the machine parked on a level, hard
surface.
» Block the wheels, to prevent the unit from moving.
» Use caution when removing inspection covers.
» Always use tools that are in good condition and proper for the job.
» Always replace hydraulic fittings with equivalent or better. Never use a
lower quality replacement.
» Be careful not to damage any electrical wiring when removing
components.
» Never connect wiring to a hose or line that contains fluid.
» Ensure that all guards or safety devices are properly installed and
functioning correctly. If a guard or safety device has to be removed to
perform a repair, use extra caution, and be sure to re-install it at the
earliest possible time.
» Always tighten connections and bolts to the correct torque.
» Never operate a machine if any part or component is damaged. Always
make sure that all shields or guards are properly installed and
functioning correctly.
Fire Prevention
Fire can create severe emergencies where both human life and property may be
lost. Even when confined, a fire may cause very expensive damage to your
equipment. A fire may start at any time, not only when the equipment is being
used, but also when left unattended between work shifts. To reduce the risk of fire,
follow the preventative instructions listed below.
» Inspect the machine daily for potential fire hazards.

» Always ensure that excess grease and oil accumulation, including
spillage, is cleaned up immediately.
12
» Use only non-flammable cleaning agents for cleaning the machine or

machine components.
» Store any combustible materials in a fireproof location.
» Before performing repair work such as welding, the area around the
repair location should be cleaned, and a fire extinguisher positioned
close by.
» Make sure the on-board fire extinguisher is charged at all times and
know how to use it.
» Always keep tools and the work area clean.
» Always use the proper tools.
» Never allow unauthorized personnel on the machine when it is being
serviced.
» Never attempt repairs you do not understand.
» Hydraulic oil is flammable. Do not weld on the hydraulic tank.
» Wear protective clothing, safety glasses, safety shoes, or other safety
items as the job dictates.
Important Machine Operation Safety Procedures
When operating the unit or any vehicle underground, safety must always be the
prime consideration. It is important that the operator learn how to operate the
machine in a safe and competent manner. It takes practice and concentration to
operate with skill and safety.
Most companies have rules regulating the use of vehicles underground. Your site-
specific rules will reflect any unique local conditions and regulations and must be
obeyed. However, the following is a list of safety recommendations, which should
always be adhered to:
» Always ensure the unit’s trailing cable is connected to an approved
Ground Fault Panel.
» Ensure the trailing cable is supported to the drift wall by a proper strain
relief mechanism to prevent pulling on the trailing cable end connector.
» Thoroughly study the operating controls and procedures in this manual
prior to operating the machine.
» Become totally familiar with your company’s rules governing vehicle
operation at your work site.
» Always complete the pre-start procedures and perform a brake test
prior to operating the unit.
» Always wear required protective clothing/devices. Avoid wearing loose
clothing.
» Always check brake operation before entering a ramp (incline or
decline).
» Travel with implements in their lowest position for increased visibility
and stability.
» Always be aware of other machines and workers in your area of
operation.
» Always travel on ramps with implements downgrade.
» Check gauges and indicator lights frequently to verify proper function
of all machine systems.
13
» Be aware of trailing cable position at all times. Ensure it does not

become caught or snagged, causing the machine to travel over the
cable.
» Ensure a rubber guard at all tunnel corners protects the training cable
from damage/fraying.
» Enter and exit the operator’s compartment only with motor shut down
and key switch off.
» Use worksite procedure for enabling/disabling high voltage power at
the main panel. If no procedure is defined MTI recommends: when
opening and closing (turning on or off) the main disconnect use your
left hand so that your body is out of line with the panel and turn your
face away.
» Always be conscientious of your actions when operating any vehicle.
» Keep the trailing cable out of fluids (water) as much as possible (shock
hazard).
Undesirable Operating Practices
There are also many undesirable practices that should be totally avoided —
examples include, but are not limited to, the following:
» Never drive over the trailing cable with the unit, or allow another unit
to drive over the trailing cable
» DO NOT operate any machine you feel is defective and immediately
report all defects to your supervisor and/or the maintenance
department.
» Do not operate the machine under the influence of drugs or alcohol.
» Never allow riders on the machine — do no lift personnel in the
implement.
» Do not allow personnel in the center hinge area while the machine is
running.
» Never operate the machine when a warning system is activated or
inoperable.
» Never get on or off the machine while it is in motion.
» Never tram with the bucket loaded and elevated (scoops only).
» Do not scale with the bucket or boom.
» Do not step on the trailing cable. Damaged insulation may create shock
hazard!
» Do not approach, or allow someone to approach the unit while it is in
motion. The trailing cable will pay in and out automatically, creating a
whip/pinch point hazard.
» Do not walk in water that the trailing cable is immersed in as possible
shock hazard may exist.
» Do not allow a person to touch or lean on the unit while it is powered
up.
» Do not handle the trailing cable manually any more than necessary.
14
These practices can cause injury, death to the personnel or severe damage to the
unit. The unit itself can be repaired; however injury to you or a co-worker is
irreversible.
PINCH POINT A “pinch point” is a general term for when at least two objects come together
SAFETY (either two moving objects or one moving object and one stationary object). A
pinch point can also be created by a machine and an outside source, such as the
material that it is processing. The safety concern of pinch points is the possibility
that personnel could be injured or killed when coming into contact with them.
Warning: Pinch points commonly impact fingers and hands, but can
impact any area of the body. Injuries can include amputations,
lacerations, contusions, crushing of tissues and bones, or even death!
Any piece of equipment with moving parts has the potential of
creating lethal pinch points!
Common Causes of Injuries from Pinch Points*

» Coming into close contact with operating equipment and machinery
without using proper safety procedures or precautions
» Not paying attention to the location of body parts when near moving
machinery; reaching into or across potential pinch points
» Working in areas with both mobile equipment and fixed structures
» Loose clothing, hair, or jewelry getting caught in rotating or equipment
» Reaching through or otherwise bypassing a safety guard
» Missing or modified guards covering moving components; not
replacing guards after completing machine maintenance
» Dropping or carelessly handling materials or suspended loads
» Not using the proper work procedures or tools
Safety Controls for Pinch Points*

» Pre-work inspection: Identify potential pinch points before starting any
work and plan the task accordingly to avoid pinch point injuries
» Verify all guarding is in place and effective
» Wearing appropriate safety equipment for the job at hand
» Use appropriate lifting devices to safely handle heavy loads
» Always make sure equipment operators know your location and status
» Use lockout/tagout procedures; always verify the equipment is de-
energized before starting any maintenance work
» Be alert around pinch points; drowsiness leads to inattentive work
habits and shortcuts; give every task your full attention to avoid
accidents
* These lists are not intended to be comprehensive lists of causes or controls for
pinch point safety. MTI cannot predict every possible circumstance where pinch
point safety may be involved. Use best practices at all times during operation or
repair of machine!
15
S YSTEMS
This section of the manual will break down the various major power systems of the
ELT-210 (hydraulic, electric and powertrain) into their individual circuits in order
to explain their function. An understanding of their function helps the service
technician to troubleshoot any problems that may not be specifically explained in
this manual. The circuits examined here are the MTI manufactured components.
For systems or circuits relating to third party equipment, please consult the
appropriate service manual, found in a separate physical section after this manual.
POWER TRAIN The power train is designed to multiply the torque from the electric motor and
SYSTEMS transmit this torque through an arrangement of drive shafts and gears to the drive
wheels. The power from the electric motor is transmitted via a coupling from the
output shaft to the torque converter that is integral to the transmission (referred to
as a transvertor). The power from the torque converter is transferred to the
transmission directly. The transvertor provides the directional and speed ranges that
are manually selected by the operator.
The transvertor’s out-put shafts are connected via drivelines to the front and rear
differentials. Universal joints are used to connect the drivelines to the components
to allow changes of alignment between components.
The differential is supported by the axle housing and directs the torque from the
transmission to both adjacent wheels by means of two axles and the planetary
assemblies.
The planetary assemblies are designed to increase the torque at the wheel ends
through a gear reduction system.
Transmission circuit
With the engine running, the converter pump draws oil through the suction screen
in the transmission sump and directs it through the oil filter and then to the
pressure-regulating valve. The pressure-regulating valve maintains pressure in the
control cover to actuate the speed and directional clutches. This is a small portion
of the volume of oil available in the system. The volume of oil that is left is
directed through the torque converter circuit and then to the oil cooler where it
returns to the transmission section for positive lubrication. The regulator valve is
made up of a valve spool operating in a closely fitted bore. The valve is held in a
closed position by a spring-loaded spool. When the pre-determined pressure is
reached the valve spool opens. Hydraulics external to the transvertor include the
cooling circuit and the throttle pedal (inching pedal).
Because the unit is driven by an electric motor, the throttle pedal controls clutch
pack engagement rather than engine RPM. It is called an inching pedal and shifts a
spool within the transmission control valve to engage or disengage the clutch
packs. It works proportional to the amount of travel, sending a stronger (more
clutch engagement equalling more speed) or weaker (less clutch pack engagement
16
equalling less speed) hydraulic signal to the control spool. It is supplied oil pressure
from the transmission itself, and returns excess oil to the transmission sump.
At the outlet of the pedal is a hose going to a 15 psi pressure switch. This normally-
closed switch is used to power the HV21 solenoid used to shift a valve in the
hydraulic load sense circuit. When the pedal is up (no throttle selected), the oil
pressure drains back to the transmission and the switch is closed energizing the
HV21 solenoid.
Also attached to the external pressure circuit are three pressure switches. The 60
and 100 psi switches are for the ABA circuit and the final switch is for engine
warning.
A temperature sender supplies the transmission temperature gauge with a reading

signal.
17
Transmission Cooling Circuit

The transmission hydraulic circuit on the unit has an external cooler to keep the
transmission oil from overheating. The oil is directed through the torque converter
circuit and then exits the transvertor to pass through the oil cooler. From the oil
cooler the oil returns to the transmission for positive lubrication. The transmission
oil cooler should be kept clean so it will function properly. Periodic inspection of
the coolers and hoses should be carried out paying attention to leaks and damage to
the hosing and cooler itself.
Servicing the Transmission Cooler

The torque converter and transmission hydraulic systems are important links in the
flow of power from the engine to the wheels. Since the two systems are
interconnected, the operation of either unit depends on the condition and operation
of the other. Whenever a repair or overhaul is performed on one unit, the condition
of the whole system must be considered and the oil cooler would have to be
thoroughly cleaned. If possible, the cooler assembly should be removed from the
machine for proper cleaning. To clean, use oil, compressed air, and steam. The
cooler should be back flushed until all foreign material has been removed. Flushing
in normal direction of oil flow will not adequately clean the cooler. Do not use any
type of flushing compounds to clean the coolers.
Transvertor Lubrication
Check oil level DAILY transmission oil temperature at 180 to 200°F (73 to 93°C)
Changing the Transvertor Oil/filter

Every 500 hours, change the transvertor oil filter element.
Drain and Filter Change Procedure

Every 1000 hours, drain and refill system as shown below:
» Run the unit to bring oil up to temperature, 150 to 200°F (65 to 93°C).
Drain oil into suitable container and dispose of oil according to
worksite procedures.
» NOTE: It is recommended that filter elements transvertor circuit be
changed after 50 and 100 hours of operation on new and rebuilt or
repaired units.
» Drain the transmission and remove sump screen.
» Clean the screen thoroughly and replace it, using new gaskets.
» Remove, drain and discard the used filter element.
» Thoroughly clean the filter mount and install new element.
» Refill the transmission to the LOW level mark.
» Run the transvertor to prime torque converter and circuit lines.
» Re-check the level with and add oil to bring level to LOW mark.
» When the oil temperature reaches operating temperature of 180 to
200°F (82.2 to 93.3°C) make a final oil level check and replenish as
necessary.
18
Converter outlet oil temperature is measured at the outlet side of the converter.
Operating temperature should be in the range of 180 to 200°F (82.3 to 93.3°C) in
NEUTRAL.
Converter pressure should be 25 PSI (172.4 kPa) minimum pressure at 2000 RPM
with a maximum of 70 PSI (482.6 kPa) outlet pressure with engine operating at the
rated no-load governed speed.
Converter outlet pressure is determined by the total pressure rate of production of

the cooler, cooler lines and backpressure of the transmission lubrication system.
Filtration
The filtration system used in the transmission circuit is a high pressure “full-flow
filter” with a safety by-pass valve built into it. There is also a strainer screen in the
sump of the transmission to keep any large particles from entering the pump. The
filters should be changed as per maintenance schedules or sooner if working in
adverse conditions. If for any reason a filter becomes clogged it should be replaced
immediately and the cause of the problem found and repaired.
Mechanical Checks
Before checking on the torque converter, transmission, and allied hydraulic system
for pressures and rate of oil flow, it is essential that the following preliminary
checks be made.
Check oil level in transmission. This should be done with oil temperatures of 18O0
to 2000 F (82.20 - 93.30 C)
DO NOT ATTEMPT THESE CHECKS WITH COLD OIL
Put the direction control in forward and select high speed and apply brakes.
Accelerate engine half to three-quarter throttle.
Hold stall until desired converter outlet temperature is reached.
CAUTION: FULL THROTTLE STALL SPEEDS FOR AN

EXCESSIVE LENGTH OF TIME WILL OVERHEAT THE
CONVERTER.
HYDRAULIC The hydraulic system is powered by a variable displacement, piston type pump for
SYSTEM the main portion and a fixed displacement gear type pump for the cable reel
function. The hydraulic system can be divided into sub-systems; the hoist and
dump system, the braking system, the cable reel system and the steering system.
The brake accumulator is charged by the hydraulic pump, and once charged can
operate completely independent of the pump until the pressure in the accumulator
lowers to a predetermined level, at which time the charge valve will send a load
sense signal to the pump, causing a re-charge of the accumulator pressure. Once it
reaches the fully charged pressure, the charge valve blocks the load sense signal, at
which time pressure is again isolated in the accumulator circuit.
19
The hoist/dump system and the steering system also uses load sensing to vary the
output of the pump as required by operator demand.
The cable reel circuit does not employ load sensing to accomplish its functions.
The hydraulic system incorporates both pressure circuit and return circuit filters (10
micron full flow) to remove any contaminates introduced into (or generated by) the
system. This keeps the fluid as clean as possible, however care must be taken when
replenishing the hydraulic reservoir to ensure that contaminates are introduced as
little as possible. Always use the on board hand pump to replenish the system as
this ensures filtration of the fluid being introduced. It will not, however, remove
water contamination so it is very important to ensure that your fluid
storage/transportation systems prevent water introduction into stored hydraulic
fluid.
Hydraulic System Settings

The settings below are taken directly from the hydraulic schematic for your unit.
Refer to the schematic for the values stated, they are shown here for reference only.
Pump flow value is 20 GPM @ 1760 rpm (electric motor), no load (see flow test in
following pages).
Note: The values shown below are correct at the time of publication. Always use
the values from the latest version of the hydraulic schematic that pertains to your
specific unit. MTI reserves the right to change the values stated for the purpose of
product improvement or upgrade at any time without prior notice.
Component Setting
Stand By @ 400 psi
Pump Pressure
System Pressure @ 2400 psi
Pump Flow 20 GPM @1760 RPM, 2000 psi
Boom Up @ 2700 psi
Boom Down @ 1450 psi
Bucket Dump @ 1450 psi
Port Relief
Bucket Rollback @ 2700 psi
Steer Left @ 2400 psi
Steer Right @ 2200 psi
Pilot Accumulator Gas Pre- 90 psi
charge
Brake Accumulator Gas 1000 psi +/- 50 psi
Pre-charge
Low Limit: 1800-1900 psi
Accumulator Charge Valve High Limit: 2250-2350 psi
Charging Rate: 1.5 GPM @ 1000 psi
P1: 1600 psi Accumulator (Brake Pending)
Pressure Switches P2: 1300 psi Accumulator (ABA)
P3: 400 psi Brake On Notification
Brake Application Pressure 800 +/- 75 psi
20
Hydraulic Components
The hydraulic system is made up of a certain number of basic components. Some
examples of components include: the hydraulic reservoir, the hydraulic pump,
accumulators, hydraulic actuators, control valves, etc.
Hydraulic Pump Description and Operation

The unit uses a single hydraulic pump for all its hydraulic functions. The pump
used is a variable displacement, axial piston pump. This type of pump is suitable
for use in the load sensing application of the unit. Note that there is only one pump
on the machine and it supplies oil to the boom/bucket/steering valve, braking
system and the pilot control circuit.
Pump flow is measured in either gallons per minute (GPM) or liters per minute
(l/min) and is proportional to pump RPM and pump displacement. The RPM is
dependent on the engine speed and the displacement is dependent on swash plate
angle.
The unit uses this type of system for several reasons. This system is efficient and
compact. By only pumping the required amount of oil, less heat is generated and
less fuel is burned. When the system is on standby, the pump only produces enough
oil flow for cooling and lubricating. A low standby pressure is produced by only
creating a small amount of flow for the cooling and lubrication functions. However,
the pump is ready to produce required output at any time.
This type of pump is also used because features such as high operating RPM, low
noise emissions, good oil inlet characteristics, and excellent choice of control
options. This type of pump is also suitable for creating oil flow at pressures up
3600 PSI with little loss of pumping volume. Shown below is a cutaway view of
the pump.
1. Pump housing 2. Cylinder barrel 3. Piston and slipper shoes

4. Ported end plate 5. Input shaft 6. Swash plate
8. Control piston 10. Shaft seal 11. Compensator control
12. Spring 13. Stroking plunger 14. Valve plate
When the pump is not turning and there is no control pressure the swash plate will
be forced to its maximum angle by the spring operated stroking plunger. As the
21
pump begins to turn, the piston slipper shoes (3) follow the angle of the swash plate
(6), causing the pistons to move in and out of the cylinder barrel (2). As any given
piston begins to move out of the cylinder barrel, it creates a void or space between
it and the valve plate (14).
At the same time the opening opposite of the piston on the barrel (2) begins to pass
a kidney shaped inlet port of the valve plate (14) allowing oil from the reservoir to
fill the void. The pump continues to rotate and the opening for that particular piston
is blocked off by the valve plate. The piston is now forced into the barrel by the
swash plate angle. At the same time the opening of the barrel for that piston is
beginning to line up with a kidney shaped outlet port of the valve plate. The piston
now forces oil out of the barrel into the outlet line of the pump.
The displacement of the pump is determined by the stroke length of each piston.
The stroke length for each piston is determined by the angle of the swash plate at
any given time. There for the pump displacement is determined by the swash plate
angle. The swash plate angle is determined by several factors. At maximum
displacement the swash plate is held at maximum angle by a spring-loaded plunger
and by the resistance of the oil being pumped out acting on the end of the pistons.
At any other angle, the control piston (8) is pushing on the swash plate forcing it
back to a lesser angle.
Because the hydraulic system is load sensing, this means the pump is able to
respond to the demands of the hydraulic system. In short the pump only supplies
what is required by the system. The compensator control (11) is responsible for
this. When a pressure signal is received from the system it causes the compensator
to adjust oil pressure to the back of the swash plate control piston (8). This causes
the swash plate to change angle according to the signal the compensator has
received from the hydraulic system.
Flow testing piston pumps with load sense

Before starting, the pump must be filled with fluid. It is also necessary to connect the
discharge line through the flow meter to the return line so air can be displaced from
the pump without pressure being developed.
Note: Ensure that the flow meter being used has a current calibration tag. Never use a
suspect flow meter. Ensure the batteries are good on flow meter models requiring
them.
» Lower bucket and boom to rest bucket on floor.

» Shut off machine.
» Drain accumulators by opening drain valves. Observe accumulator
gauge to determine when accumulator pressure has dissipated.
» Release hydraulic tank pressure by pulling the ring on the vacuum
pressure relief valve located on the tank cover.
» Disconnect the pressure hose from the pump at the high-pressure filter.
» Connect the discharge hose to the inlet of a flow meter with an
adjustable restrictor and gauge with minimum 3000 psi range.
22
» Hook up the load sense line to a tee on the flow meter on the pump side
of the adjustable restrictor.
» Install a return line from the flow meter restrictor outlet to the return
circuit.
Note: Ensure pump case drain remains connected in its original configuration!
» Back out flow restrictor valve all the way.

» Start the engine (transmission in neutral, park brake on) and check the
pump flow at full throttle. Record flow values in flow test and cycle
time sheets.
» Adjust restrictor, loading valve in flow meter to values specified on
table below. Record the values.
» Disconnect flow meter and restore the circuit to its original
configuration.
» Close accumulator drain valves.
Theoretical Flows Actual Flows  1 GPM theoretical

‐ 21 GPM @ no load @ 1800 rpm -_________ @ no load _____ engine RPM
- 19 GPM @ 2100 psi -__________ @ 2100 psi _________ lugged RPM
-Volumetric efficiency @ 95%
Pressure Compensated at 0-GPM @  50 psi Actual _______
2400 psi
Cycle Times (Using 4600 lbs.)
Theoretical (Empty) Empty Loaded
BOOM RAISE 6  1 second 1 1
2 2
3 3
4 4
Average Average
BOOM LOWER 5  .75 seconds 1
2
3 N/A
4
Average
BUCKET DUMP 7.5  1 second 1
2
3 N/A
4
Average
BUCKET ROLL BACK 5.5  1 second 1
2
3 N/A
4
Average
STEER L/H 2.5  0.75 second 1 1
2 2
3 3
4 4
Average Average
STEER R/H 2.0  0.75 second 1 1
2 2
3 3
4 4
Average Average
23
Hydraulic Reservoir
The hydraulic reservoir is a major component of an efficient hydraulic circuit. It
holds more fluid than is necessary to supply the circuit. Extra oil is stored within to
compensate for the constantly changing volume of all of the systems. For instance
when the boom is lifted, it requires more oil. The primary reason for the additional
oil however is so it acts as a heat exchanger maintaining the hydraulic system
temperature.
Note: Due to the heat exchange nature of the reservoir, it is extremely important
that the reservoir be kept as clean as possible. Dirt, grease, oil residue and any other
contaminates should be removed or cleaned away to allow the walls of the reservoir
to dissipate the heat from the fluid to atmosphere.
Aeration inherent in any hydraulic circuit is also dissipated as the oil idles in the
reservoir prior to re-circulation. Excessive aeration however, would indicate a
vacuum leak within the circuit, and would be detectable by a marbling sound from
the hydraulic pump. Note that due to the positioning of the pump at appoint above
fluid level on this unit, there will be a tendency for the pump to marble for a very
brief period upon initial start-up. This would only be a concern if it continues for a
period of more than a few seconds.
The reservoir also provides convenient attachment points for the system return
filter, a filtered breather, the oil level check point (sight plugs or gauge) and the
various ports required by the system.
The reservoir breather serves several purposes. The first purpose is to prevent a low
or negative pressure from developing in the reservoir, which would cause the
hydraulic pump to cavitate. It does so by creating a slight positive pressure in the
reservoir through a spring-retained ball check. The type of breather used also filters
any air drawn into the reservoir to prevent contamination of the hydraulic system.
A safety relief is attached to the reservoir to ensure that if the breather malfunctions
and attempts to develop excessive positive pressure in the reservoir it can be
prevented. The safety relief incorporates a manual ring pull mechanism to vent all
pressure from the reservoir as necessary.
Because the most common introduction of contaminates to a hydraulic system is

during oil replenishment, a fill pump has been attached to the circuit. This pump
adds fluid to the reservoir via the incorporated return filter, preventing solid
contaminates from being introduced. Note that the filter will not remove any water
contamination from the fluid being added, so it is the sites responsibility to ensure a
water-free oil supply.
Return Circuits
The return system of the unit will bring all of the hydraulic oil back to the reservoir.
The majority of the oil is filtered, including the main valve bank that actuates the
boom, bucket and steer functions. Certain circuits must be returned directly to the
reservoir as they can be affected by back pressure from the return circuit itself. The
high volume of oil in the return circuit may cause enough resistance that it can
affect the circuits in question, causing component failure. The circuits that must be
24
returned directly to the reservoir are the pump load sense/case drain connection and
the cable reel motor case drain/reel out port circuits.
The circuits that pass through the filter are gathered through two manifolds that
connect together, and are then brought to the filter via a common return hose.
The return filter is a full flow 10-micron filter and should be changed every 250
operating hours or sooner if conditions dictate.
Note: Case drain circuits are never to be combined with any other type of circuit,
including the returns! They must connect direct to the reservoir!
Pressure Circuits
All of the various hydraulic systems except the cable reel are fed flow/pressure
from a common pump. The pump is driven from the electric motor via the
transvertor. It produces a standby pressure as soon as the shaft begins to turn, and
when a function is used, a load sense signal will cause the pump to produce the
pressure required to meet the load demand, up to the pump’s compensated pressure.
The system is protected by a safety relief set above pump compensated pressure,
meaning that it is passive and will only work if a malfunction occurs.
25
Once the oil is past the safety relief it is then filtered by a 10-micron full flow filter
that removes any contaminates drawn from the reservoir or produced by the pump.
From the filter the oil flow/pressure is connected to the main valve and accumulator
charge valve. The accumulator charge valve will maintain a constant pressure of
between 1800 and 2350 psi at all times within the brake accumulator.
Load Sense Circuit

The main hydraulic pump used on this unit is a variable-displacement, load-sensing
axial piston pump. Variable displacement means that the output of the pump can be
altered to suit changing conditions. Load sensing means that the variations in
output are controlled by an external source that provides a hydraulic signal to
achieve this control. Simply put, load sensing is a pump and load control working
as a team. For an in depth explanation into the dynamics of the pump, refer to the
pump description and operation section of this manual.
There are two load sense signal sources available: the main control valve and the
accumulator charge valve. Each of these can send a signal to the pump, but if more
than one does so at the same time, then the function demanding the highest load
will gain control over the pump. This is the purpose of the shuttle valve; it allows
the highest pressure (signal) to reach the pump, thereby ensuring that the highest
load demand is met.
Note: Ensure that the load sense/case drain port at the pump is always connected
direct to the reservoir and does not combine with any other circuit or pass through a
filter or serious product damage will result!
Example circuit only

26
Pilot Pressure Supply Circuit

The main control valve’s hydraulic functions are actuated using a remote signal
supplied by a manual joystick (see pilot valves and functions section in this
manual).
The pilot joysticks are fed a low pressure from the pilot pressure regulator in the
main control valve bank. Normal pressure felt at the regulated pressure outlet (‘Pp’)
would be 450 psi. From the outlet the fluid passes through a one way check valve
and then charges an accumulator. The check valve prevents discharge of the
accumulated pressure back into the circuit.
The pilot accumulator ensures adequate supply of oil pressure when the controls
are being actuated repeatedly which would normally cause a pressure drop, or loss
function. This accumulator is connected to the two manually operated joysticks.
The HV6 steer cut-out valve (item 36) is used to disable the steering of the unit
when the frames are fully articulated in either direction. The valve blocks the pilot
pressure and prevents any further actuation of the steer cylinder.
An accumulator drain valve (in the operator’s area) can be used to drain the circuit
after machine shut down or during repairs.
27
Cable Reel Circuit

The cable reel circuit is fed flow/pressure from a single constant displacement gear
pump. The pump is driven from the electric motor/transvertor via a through shaft in
the main hydraulic pump.
Because it is a constant displacement pump, there is constant flow and a need to

protect against over-pressurization using the 1500 psi safety relief (item 7) that
diverts excess oil to the return manifold (item 10).
The cable reel circuit has two modes, reel in and reel out that are significantly
different in their function. To reel the cable in while reversing the unit, the cable
reel is powered (automatically as soon as reverse is selected), while reeling out
cable is accomplished by having cable tension “pull” the cable off the reel against
hydraulic power.
Reel Out
As the unit drives forward, cable tension pulls on the drum exerting rotary pressure
on the hydraulic motor, drawing oil from the reservoir and causing it to induce
pressure in the opposite port. Oil returning from the cable reel motor unchecks the
ball in the check valve (item 38) and is sent to the cable reel reverse solenoid valve
(item 46). The oil continues to tank through this valve and encounters the counter-
balance valve (set to 75 psi). The counter-balance valve controls the flow of oil to
the reservoir, allowing the motor to freely turn, causing the drum to pay out cable
while maintaining tension on the cable and preventing over-rotation of the reel.
28
Oil to run the cable reel motor is sent to the HV30 cable reel solenoid (item 46).
The solenoid valve determines whether to connect flow from the gear pump to the
cable reel motor or direct it back to tank. When the machine is put into reverse
gear, the valve shifts and directs oil to the motor via a 400 psi pressure
reducing/relief valve (item 45). This valve ensures the speed of rotation by
reducing the oil pressure and ensures relief of excess oil in case of the motor being
stopped.
Reel In
As soon as reverse gear is selected, the HV30 control solenoid will shift. This
delivers oil flow/pressure from the cable reel pump through the pressure
reducing/relief valve (item 45) and to the cable reel motor. The motor is forced to
turn, causing the cable to be picked up. Once a certain tension is met on the cable,
the regulator will relieve enough oil to the reservoir to prevent over-tensioning the
cable.
Pilot Valves and Functions Circuits

The steer, boom and bucket functions are actuated by the operator’s pilot joysticks.
For instance, when the operator selects a steer function, a hydraulic signal is sent
from the appropriate port of the steer joystick to the pilot piston on one end of the
appropriate spool in the main valve bank. This low pressure pilot signal shifts the
spool, making the correct connections to cause movement of the cylinder; oil
exiting the opposite pilot piston on the same spool flows back to the return circuit
via the joystick.
When a control spool has been shifted, several connections are made. The pressure
port is connected to one end of the function’s cylinder, along with the load sense
circuit to request flow from the pump. The pump meets the demand and the
function moves. The pressure oil also is felt by the appropriate port relief valve
inlet. If the pressure is higher than the port relief setting, then the relief will open,
venting excess pressure to the reservoir. The opposite portion of the cylinder is
venting oil and is connected to the reservoir via the control spool.
The relief may also open without actuation of the function if a sudden shock is felt
by the function’s cylinder, causing a pressure surge within the circuit. This prevents
damage to the circuit in this type of event.
Note that the steer section of the valve bank incorporates a relief valve to limit the
load sense circuit (and subsequently the steer circuit) to a certain value.
Brake Pressure Supply Circuit

The brake system is made up of two circuits that interact with each other at certain
times. The first is the emergency/park brake circuit, and the second is the service
brake circuit. Safety interlocks are installed in the emergency/park brake circuit and
are explained if further detail in the electrical section.
Oil flow is supplied to the brake controls via an accumulator charge valve. The
charge valve cycles between low and high pressure limits of 1800 to 2350 psi.
There is a connection to the return circuit to vent the load sense port when charging
29
is not being demanded, and a connection to a set of pressure switches via a

snubbing adapter.
The pressure switches are used to monitor the accumulator pressure and are part of
the ABA circuit (see electrical section of this manual).
There is a load sense port that sends a signal to the pump to demand flow when
charging of the circuit is required.
The two outlet ports are joined together and direct oil flow to an accumulator
manifold. The manifold has connections to the accumulator, a gauge, a safety relief
to prevent overcharging, a drain valve to relieve pressure when servicing of the
system is required, the emergency/park brake solenoid block, and the two ports on
the service brake pedal.
Park Brake Circuit (Brakes Applied)

The park brake system consists of the emergency/park brake solenoid block, the
park brake (spring-applied and hydraulically-released), a pressure switch to monitor
when the brakes are released and applied (red light that is on when brakes are
applied and off when the brakes are released), and a connection to the service brake
pilot pressure (PP) port.
30
Note that the top solenoid (HV3) of the park brake block is energized and shifted
when there is power to the key switch on the main dash. It will remain in this state
unless the operator pushes the ‘Brake Test’ button. We will return to that function
in the next section.
When brakes are applied, the bottom solenoid (HV2) is de-energized and shifted by
the spring so that the EBR port is connected to port T, removing pressure from the
brake piston and allowing the brake springs to apply. With HV2 not shifted and
HV3 shifted, the oil pressure from port PR is connected to the ‘Mod Ped’ port. This
applies the pressure to port PP at the top of the service brake spools, shifting them
and holding the service brakes fully on. We now have all four wheel end brakes and
the park brake holding the unit stationary.
Park Brake Circuit (Brake Test)

The park brake test function is intended to allow the operator or maintenance
person to test the function of the park brake independent of the wheel end (service)
brakes. As explained previously, when the emergency/park brake button is pushed
down, both sets of brakes are applied to stop the unit.
To test the park brake it is necessary to allow the service brakes to release while
keeping the park brake applied. When the operator presses the ‘Brake Test’ button,
the HV3 brake test solenoid de-energizes, and allows the spring to return the spool
to its relaxed position.
This interrupts the pilot signal to the service brake pedal port PP, allowing the
pedal to shift and causing the service brakes to become released. The park brake
can now be tested (in second gear, forward or reverse) to ensure it functions
correctly.
31
Note: Brake test procedure for park and service brake system is posted in the
operator’s compartment.
Park Brake Circuit (Brakes Released)

Note that no change occurs to the brake test solenoid when the park brakes are
released.
To release the park brake, the operator will pull up on the park brake button. If
conditions are right (see ABA section of electrical explanations) the park brake
solenoid will energize and shift. This isolates the pilot signal to the service brakes,
releasing them. It also applies pressure to the park brake, causing the springs to
compress, releasing the park brake.
This same pressure is also felt by the brake on pressure switch, which opens and
extinguishes the ‘Brake On’ light.
Testing the Accumulators

Testing the pre-charge pressure of an accumulator is very simple and requires no
special tools. If your unit is equipped with a system gauge on the dash, simply run
the unit until the gauge shows full system pressure. Shut the machine off and open
the accumulator drain, if equipped, or cycle the circuit to discharge it. Watch the
pressure gauge drop. It will drop slowly until the accumulator is empty. Once
emptied, the gauge will drop to 0 PSI almost instantly. The last reading on the
gauge just before the pressure went to 0 PSI is the accumulator pre-charge pressure.
Brake Test Procedures

These tests of the brake systems must be performed before operating this machine.
It is also highly recommended that these tests also be performed before entering a
ramp. Before starting tests, the park brake button MUST be pushed in (applied).
Note: The brake test procedures are located on a decal in the operator’s
compartment.
SERVICE BRAKE TEST
With the service brake pedal depressed, release the parking emergency brakes by
pulling out on the large red button labeled Park Brake. Place the transmission in
forward or reverse 2nd gear (3rd gear for 2604). Rev the engine to full throttle. The
machine should not move. If it does, the service brakes system is considered unsafe
and the defect should be reported to your supervisor.
If the test fails, do not operate the machine!
PARKING BRAKE TEST

The large red button labeled Park Brake will need to be in the pushed in position.
Place the transmission in forward or reverse 2nd gear (3rd gear an 2604). Release
the service brake foot pedal. Push the button labeled ‘Brake Test’ and hold. Rev the
engine to full throttle. The machine should not move. If it does, the parking brake is
considered unsafe and the defect should be reported to your supervisor.
32
EMERGENCY BRAKE TEST

The large red button labeled Park Brake will need to be in the pushed in position.
Place the transmission in forward or reverse 2nd gear (3rd gear on 2604). Release
the service brake foot pedal. Rev the engine to full throttle. The machine should not
move. If it does, the emergency brake is considered unsafe and the defect should be
reported to your supervisor.
Note: When the Park Brake button is pushed in, both the parking brake and the
service brakes are applied. When the power switch is turned off, the service brakes
release, leaving only the parking brake holding the machine.
STEER CUTOUT TEST PROCEDURES (IF EQUIPPED)

Steer cut-out test must be performed before operating the machine and before
entering a ramp. The Park Brake button MUST be pushed in (applied). Steer
function MUST NOT operate at this point. Once park brake is released, steering
function MUST be operational. If any of these tests fail, steer cut-out is not
functioning properly and is considered unsafe, DO NOT OPERATE, report to your
supervisor.
33
ELECTRICAL The following section is a review of some important safety recommendations for
SYSTEM working on or around electrical systems or components. These are not all inclusive
and do not replace site-specific safety regulations that pertain to the
troubleshooting, repair and maintenance of electrical systems.
» Always open master disconnect switch and/or disconnect the source

prior to performing any electrical repair.
» Always follow correct lock out/tag out procedures for your site.
» Verify that the system has no potential or realized energy prior to
working on an electrical system.
» If a system must be live to facilitate troubleshooting, take the
appropriate steps to safeguard personnel and equipment from damage.
» Never speak to, or disturb the concentration of, a person working on
electrical equipment/systems.
» Only fully trained and qualified persons should work on electrical
systems.
» Always replace components with manufacturer-approved items.
» Use the proper tools and test equipment for the task at hand.
» Never use magnetic tools or instruments on or around electronic
components especially PLCs or ECMs.
» Ensure that the master disconnect switch is open prior to welding
anywhere on the unit.
» Only trained and qualified technicians should perform troubleshooting
and repairs.
» Always disconnect power prior to attempting repairs.
» A thorough understanding of the electrical system (study the system
schematic prior to attempting diagnostics) and a good quality
multimeter are essential tools to troubleshoot and repair the electrical
system.
» Always repair the circuits to OEM standards.
This unit is driven by a high voltage electric motor! Extreme care

must be taken regarding the high voltage (power feed) trailing cable,
and the unit itself, as high voltage hazards exist whenever the unit or
cable is connected to live power! Follow your site rules for the use
and care of high voltage equipment/components!
General Design
The Electrical System on the unit contains elements of both high voltage (460V)
and low voltage (24V). The main motor and cooler motors are fed from the 460V
supply, while all of the control circuits are fed 24V from either a transformer or
two parallel 24V power supplies.
The electrical system is made up of many various subsystems which will be

explained in this section. Some circuits will be explained individually as they are
somewhat complicated, while others will be grouped together due to their
simplicity.
34
The main disconnect switch interrupts all power when open; the switch should be
used when the machine is not in use, or in case of an emergency.
There is also a Power (key) switch located on the operator’s dash allowing power
feed to the control circuits to be interrupted by the operator.
Note: When servicing/troubleshooting/repairing the electrical system, you must

open the Power On switch and Master Disconnect. Also physically disconnect the
trailing cable from the power supply and use your site specific Lock Out/Tag Out
procedure prior to commencing work. Only trained and fully qualified electrical
personnel are to perform servicing/troubleshooting/repairing of the high voltage
system.
The transvertor and hydraulic pump are driven by the 50HP 460V main electric
motor that is powered via a genset or mine substation through the high voltage
trailing cable. The power supply should provide ground fault capabilities. The
purpose of the ground fault is to protect the machine due to the high voltage present
on the unit. It does not afford personnel protection, so it is very important that the
unit be disconnected when either repairing or troubleshooting the unit.
Power Supply Circuits

Power is transferred from the trailing cable to the main disconnect through the use
of a collector ring set in the middle of the cable drum. A ground conductor
incorporated into the trailing cable passes through the collector ring, and is
connected directly to ground. The yellow conductor is the monitor wire for the
ground check circuit. It passes across the cable reel limit switch and normally-
closed (n/c) fire suppression switch before being connected to ground via a Zener
diode. If the cable reel is depleted or fire suppression system is activated, the
pressure switch opens, causing a ground check condition, shutting down the unit.
Re-start will not be possible until the pressure switch is returned to normal by
correcting the ground check condition.
35
Incoming power encounters the main breaker (master disconnect) which has to be
closed to send power onward to the 460/120V transformer, the phase voltage relay,
voltmeter and the two electric motors (main and cooler fan motors). The motors are
protected by the main breaker while the cooler fan motor also has 5A fuses on each
conductor. Over-current conditions will cause the motor overloads (O/L1 & O/L2)
to trip (similar to a circuit breaker), affording protection for the motors also.
The phase voltage relay (PVR) will monitor the incoming power to ensure that it
follows the phase requirements of the unit. If the phases are not correct, the PVR
will cause a red light marked “Incorrect Phase” on the main electrical panel to
illuminate, indicating this condition. The PVR will also cause the motors to
immediately shut down when they are started.
Power entering the 460/120V transformer is reduced and then fed to two power
supplies (120/24V). The input side of the 460/120V transformer is protected by
16A fuses on both conductors. The 24V output power is passed through a rectifier
to ensure DC current, and then supplied to the control circuits via the emergency
stop button on the main dash.
The control power is supplied to the Power (key) switch via a 20A circuit breaker
that affords control power protection from over current conditions. If the key
switch is closed, it will supply power to the various control and load circuits.
Insulation monitors (IM1 and IM2) are installed on the two motors. These devices
are used to monitor the windings of the electric motors when they are not running.
36
The insulation monitors feed current to the windings via the normally-closed M1
and M2 contacts. The monitors will energize the IM1 or IM2 relays and open the
respective contacts in the Enable circuit (see motor start section for more detail).
Motor Start Circuit - Manual

We will examine the circuit with the master disconnect in the ON (closed) position
and the power key closed. The PVR has determined that the incoming conductor
phasing is correct, causing the n/c PVR relay to open, extinguishing the red
‘Incorrect Phase’ light and closing the n/o PVR contacts in the (ER) enable relay
circuit. Power will be sent to the (ER) enable relay assuming there are no issues
with the motors (insulation monitors and overloads are normal). This relay will
close the normally open ‘ER’ contacts in the motor start circuit allowing power to
reach the motor start/stop button.
Pulling up on the start/stop button closes the start button contacts and sends power
to the normally-open ‘NR’ contacts. If the transmission is in neutral, these contacts
will be closed. The next set of contacts are for the brake circuit. If the brakes are
applied, the brake relay is de-energized and these ‘BR’ contacts in the start circuit
remain closed.
At this point (enable relay closed, transmission in neutral, brakes applied) the
motors are ready to be started. Power is sent to several motor start components
simultaneously. We will discuss the items as they appear on the schematic from top
to bottom. The (M1) relay closes the normally-open ‘M1’ contacts on the three
phase conducts at the main motor and the normally-open contacts that bypass the
start/stop circuit described previously.
37
The (R1) Wye/Delta relay controls the application of the three phase power to the
main motor. The relay initially closes the ‘R1-Y’ contacts and powers the (Y1) and
(UL) relays. The HV1 solenoid is used to shift a valve spool in the hydraulic
system. This valve dumps load sense pressure from the spool compensator to
decrease the load on the transvertor during motor start-up. The (Y1) relay closes the
‘Y1’ contacts on the main motor; this provides a “soft start” to the electric motor by
stepping up power to the motor in stages. After a short delay the wye/delta relay
opens the ‘R1-Y’ contacts, de-energizing the (Y1) relay and closes the ‘R1-D’
contacts to energize the (D1) relay. At the motor the three ‘Y1’ contacts open and
the three ‘D1’ contacts close, sending full power to the electric motor.
The green ‘Motor On’ light and motor hourmeter are powered. Finally, the (M2)
cooler fan motor relay is energized, closing the three normally-open ‘M2’ contacts
and causing the cooler fan motor to run. The (M2) relay also closes the normally-
open contacts that bypass the start/stop button, sealing the motor circuits in the
“run” state.
Motor Running/Motor Stop

After the operator releases the motor start/stop button (which spring returns to the
center open position), the motors will continue to run, as the ‘M1’ and ‘M2’
latching contacts will continue to supply power to the motor start circuit.
The motors will continue to run until such a time as one of the stop buttons is
pressed (opening the closed circuit) or one of the components in the enable relay
circuit opens. In addition, the hour meter continues to log run time as indicated by
the ‘Motor On’ light remaining illuminated.
Note that during motor start, the warning circuit will be active until the unit runs
long enough to develop at least 100 PSI transmission pressure and the accumulator
circuit develops in excess of 1600 PSI. If desired, pushing the ‘Horn Override’
button will silence the horn until these two systems stabilize, at which time the
switches will open, silencing the horn.
Light Circuit
The light circuit is fed from the 120/240/16/32 transformer via the rectifier bridge.
Incoming power first encounters the n/o ‘PR’ contacts. These contacts are closed
by energizing the (PR) power relay under the 24V control circuits.
The ‘PR’ contacts connect power to the 20A breakers that protect the light circuits
from over-current conditions. Power will then be fed to the front and rear light
controls. Closing a switch will cause the lights on that run to illuminate.
38
Monitor Circuits
The ELT-210 has various indicators that monitor what are considered vital system
conditions. All of the monitors (and panel fan/heater) are fed current directly from
the Power (key) switch.
The voltmeter depicted below will indicate 24V control power to ensure an
adequate supply voltage.
The panel fan and heater are not monitors, but instead they prevent or reduce
moisture contamination within the dash panel. The main panel does not require
these devices as the 600/120V transformer creates sufficient heat to remove or
reduce moisture.
The transmission temperature is monitored through the use of a gauge and sending
unit combination. The sending unit will react to differing temperature in the
transmission hydraulic circuit, sending a varying signal to the gauge, which
displays the signal as a temperature value. Normal operating temperature is 180° –
200°F (82° - 93° C). Maximum allowable transmission operating temperature is
approximately 230°F (110°C).
The transmission pressure is monitored through the use of a gauge and sending unit
combination. The sending unit will react to differing pressures in the transmission
hydraulic circuit, sending a varying signal to the gauge, which displays the signal
as a pressure value. Normal operating pressure is 140 – 160 PSI.
39
Horn Circuit
The ‘WR’ contacts are for the warning relay (see warning circuit). The horn can be
automatically actuated by closing the WR contacts or by closing the manual Horn
switch.
Warning Circuit
When the transmission is producing in excess of 100 psi hydraulic pressure it
causes the transmission switch to open; when the hydraulic pressure in the brake
accumulator circuit is greater than 1600 psi, it causes the accumulator switch to
open. This ensures that both the warning relay and the yellow ‘Brake Impending’
light are de-energized. The ‘WR’ contacts in the horn section remains open, and the
horn remains silent.
If the hydraulic pressure in the transmission circuit has dropped to a value below
100 PSI, it causes the transmission switch to close. This energizes the (WR) relay,
and illuminates the yellow ‘Brake Impending’ light, illuminating it. The (WR) relay
will close the ‘WR’ contacts in the horn section, causing it to sound, warning the
operator of a potentially dangerous/damaging situation.
Note: The effect will be the same (horn sounds) if the accumulator switch were to
close due to a lack of pressure in that circuit, or if both switches closed together.
Transmission Circuit - Manual

The transmission is shifted using electrical
solenoids. The solenoids are powered via the
manually shifted, dual lever transmission shifter
(shown right).
The left lever (both shift levers shown in graphic to

the right) will select 1st (bottom position) or 2nd
(central position) gear range. 3rd gear range is not
enabled on this unit, and selection is physically
prevented.
The right lever selects reverse (bottom position),

neutral (central position) and forward (top position) directional ranges.
Power to the shift selections (gear and directional ranges) is supplied from the key
switch. Note that any time the key switch is closed there will also be power
supplied directly to the neutral safety switch and reverse contact (RV).
40
When reverse gear is selected, both the reverse solenoid (HV9) and the (RR)
reverse relay are energized. When closed, the ‘RR’ contacts will energize the
reverse strobe light, the audio backup alarm, and the HV30 cable rewind solenoid.
This solenoid shifts a valve spool in the hydraulic system to direct gear pump oil
the cable reel motor, causing it to spool the trailing cable when driving in reverse.
The (NR) neutral relay is used in the electric motor start circuit to prevent motor
start-up when the transmission is in any gear other than neutral.
The gear range selector constantly enables one of the two ranges when on manual.
When the selector lever is in 1st or 2nd position, the appropriate solenoid(s) are
energized, hydraulically enabling the respective gear range.
Transmission Shifting Logic

The transmission design on the unit requires that multiple gear ranges be enabled at
the same time to provide the speed range necessary. Shown on the right is the
transmission spool block layout. Listed below are the shift sequences necessary for
your unit:
Function Solenoid(s) Activated
Neutral NR relay only
Forward, 1st Gear Forward, 1st and 2nd
Forward 2nd Gear Forward, 2nd
Reverse, 1st Gear Reverse, 1st and 2nd
Reverse, 2nd Gear Reverse and 2nd
41
Emergency/Park Brake Circuit

The park brake control is a three-position button that is used to apply and release
the braking system. The park brake button is shown below in the applied position
(no power to any circuits after the button).
The switch is detented when pushed in by the operator, detented in the released
position (button pulled to middle), and spring loaded in the reset position (button
pulled fully up). In the reset position, the spring returns the button to the released
position only.
In the brake circuit, 24V is fed to the brake contact via the 60 psi transmission
pressure switch and the 1300 psi accumulator pressure switch. These switches
ensure those vital systems are functioning in the safe range, before allowing the
brakes to be released (see ABA explanation).
Brakes Released
When the park brake button is pulled up to release the brakes, the upper brake
button contact is closed. This bypasses the normally-open ‘BR’ contacts and
connects power to the (BR) brake relay, the HV2 brake solenoid, and the HV6 steer
cut-out valve.
When the (BR) relay is energized, it closes the normally-open ‘BR’ contacts in the
brake circuit and latches power to the (BR) relay via a new path that bypasses the
brake button. When the brake button is released, it spring returns to the center
42
position (‘B’ in diagram above) and continues to supply power via the ‘BR’
contacts.
The two solenoid valves (HV2 and HV6) are used to shift valve spools in their
respective hydraulic circuits. See the hydraulic system section for more detail.
As the hydraulic pressure in the brake system builds, it will act on the brake
pressure switch and open the brake pressure switch contacts, de-energizing the
‘Brake On’ light.
Brake Test Circuit

The ‘Brake Test’ solenoid is normally energized at all times when the machine is
running. The ‘Brake Test’ button is used to temporarily de-energize the solenoid
valve to test the holding power of the park brake by itself.
ABA Circuit
An Automatic Brake Application (ABA) can occur should a mechanical or
hydraulic failure cause the transmission or brake accumulator pressures to suddenly
drop.
When one (or both) of these monitored switches opens, the current flow through
the brake circuit is broken. This has the same effect as if the operator had pushed
down on the brake button during operation. The (BR) relay loses power and
unlatches the brake circuit. The motor remains running, but if it is shut down, it
cannot be started again until the ABA issue is resolved.
43
FLUID Listed below are the fluids that should be used in the unit. For fill point and level
SPECIFICATIONS check locations, see the following pages.
Component Recommended Fluid Quantity

Transmission Fluid Essotrans-30 18.9 litres
(Trans. only)* (5.0 USG)
Axle Oil Esso Gear Oil 85W-140 14.6 litres [3.0 USG]
Essolube 15W-40 Approx. 102 litres
Hydraulic Oil
(27 USG)
Pivot Point Grease Good quality EP grease As required
Hydraulic Oil (15W-40 oil only)
Electric Fill Pump Control Level sight glasses (side of hydraulic tank)
Transmission Oil (Hydra-Trans 30)
Check Point (dipstick inside access) Fill point (under access cover, rear hood)
44
Greasing Requirements
The daily maintenance procedure includes greasing of certain components. Use
only good quality EP grease to lubricate all pivot points on the unit. All points get
two “shots” per shift from a manual grease gun.
Steer Cylinder Grease Point Mid-ship Grease Manifold
Rear Frame Grease Points(right) Cable Reel Grease Point
Upper Articulation Grease Point Dump Cylinder & Boom Pin Points
Differentials
The planetaries are checked and filled via the plug in each wheel end. Position the
plug horizontally to check the level or fill the wheel ends, downwards to drain the
planetaries. Check/fill the differentials via the plug in the center section of axle
housing.
Note: do not overfill these components. Perform level check/fill with unit on level
ground.
45
PERIODIC This section will outline MTI’s recommended actions for periodic preventative
MAINTENANCE maintenance. Each service period will have its goals outlined in chart form for ease
CHARTS of checking and reading. It is the responsibility of the customer to review and
revise these recommended checks as required based on worksite rules and
regulations.
Recommended service intervals are based on typical working conditions. The

customer’s worksite conditions may influence the frequency of these intervals (i.e.
frequency of element/fluid changes).
Period: Every 8 Service Hours (Daily)

PREVENTIVE MAINTENANCE INSPECTION ORDER
Date: Unit#:
Equipment: ELT-210 Pm type: 8 hours
Date issued: Date completed:
Location: Hour meter reading:
Perform ‘Pre-start Check’ from Operator’s Manual
Item Done by OK or X
Check level / replenish as
System Fluids
necessary
Indicators & gauges Inspect for proper operation
Grease all manifold points and
Greasing
manual grease points
Leaks / damage / loose
components
Proper operation of lights
Bucket damage / wear
Tire wear / pressure - 80 psi
Walk around inspection
Wheel fastener torque 480 lb.fts
Drain fuel/water separator
Check pins and pin guards for
damage / wear / torque /
lubrication
Fire suppression and related
Back-up alarm
Safety equipment (if installed) Seat belt
ROPS and fasteners
Check horn operation
Emergency/Service Brakes Test function before operation
Expander Pin Installations

If an expander-type pin has been replaced the torque needs to be re-checked after 1
hour, 3 hours, 10 hours (or 1 day) and 40 hours (4 days) of operation regardless of
the existing service schedule. After this initial re-checking period, the torque can be
re-checked at regular servicing periods.
46
250 Hour Service

Date: Unit#:
Shift:
Filter list
Stock
Part number Description Quantity
number
See parts manual Hydraulic filter element
See parts manual Return filter element
See parts manual Transmission filter
Note: this information may be from operation and maintenance and/or service
manuals for this machine. Refer to those publications for safety messages,
additional information and procedures to perform these functions.
Utilize lock out procedure, install steering lock & wheel chocks
Ok or
Pre-checks Done by
X-see note
Steam clean complete unit - remove all covers
Inspect unit for any leaks or visible damage
Inspect and test fire suppression
Operator’s compartment
Check seat cushions, suspension and seat belt operation
Seat properly secured
Wire seal is installed on fire suppression actuator
All decals in place
Inspect dash for damage, damaged connections, frayed
or loose wiring
Inspect all switches and gauges
Inspect throttle pedal
Inspect brake pedal
Inspect transmission controls
Dump hoist controls move without interference / boot
in good condition
Inspect steering control / boot in good condition
Horn operation
Does warning system work
Inspect back up alarm operation
Inspect fire extinguisher & bracket
Inspect master switch
47
Start unit (check all fluid levels first)

Before starting, turn key to on position, does horn
sound
Does unit only start in neutral
Does unit only start with brake button applied
Operation of all gauges
Does voltage indicator work
Perform brake test and record results (2nd gear, full
throttle)
Service brake operation
Park brake operation
Brake system, kick in pressure (__________psi) kick
out pressure (___________psi)
Transmission clutch pressure (____________psi)
Pilot pressure (____________psi)
Main hydraulic pressure (________________psi)
Volt meter reading (_________________V)
Articulate unit left (any visual play)
Articulate unit right (any visual play)
Raise / lower boom (any visual play)
Roll and dump bucket any visual play
Transmission clutch pressure (________________psi)
Warning system
Transmission oil pressure: audio/visual
Transmission temperature: audio/visual
Mid ship
Safety decal (pinch point) in place
Wiring harness through mid-ship (damaged or showing
frayed wiring)
Steer stops condition
Mid ship upper has it been greased
Mid ship upper , assembly (record play )
Mid ship lower has it been greased
Mid ship lower assembly (record play)
Tires and planetaries
Check oil level in left/rear planetary –
Check oil level in right/rear planetary –
Check oil level in right/front planetary –
Check oil level left/front planetary –
Check oil in front axle
48
Check oil in rear axle

Check all rim conditions
Condition of tires
Inspect/replace studs/nuts/check torque on all wheels
Frame
Inspect all grease lines and manifolds
Inspect all hoods, hinges and grab handles for damage
Check for body damage, cracks
Inspect bucket and lip for cracks and wear
Check condition and mounting of side cutters
Record bucket size (lip) & condition (bucket # )
L/h_________ c___________ r/h_____________
Inspect boom for cracks (record location)
Inspect boom and bucket - pins & bushings
Inspect frame for cracks (record location)
Inspect oscillation cradle assembly for cracks
Inspect oscillation cradle bolts
Inspect oscillation stops (are they worn)
All protection plates / belly plates installed
Grease complete unit
Drive train
Check axle assembly for leaks & torque axle bolts
Inspect all U-joints for play and bolt tightness
Grease all U-joints
Check hanger bearings for play and bolt tightness
Grease hanger bearing
Grease all drive lines and hanger bearings
Check transmission oil level
Check tightness of transmission mount bolts
Change transmission filter (does oil smell burnt)
Electrical
Check inside of dash for loose or missing parts
Check seal of dash panel
Check for frayed, bare or loose wires
Inspect all switches and connections
Check shift tower controls and wires
Hydraulic
Check all valves for leaks and mountings
Inspect all cylinder for leaks and damage :
Hoist cylinder
49
Dump cylinder
Steer cylinder
Inspect dump cylinder hoses for bursting protection
(nylon/plastic sleeve)
Check dump/steer/hoist cylinder swivel fittings for
leaks
Inspect hydraulic tank for leaks or damage
Replace HP filter element
Replace return filter element
Replace fill filter
General
Check overall appearance of machine
Test drive
Item Work to be done Work done Initial
TRADESPERSON’S SIGNATURE: ______________________DATE:________________
50
500 Hour Service

Date: Unit#:
Shift:
Filter list
Stock
number
See parts manual Hand pump filter
See parts manual Tank breather
See parts manual Clog indicator
See parts manual Axle breather
See parts manual Transmission breather
Note: this information may be from operation and maintenance and/or service manuals for
this machine. Refer to those publications for safety messages, additional information and
procedures to perform these functions.
Utilize lock out procedure: install steering lock & wheel chocks
Ok or
Pre-checks Done by
X-see note
Inspect and test fire suppression
All decals in place
Inspect dash for damage, damaged connections, frayed or
loose wiring
Inspect brake pedal
Dump hoist controls move without interference / boot in good
condition
Horn operation
51

Start unit (check all fluid levels first)
Before starting, turn key to on position, does horn sound
Perform brake test and record results (2nd gear, full throttle)
Brake system, kick in pressure (__________psi) kick out
pressure (___________psi)
Transmission clutch pressure (________________psi)
Pilot pressure (________________psi)
Main hydraulic pressure (________________psi)
Volt meter reading (_________________v)
Do a hydraulic stall test (______________rpm)
Warning system
Transmission oil pressure: audio visual
Transmission temperature: audio visual
Mid ship
frayed wiring)
Steer stops are they in good condition
Take oil sample (any indication of water contamination)
52

Condition of tires l/f____________
r/f____________l/r_________r/r____________
Tire height and groove depth l/f________
r/f__________l/r_________r/r__________
Frame
L/h_____________________
c______________________ r/h______________________
Drive train
Grease all U-joints
Change transmission breather
Ok or
Electrical Done by
X-see note
53

Hydraulic
Take oil sample
Inspect all hosing and replace as necessary
Flow test hydraulic pump:
24 U.S GPM @free flow (+/- 1 GPM)
16 U.S GPM @2400 psi (+/- 1 GPM)
Inspect all cylinder for leaks and damage :
hoist cylinder
Dump cylinder
Steer cylinder
Check dump/steer/hoist cylinder swivel fittings for leaks
Replace fill filter
Cycle times (empty bucket)
Boom raise (4 – 6 sec)
Boom lower (2.5 – 5 sec)
Bucket dump (3 – 5 sec)
Bucket rollback (3 – 5 sec)
Steer left (2.5 – 4 sec)
Steer right (2.5 – 4 sec)
General
Check overall appearance of unit
Test drive
54
TRADESPERSON’S SIGNATURE: _____________________DATE:______________
55
750 Hour Service

Preventive maintenance inspection order
Date: Unit#:
Equipment: ELT 210 Pm type: 750 hours
Shift:
Filter list
Stock
number
Note: this information may be from operation and maintenance and/or service
manuals for this machine. Refer to those publications for safety messages,
additional information and procedures to perform these functions.
Ok or x
Pre checks Done by
see note
Check seat cushions, suspension and seat belt
operation
All decals in place
Inspect dash for damage, damaged connections,
frayed or loose wiring
Inspect brake pedal
Dump hoist controls move without interference / boot
in good condition
56
Horn operation
Start unit (check all fluid levels)
Before starting, turn key to on position, does horn
sound
throttle)
Brake system, kick in pressure (__________psi) kick
out pressure (___________psi)
Transmission clutch pressure
(________________psi)
Pilot pressure
(________________psi)
Main hydraulic pressure
(________________psi)
Volt meter reading
(_________________v)
Warning system
Transmission oil pressure: audio
visual
Transmission temperature: audio
visual
Midship
Wiring harness through mid-ship (damaged or
showing frayed wiring)
Steer stops are they in good condition
57

Take oil sample (any indication of water
contamination
r/f____________l/r_________r/r____________

r/f__________l/r_________r/r__________
Frame
L/h_____________________
c______________________
r/h______________________
Inspect steering pins and bushings
Drivetrain
58
Grease all U-joints

Take sample of transmission oil
Change transmission oil
Ok or x
Electrical Done by
see note
Hydraulic
Top up hydraulic oil as required
Inspect all cylinders for leaks and damage :
hoist cylinder
Dump cylinder
Steer cylinder
Check dump/steer/hoist cylinder swivel fittings for
leaks
Dirty filter indicator/warning is functional
Replace fill filter
Accumulator drain is functional
General
Test drive
59
TRADESPERSON’S SIGNATURE: ____________________DATE:_______________
60
1000 Hour Service

Date: Unit#:
Location: Hourmeter reading:
Shift:
Filter list
Part number Description Quantity Stock number
Note: this information may be from operation and maintenance and/or service manuals
for this machine. Refer to those publications for safety messages, additional information
and procedures to perform these functions.
Ok or x see
Pre-checks Done by
note
Inspect fire suppression system
All decals in place
Inspect dash for damage, damaged connections, frayed or
loose wiring
Inspect brake pedal
Dump hoist controls move without interference / boot in
good condition
61
Horn operation
Start unit (check all fluid levels)
Before starting, turn key to on position, does horn sound
throttle)
Brake system, kick in pressure (__________psi) kick out
pressure (___________psi)
Transmission clutch pressure
(________________psi)
Pilot pressure
(________________psi)
Main hydraulic pressure
(________________psi)
Volt meter reading
(_________________v)
Warning system
Transmission oil pressure: audio visual
Transmission temperature: audio visual
Mid-ship
frayed wiring)
Replace protective cover over wires
Inspect all mid-ship hosing, replace as necessary
Replace protective cover over hosing
62

Replace steer stops
Ok or x see
Tires and planetaries Done by
note
Take oil sample (any indication of water contamination
Change oil level in left/rear planetary –
Change oil level in right/rear planetary –
Change oil level in right/front planetary –
Change oil level left/front planetary –
Change oil in front axle
Change oil in rear axle
r/f____________l/r_________r/r____________

r/f__________l/r_________r/r__________
Frame
L/h_____________________
c______________________
r/h______________________
Inspect hoist pins and bushings
Inspect steering pins and bushings
Drivetrain
63
Inspect park brake caliper for leaks

Inspect park brake disc and replace as necessary
Change brake pads on park brake caliper
Grease all U-joints
Take sample of transmission oil
Ok or x see
Drivetrain Done by
note
Electrical
Inspect all lights
Inspect/test brake impending pressure switch
Front accumulator pressure switch – 1600 psi
Rear accumulator pressure switch – 1600 psi
Transmission pressure switch – 100 psi
Inspect/test brake application (aba) pressure switch
Front accumulator pressure switch – 1300 psi
Rear accumulator pressure switch – 1300 psi
Transmission pressure switch – 60 psi
Hydraulic
Inspect all cylinders for leaks and damage:
hoist cylinder
dump cylinder
steer cylinder
Check dump/steer/hoist cylinder swivel fittings for leaks
64
Dirty filter indicator/warning is functional

Take oil sample
Drain hydraulic tank
Clean inside tank
Replenish tank and prime pump(s)
Flow test hydraulic pump
20 U.S GPM @ free flow (+/- 1 GPM)
16 U.S GPM @ 2400 psi (+/- 1 GPM)
Check pilot pressure (450 psi)
Check and adjust (if req'd) pump standby pressure (400
psi)
Check and adjust (if necessary) pump compensated
pressure (2400 psi)
Check and adjust (if necessary) steer port relief (2000 psi)
Check and adjust (if necessary) boom up port relief (2400
psi)
Check and adjust (if necessary) boom down port relief
(1450 psi)
Check and adjust (if necessary) bucket rollback port relief
(2400 psi)
Check and adjust (if necessary) bucket dump port relief
(1450 psi)
Check pilot accumulator pre charge (90 psi)
Check brake accumulator pre charge (1000 psi, +/- 50 psi)
Cycle times (empty bucket)
Boom raise (4 – 6 sec)
Boom lower (2.5 – 5 sec)
Bucket dump (3 – 5 sec)
Bucket rollback (3 – 5 sec)
Steer left (2.5 – 4 sec)
Steer right (2.5 – 4 sec)
General
Test drive
65
TRADESPERSON’S SIGNATURE: ___________________DATE:________________
66
M AJOR C OMPONENT R EPLACEMENT

The following section provides a general overview on the removal and
installation of major components and assemblies for the unit. For
specific technical information that may be required in addition that
provided here (for example additional torque values for specialty
assemblies/fasteners), contact your MTI representative who can
provide the necessary technical assembly schematics.
The outlines provided in this section will provide only the assembly
and disassembly procedures, for all safety recommendations see the
information provided below and apply the items as necessary to all of
the information provided.
SAFETY AND Safety must be the prime consideration when performing all of the
WORKING procedures listed in the major components replacement section.
PRACTICES General guidelines to be able to perform the tasks safely are listed here;
they are however not all inclusive and must be reviewed and approved
by your sites maintenance/safety departments. It may be necessary to
add to the following items as determined by your site procedures.
Caution! This unit contains elements of high voltage!

Be sure to open both the master disconnect switch and
the mine supply disconnect, and disconnect the trailing
cable prior to beginning any repairs!
» Follow the five step safety system at all times.

» Practice site specific fire prevention practices.
» There are many hot components and systems on the unit; be
aware of their presence and guard against them at all times.
Be aware that many of them (e.g. hydraulic circuits) remain
hot for some time after the unit is shut down and this fact
must be taken into account prior to working on certain
circuits/components.
» Practice site specific lifting practices. Do not lift any items
over 40 lbs (18 kg). Instead use an approved lifting device
with the proper rigging required to perform the lift.
» Many of the procedures listed will require a movable lifting
device to perform them safely. Ensure that you use this
type of lifting device whenever it is required by the task at
hand.
» Properly inspect all lifting devices and rigging prior to their
use. Never use damaged or worn rigging, render them
unusable and dispose of them as necessary.
67
» Always be aware of pinch points and guard against them.

This includes those created when lifting/maneuvering parts
during disassembly/assembly.
» Install mid ship locking bar whenever working in the mid
ship area or when removing any major components.
» Use only proper tools designed to perform the task at hand.
Never use power or hand tools that were not specifically
designed to perform a function, including “home-made”
tools, or tools that have been altered from their original
design.
» Always wear the necessary personal protective equipment
as dictated by the task, including but not limited to; safety
footwear, hardhat, hearing protection, full length
sleeves/legs on your outerwear, and gloves to protect your
hands. Additional items may be required as necessary.
» Never wear loose clothing or jewelry that may be caught in
moving/rotating parts of the unit.
» Use extreme caution when working around moving/rotating
parts.
» Perform repairs with the unit on solid, level ground. Chock
the wheels to prevent movement of the unit.
» If the machine has to be raised off the ground, properly
block underneath the unit in your sites prescribed method.
» Never work or pass under a suspended load.
» Never weld on fluid reservoirs as almost all liquids
contained within are flammable.
» Lock out/tag out/prove all potential sources of energy prior
to beginning a task.
» Deplete/secure all potential energy sources prior to
beginning a task.
» Ensure that personnel are not able to be placed in harm’s
way by any of your actions or work methods.
» Do not allow other personnel into the work area unless
necessary.
» Do not smoke when working with or around flammable
liquids.
» When necessary to perform the task safely, get assistance
from others.
» Tighten all fasteners to the proper torque specification.
Specialty item torque specifications can be obtained from
your MTI representative by requesting the appropriate
assembly schematic.
» Always take the time to ensure that the task can be done
safely! Never sacrifice the safety of yourself or others for
the sake of getting a job done faster.
68
CHANGING THE Note: Be sure to read and fully understand the safety
TRANSMISSION warnings/procedures found at the beginning of this section prior to
performing this procedure!
» Remove any covers over the transmission

» Drain the oil from the transmission sump
» Remove any hoses, cables and hardware that will prevent
you from removing the transmission, match-marking all
hosing and cabling for ease of re-installation
» Disconnect the high speed input shaft from the coupling
» Remove the output drive lines from the transmission
» Disconnect all hydraulic lines from the transmission
» Attach an appropriate lifting device/rigging to the
transmission and support it
» Remove the transmission mounting bolts
» Using the lifting device remove the transmission from the
frame of the machine and set it aside in a clean dry area
Transmission Installation
Note: Be sure to read and fully understand the safety
warnings/procedures found at the beginning of this section prior to
Reverse the removal procedure to install the transmission, paying

attention to the following:
» Remove fittings from the old transmission and install on

new or rebuilt unit prior to installation
» Tighten all fasteners to the proper torque specifications
» Install new gaskets and seals as necessary
» When installing hydraulic hoses and lines make sure no dirt
gets into system and tighten fittings to specs
» Install new filters and fill unit with fresh oil of the proper
grade and type
» Start and test drive unit and check for leaks prior to
returning the unit to service
» Recheck mount bolt and drive line fastener torque after a
few hours of operation
69
CHANGING AN Note: Be sure to read and fully understand the safety

ELECTRIC warnings/procedures found at the beginning of this section prior to
MOTOR performing this procedure!
It will be necessary to have an electrician qualified to work on high

voltage circuits to perform the electrical aspects of the following
procedure:
» Remove any covers over the electric motor

» Disconnect the power supply cables connected to the
electric motor
you from removing the electric motor, match-marking all
hosing and cabling for ease of re-installation
» Disconnect the high speed output shaft from the coupling
» Attach an appropriate lifting device/rigging to the electric
motor and support it.
» Remove the electric motor mounting bolts
» Using the lifting device remove the electric motor from the
frame of the machine and set it aside in a clean dry area
Electric Motor Installation

It will be necessary to have an electrician qualified to work on high

voltage circuits to perform the electrical aspects of the following
procedure:
Reverse the removal procedure to install the electric motor, paying

» Tighten all fasteners to the proper torque specifications

» Install new gaskets and seals as necessary
» When installing hydraulic hoses and lines make sure no dirt
gets into system and tighten fittings to specs
» Reconnect the high voltage supply cable
» Be sure that the motor phase is correct prior to testing the
unit
» Start and test drive unit and check for leaks prior to
returning the unit to service
» Recheck mounting bolt torque after a few hours of
operation
70
CHANGING A Note: Be sure to read and fully understand the safety

DRIVELINE warnings/procedures found at the beginning of this section prior to
performing this procedure! Care must be taken when detaching a
driveline as it may be under tension from the drive train. The unit may
move, or the driveline/attached component may turn causing a safety
hazard!
During this procedure, the ELT-210 should be on level

ground and have the wheels chocked.
If the driveline to be removed has access only from

below, raise the unit using an appropriate method and
block up the unit properly.
» Remove any covers required for access to the driveline to

be removed
» If the driveline is heavy enough to warrant, support it using
an appropriate lifting device
» First loosen all of the driveline bolts at both ends, then fully
remove the bolts from one end only
» Ensure the driveline is properly supported and cannot fall
(either by a lifting device, yourself, or a partner) and then
perform the next item
» Using an appropriate pry bar, collapse the driveline
sufficiently to clear the yoke from the component it
attaches to
» Remove the remaining driveline bolts from the end that
remains connected
» Remove the driveline from the machine and set it aside in a
clean dry area
Driveline Installation
Note: If the driveline is a two-piece unit observe the phasing (See

illustration below) before installing it in place (yokes should match
position from end to end).
Reverse the removal procedures to install driveline paying attention to

the following:
» Check U-joints for wear or damage and replace if necessary

» Check splined slip joints for wear or damage and replace if
necessary
71
» It may be necessary to start the unit, release the brakes, and

turn either the transmission or axle assembly to re-align the
driveline to both components while re-installing. Do not,
however, alter the phasing of the driveline to accomplish
this
» Start and test drive unit prior to returning the unit to service
» Recheck mounting bolt torque after a few hours of
operation
HYDRAULIC warnings/procedures found at the beginning of this section prior to
PUMP performing this procedure!
» Drain the hydraulic reservoir into a suitable container and

discard the used fluid
» Remove any covers over the pump
» Mark or note the pump orientation prior to removal
you from removing the pump, match-marking all hosing
and cabling for ease of re-installation, including those
connected to the pump itself
» Attach an appropriate lifting device to the pump using the
proper rigging
» Remove the hydraulic pump mounting bolts
» Work the pump evenly off the mounting flange. It may be
necessary to use a pry bar to accomplish this, taking care
not to damage the flange or pump face
» Lift the pump from the unit and set aside in a clean dry area
» If a drive coupling is used to adapt the pump to the driving
shaft in the transmission, ensure it remains with the
transmission
» Clean the pump mounting surface, taking care that dirt or
debris do not enter the transmission opening
» Inspect the transmission housing for cracks or for any sign
of damage
72
» Remove the hydraulic reservoir access cover(s) and

thoroughly clean the inside of the reservoir. Once cleaned,
replace the cover(s) using new seals.
Hydraulic Pump Installation

Reverse the removal procedures to install the pump paying attention to

the following:
» Replace mounting seals as necessary and take care to

prevent damage to them during installation
» Ensure the splines on the shaft and opening are clean and
free of burrs or other damage. Lubricate the splines with an
appropriate lubricant
» Ensure the pump is installed to same orientation as the one
removed
» Replenish the reservoir with clean fresh fluid of the proper
type and grade
» Once all hosing is reconnected (and reservoir is full), flood
the pump housing with hydraulic fluid prior to start up
» Connect a flow meter to the pump prior to start up (see
“flow testing piston pumps with load sense” in the
hydraulic section of this manual). Open the metering screw
fully to allow free flow to the reservoir so pump initially
runs under a no-load condition, and is able to clear any air
bubbles trapped in the inlet hosing
» Perform a flow test; remove flow meter and reconnect
hosing
» Start and test drive unit prior to returning the unit to service
FRONT AXLE warnings/procedures found at the beginning of this section prior to
» Raise the front of the machine with an appropriate lifting

device, until the wheels are off the ground, and install
support stands or blocking under the frame of the machine
» Raise the boom approximately half way, support it with
proper stands and roll the bucket out fully until the cylinder
bottoms out
» Remove the wheels from the front axle, place them aside in
a secure position
» Drain the oil from the wheel ends and differential housing
73
» Remove any brake lines from the wheel ends and install
match-marked caps and plugs to prevent dirt entry and to
ensure proper replacement position
» Remove the disc brake caliper from the front driveline
» Remove the front drive line universal joint fasteners from
the front differential yoke, and collapse the driveline
sections
» Support the front axle with an appropriate lifting device
and rigging
» Remove the axle mounting bolts, ensuring you do not place
yourself beneath the suspended axle
» Lower the axle to the ground
» Pull the axle out from under the machine, exercising
caution not to disturb the supports
» Transfer all hardware to the replacement axle prior to its
installation
Front Axle Installation

Reverse the removal procedures to install the front axle paying

» Ensure mounting faces are clean and damage free

» Always replace axle mounting fasteners with new ones
» When installing mount bolts be sure to install hardened
washers and compression tubes
» Ensure no dirt entry when re-installing hosing
» Refill wheel ends and axle assembly with clean fresh fluid
of the proper grade and type
» Test drive unit, check for leaks and perform a brake test
prior to returning unit to service
REAR AXLE warnings/procedures found at the beginning of this section prior to
Raise the rear of the machine with an appropriate lifting

device, until the wheels are off the ground, and install
support stands or blocking under the frame of the
machine
» Remove the wheels from the rear axle, place them aside in
a secure position
» Drain the oil from the wheel ends and differential housing
74
» Remove any brake lines from the wheel ends and install
match-marked caps and plugs to prevent dirt entry and to
ensure proper replacement position
» Remove the rear drive line universal joint fasteners from
both ends, collapse the driveline and remove it completely
» Support the rear axle with an appropriate lifting device and
rigging
» Remove the front retainer plate bolts and remove the
retainer and O-ring
» Remove the rear end cap bolts and remove the end cap and
O-ring
» Remove the trunnion mounting bolts, ensuring you do not
place yourself beneath the suspended assembly
» Lower the assembly to the ground
» Pull the assembly out from under the machine, exercising
caution not to disturb the supports
» Remove the old cradle bushings and thrust washers
» Inspect the bearing load area for any damage or wear,
replace components as necessary
» Transfer all hardware to the replacement axle prior to its
installation
Rear Axle Installation

Reverse the removal procedures to install the rear axle paying attention
to the following:
» Lubricate all friction surfaces with EP grease prior to

assembly
» Ensure mounting faces are clean and damage free
» Install the front and rear cradle bushing in place along with
the O-rings. Note: ensure that the rear cradle sleeve is
installed on the rear side
» Install the axle in place and align the cradle bushings in
place, along with the inner thrust washer and O-rings
» Install the trunnion cradle supports, bolt and torque them in
place
» Install the front retainer plate bolts and the retainer and O-
rings
» Install the rear end cap, end cap bolts and O-rings
» Always replace axle mounting fasteners with new ones
» When installing mount bolts be sure to install hardened
washers
» Ensure no dirt entry when re-installing hosing
75
» Refill wheel ends and axle assembly with clean fresh fluid
of the proper grade and type
» Lubricate the oscillating bushings with EP grease prior to
operating unit
CHANGING AN Note: Be sure to read and fully understand the safety

ACCUMULATOR warnings/procedures found at the beginning of this section prior to
» Shut down the unit and tag it out

» Release hydraulic pressure in the cylinders
» Drain the accumulator hydraulic pressure by opening the
accumulator drain valve(s)
» Remove the accumulator service valve protector cap.
» Discharge the accumulator gas completely by depressing
the service valve (Schrader valve) with a blunt tool, taking
care not to damage the service valve
» Reinstall the accumulator service valve protector cap
» Disconnect the hydraulic hose from the accumulator.
Note: Be careful when removing the hose. It may still have residual
hydraulic pressure.
» To remove the hose safely, unscrew the fitting about 2

turns and wiggle the hose to let any remaining pressure to
escape.
» Cap the hose and the accumulator port.
» Remove the accumulator mounting bolts
» Remove the accumulator off the mounting bracket.
Accumulator Removal
Reverse the removal procedures to install the rear axle paying attention
to the following:
» If the accumulator has been pre-charged prior to installing

(not recommended), handle it with extreme caution as it
constitutes a pressurized vessel and must be handled as
such
» Take care not to over tighten the mounting bolts as this
may cause undue stress on the accumulator body
76
» Once in place, with the hosing attached it will be necessary

to pre-charge the accumulator (see “accumulator charging”)
Accumulator Charging
A basic charging station consists of a bottle of dry nitrogen and a gauge

set and an adapter to connect to the accumulator service valve.
Note: Use care handling the dry nitrogen bottle as it stores gas under
high pressure!
» The charging station should be placed as close to the unit as

possible without hampering work efforts. Attach the gauge
set to the bottle
» Turn the gauge set adjusting handle counter clockwise until
the spring tension is completely release
» Remove the accumulator service valve protective cap
» Install the charging station adapter on the accumulator
service valve
» Turn the adapter handle clockwise completely
» This action will open the accumulator service valve
» Open the dry nitrogen bottle valve clockwise
» Verify on the gauge set sufficient gas in the bottle before
proceeding
» Turn the gauge set adjusting handle clockwise slowly until
the line pressure gauge shows the desired pressure
» Turn the adapter handle counter clockwise completely
» This action will close the accumulator service valve
» Shut off the dry nitrogen bottle valve by turning the bottle
valve counter clockwise
» Turn the gauge set adjusting handle counter clockwise until
the spring tension is completely released
» The line pressure gauge will show 0 psi
» Remove the charging station adapter carefully from the
accumulator service valve
Note: After removing the adapter off the accumulator service valve,
turn the gauge set adjusting screw handle clockwise about 1/2 turn to
release the gas pressure in the gauge set.
» Reinstall the service protective cap on the service valve

» Recheck the accumulator gas pre-charge (see “checking the
accumulator pre-charge”)
Checking the Accumulator Pre-charge
77

To test the accumulator gas pre-charge, follow this procedure:
» Start the unit

» Allow the unit to charge the accumulator to it maximum
hydraulic pressure
» Shut the unit down
» While observing the accumulator hydraulic gauge,
carefully open the accumulator drain valve until a slow,
steady drop in pressure is observed
» Continue to adjust the drain off rate of descent so that the
slow, steady drop is observed
» The pressure will suddenly drop to 0 PSI at a certain point
» The last reading before the sudden drop to 0 is the nitrogen
pre-charge (+/- 100 PSI if the procedure is followed
properly)
FRONT FRAME warnings/procedures found at the beginning of this section prior to
Items stating “optional, may not be necessary” will only have to be

removed if defective or if your lifting device is not rated for the fully
assembled front frame.
When separating the frames, ensure the opposite frame is not caused to
move or serious injury may occur.
» Raise the front frame off the ground and place on stands or
blocking.
» Remove the front tires
» Remove the bucket using the bucket removal procedure
(optional, may not be necessary)
» Remove the boom using the boom removal procedure
(optional, may not be necessary)
» Remove the hoist cylinders (optional, may not be
necessary)
» Remove the front axle (optional, may not be necessary)
» Remove the mid ship driveline.
» Disconnect the steering cylinder at the rod end.
» Disconnect all hydraulic hosing at mid ship using match-
marked caps and plugs to prevent dirt entry and to facilitate
proper installation position
78
» Disconnect any cabling that runs through the mid ship

match larking them to ensure proper installation position
» Attach an appropriate lifting device and rigging (capable of
lifting and moving the front frame) to the front frame and
support it
» Remove the stands or blocking from under the front frame
» Remove mid-ship lock bar
» Remove the top and bottom hinge pins using the proper
tools
» Separate the front and rear frames
» Place the front frame on blocks so that it is secure
Front Frame Installation

Items stating “optional, may not be necessary” during removal will

only have to be re-installed if they were originally removed.
When joining the frames, ensure the opposite frame is not caused to
move or serious injury may occur.
Reverse the removal procedures to install the front frame paying

» Brakes must be bled prior to operating unit

» Ensure all torque specifications are adhered to
» Re-tighten/torque all fasteners after 8 hours of operation
» Check all hydraulic functions prior to operating unit
79
CHANGING Upper Articulation Pin Procedure

ARTICULATION
PINS Note: Be sure to read and fully understand the safety
It is very important to observe safety rules and work safely when

changing the mid-ship bushings because the frames are very heavy and
bulky. Be sure the machine you are working on is properly blocked,
tagged and secured according to your company's standard safety
procedures and policies. Always use approved slings and lifting devices
whenever lifting components and never go under a suspended load. The
proper gloves should always be worn when working with slings.
Safe Working Procedures

» The frames are heavy and bulky. Handle with care and with
the proper lifting devices.
» Park the unit with the boom and the bucket at ground level.
» Shut the engine off and turn the master switch off.
» Tag and chock the machine according to the shop
procedures.
» Install the mid-ship steering locking bar.
» Secure the front and the rear frame on blocks properly
according to your shop blocking procedures.
Pin Removal
» Remove HHCS, washer and lock nut.
» Drive pin clear of bore connections.
Pin Installation
» Shrink fit bushings (items 2 & 7) into pin bores in rear
frame.
» Install sleeve (item 3) into front frame.
» Install spherical bearing (item 4) into sleeve in front frame.
» Marry frames together lining up top and bottom bores.
» Select appropriate shims to center cylinder lug into frame,
providing a vertical movement of 0.0625".
» Install the pin (item 1) through the aligned bores. Note: The
retainer bolt (item 9) is shown out of position on this
drawing.
» Install the retainer bolt (item 9), washers (item 8) and lock
nut (item 10). Anti-seize the entire length of the bolt,
including threads. Use new washers only.
» Torque locknut to 55 ft./lbs.
» Install grease fitting and lubricate with 'E.P. Grease'.
80
Check the Articulation Operation

» Remove the mid-ship lock bar.
» Start machine and steer from left to right to check for
proper steering function.
» Raise and lower the boom to check for proper boom
operation.
» Tilt and dump the bucket to check for proper operation of
the dump cylinder.
» Perform brake test as per manufacturers recommended
procedures.
» Check operation of front lights and any other electrical
functions.
» Check for any fluid leaks.
Lower Articulation Pin Procedure

It is very important to observe safety rules and work safely when
changing the mid-ship bushings because the frames are very heavy and
81
bulky. Be sure the machine you are working on is properly blocked,

tagged and secured according to your company's standard safety
procedures and policies. Always use approved slings and lifting devices
whenever lifting components and never go under a suspended load. The
proper gloves should always be worn when working with slings.
Safe Working Procedures

» The frames are heavy and bulky. Handle with care and with
the proper lifting devices.
» Park the unit with the boom and the bucket at ground level.
» Shut the engine off and turn the master switch off.
» Tag and chock the machine according to the shop
procedures.
» Install the mid-ship steering locking bar.
» Secure the front and the rear frame on blocks properly
according to your shop blocking procedures.
Pin Removal
» Remove HHCS, washer and lock nut.
» Drive pin clear of bore connections.
Pin Installation
» Shrink fit bushings (items 2 & 7) into pin bores in rear
frame.
» Install sleeve (item 3) into front frame.
» Install spherical bearing (item 4) into sleeve in front frame.
» Marry frames together lining up top and bottom bores.
» Select appropriate shims to center cylinder lug into frame,
providing a vertical movement of 0.0625".
» Install the pin (item 1) through the aligned bores. Note: The
retainer bolt (item 9) is shown out of position on this
drawing.
» Install the retainer bolt (item 9), washers (item 8) and lock
nut (item 10). Anti-seize the entire length of the bolt,
including threads. Use new washers only.
» Torque locknut to 55 ft./lbs.
» Install grease fitting and lubricate with 'E.P. Grease'.
82
Check the Articulation Operation

» Remove the mid-ship lock bar.
» Start machine and steer from left to right to check for
proper steering function.
» Raise and lower the boom to check for proper boom
operation.
» Tilt and dump the bucket to check for proper operation of
the dump cylinder.
» Perform brake test as per manufacturers recommended
procedures.
» Check operation of front lights and any other electrical
functions.
» Check for any fluid leaks.
83
BOOM warnings/procedures found at the beginning of this section prior to
» Raise the left front frame off the ground and place on
stands or blocking.
» Remove the left front tire
» Remove the bucket dump cylinder
» Raise the boom and support with a suitable lifting device
and rigging
» Remove the boom to hoist cylinder
» Retract the hoist cylinders
» Lower the boom and reposition the rigging so the boom can
be lifted evenly
» Remove the main boom pin
» Lift the boom from the unit and set aside in a safe area
» Clean up all pins, bushings and hardware to be re-used
Boom Installation
Reverse the removal procedures to install the boom paying attention to

the following:
» Ensure all fasteners are properly torqued

» Take care that all bores are properly aligned prior to
installing pins to prevent damage to them
» Test drive unit and check for leaks prior to returning unit to
service
BUCKET warnings/procedures found at the beginning of this section prior to
Removing the bucket

» Position unit so bucket lip just touches ground and it is
supported at the machine end by blocking
» Support the dump cylinder using a suitable lifting device
and rigging.
» Remove the dump cylinder rod end pin
» Fully retract the dump cylinder, then lower it to the
machine frame
» Remove the lower boom pins from the bucket
84
» Start unit and carefully back it away from the bucket, or

attach a suitable lifting device and rigging to the bucket and
lift it from the boom
» Clean up all bores, pins and hardware to be reused
Bucket Installation
» Reverse the removal procedures to install the bucket

service
HOIST warnings/procedures found at the beginning of this section prior to
CYLINDER performing this procedure!
Removing the hoist cylinder

» Raise the left front frame off the ground and place on stand
or blocking
» Remove the boom using the boom removal procedure
» Support the hoist cylinder with a suitable lifting device and
rigging
» Remove the hydraulic hosing from the cylinder
» Remove the hoist cylinder lower pin
» Carefully lift the hoist cylinder from the unit and set aside
in a safe area
OR
» Raise the left front frame off the ground and place on stand
or blocking
» Raise the boom high enough to facilitate hoist cylinder
removal and place on appropriate stands
» Roll the bucket out fully so that it cannot drop
» Support the hoist cylinder with an appropriate lifting device
and rigging
» Remove the rod end hoist cylinder pin and retract the
cylinder
» Remove the barrel end cylinder pin
85
» Lift the unit carefully from the frame and set aside in a safe
area
Hoist Cylinder Installation

» Reverse the removal procedures to install the hoist cylinder

service
DUMP warnings/procedures found at the beginning of this section prior to
CYLINDER performing this procedure!
» Position the unit so the bucket lip is on just touching the

ground and the machine end is supported on blocking
» Attach a suitable lifting device and rigging to the dump
cylinder and support it
» Remove the rod end pin from the d\ump cylinder
» Fully retract the dump cylinder
» Remove the barrel end pin from the cylinder
» Carefully lift the cylinder from the unit and set it aside in a
safe area
Dump Cylinder Installation

» Reverse the removal procedures to install the dump

cylinder
service
CHANGING THE Warning: Use of anti-seize lubricant on tapered cone surfaces or on

ELECTRIC bolt threads when mounting may result in damage to sheaves and
MOTOR sprockets. This voids all manufacturers’ warranties!
COUPLING
86
Installation
» Clean all oil, dirt, and paint from shaft, bushing bore,
outside of bushing and component (sprocket, sheave…etc.)
bore.
» Insert bushing into component. Match the hole pattern, not
the threaded holes (each hole will be threaded on one side
only.)
» Oil set of cap screws and thread into those half-threaded
holes indicated by O on diagram. Mount assembly on shaft.
» Alternately torque set of cap screws* to recommended
torque setting in chart below.
» On larger bushings, use a block, sleeve or drift and hammer
large end of bushing (do not hammer bushing directly).
» Repeat torqueing and hammering until torque wrench
reading, after hammering, is the same as before
hammering.
» Fill all unoccupied holes with grease.
Removal
» Remove all set or cap screws.
» Insert set or cap screws in holes indicated by ● on diagram.
Loosen bushing by alternately tightening set or cap screws.
» To reinstall, complete all installation steps.
Recommended Torque Table

Bushing Set or Cap Screw Wrench Torque (in. /lbs.)
A 1/4-20 Socket Set Screw 55
3/8-16 Socket Set Screw 175
B 7/16-14 Socket Set Screw 280
C 1/2-13 Socket Head Cap Screw 1000
5/8-11 Socket Head Cap Screw 1700
3/4-10 Socket Head Cap Screw 2450
D 7/8-9 Socket Head Cap Screw 3100
1 ¼-7 Socket Head Cap Screw 7820
1 ½-6 Socket Head Cap Screw 13700
*If two bushings are used on the same component and shaft, fully tighten one bushing before working
on the other.
87
O PTIONAL E QUIPMENT
In this section you can find service information on some of the major
options purchased with your particular ELT-210 unit. Further
breakdowns of individual parts can be found in the accompanying Parts
manual. More detailed operating instructions can be found in the
appropriate section of the Operator’s manual.
FIRE The unit is equipped with a fire suppression system capable of

SUPPRESSION extinguishing any fire that might start on the unit. The system
SYSTEM distributes a fire suppressant dry chemical onto the machine when set
off by the operator. Distribution of the fire suppressant is done through
a series of hoses, manifolds and nozzles. The suppressant is discharged
when the operator, or nearby personnel depresses one of two actuators
on the machine. Nozzle placement is specific. Areas that are
traditionally considered a fire risk are protected. These areas include
the engine compartment, disc brake area and around the transmission.
Example only, actual unit/components/system may not be exactly as

shown
88
The operator removes the safety pin from the remote/dash actuator (1)
and strikes the actuator button to puncture the actuator gas cartridge.
This allows nitrogen to pressurize the propellant cartridge actuator /
receiver (2). The propellant cartridge actuator/receiver punctures the
propellant cartridge (4) seal. This releases high pressure nitrogen gas
into the chemical suppressant canister (5).
This causes the high-pressure nitrogen to mix with the suppressant

powder and makes it fluid enough to flow though the hoses. The
bursting disc at the discharge union (6) holds the mixture in the tank
until the pressure is high enough to burst the disc. This allows the
suppressant/propellant mixture into the distribution hoses to the nozzles
(7). At the nozzles, the pressure forces the packing grease or plastic
caps off the nozzles and spreads the fire suppressant chemical
throughout the machine.

shown
Main Components
Most fire suppression systems are very similar to one another. This
machine carries the standard compliment of fire suppression equipment
for a machine its size. The system uses a manual trip or actuation
system. There are no forms of automatic system actuation
employed on the UNIT. Components that are installed are:
89
Dry Chemical Tank
Main propellant (nitrogen) cartridge
Manual actuators (2)
Nozzles
Hoses, Lines and Tees
Dry fire suppressant chemical (powder form)
Examples only, actual unit/components/system may not be exactly as

shown
Main Suppressant Tank

The fire suppressant powder is stored in a large tank. This tank is
normally at or near atmospheric pressure. The tank is only pressurized
when the system is activated. Because the suppressant is a powder and
is discharged from the system under pressure, the tank is sealed from
the atmosphere by a screw on cap with an O-ring seal. The tank‘s role
is to ensure that the suppressant is free of moisture until it is used.
There are only two ports on the tank; an inlet for the propellant gas and
a large discharge port at the bottom to allow the suppressant out into
the distribution hoses.
90

shown
Actuators
The main actuator pierces the seal of the main discharge cartridge. It is
operated by high-pressure gas from the dashboard or remote actuators.
The dashboard and remote actuator are operated by hand. They work in
a similar manner to the main actuator. The operator strikes the button
the top of and pierces the seal on the remote actuator cartridge. The
pressurized gas from one of these actuators is used to operate the main
actuator. Note that the dashboard and remote actuators are protected
from accidental tripping by a safety pin. The pin must be removed
before the button can be depressed.

shown
Nozzles
91
The nozzles are the responsible for directing the suppressant at areas at
risk of fire. The nozzles produce a fan shaped discharge pattern that
effectively blankets the machine with chemical suppressant in the event
of a fire. Keeping the nozzles clean is very important and you will find
that they are either packed with special grease or capped with a plastic
cap to prevent the entrance of dirt. See Maintaining the Fire
Suppression System for more details.

shown
Hoses and Lines

To ensure proper performance of the fire suppression system, the
correct type and size of must be used. The UNIT is equipped with
special fire suppression hose, which is similar to hydraulic hose. Hoses
that are used in the fire suppression system are colored red for easy
identification. It also signifies that it is a special type of hose. Care
must be taken when replacing or moving the hoses to ensure that they
have the proper minimum bend radius, are not too long and are not
crushed or kinked in any way.
92
Daily Inspection
The fire suppression system must be inspected daily as part of the pre-
operative walk around inspection. This will ensure that the system is
operable for your shift and will give proper protection for you and the
machine. The inspection is similar to a bi-weekly or monthly
inspection. DO NOT OPERATE THE UNIT IF THE FIRE
SUPPRESSION IS NOT IN WORKING ORDER!
Check all components for physical damage
Check nozzles for damage and blockage
Check hose routing
Make sure safety pins are in place and easy to remove

shown
Response to the Fire

In the event of a fire, you, as the operator will want to react as quickly
as possible. How fast you react to the fire and the order in which you
93
perform the actuation procedure will greatly affect the amount of

damage to the machine and possible injury to yourself and surrounding
personnel.
When a fire starts follow these steps

Shut the machine down as quickly as possible. This will prevent fuel or
oil from being added to a hot area, which will re-ignite the fire.
Remember don’t try to park the machine first, shutting down will
automatically park the machine.
Break the pin seal.
Pull the safety pin from the dashboard or remote actuator and strike the
actuator button with just enough force to pierce the gas cartridge seal.
Once the fire suppression system has discharged evacuate the machine
as quickly and safely as possible. When you leave the machine take the
portable fire extinguisher with you in the event the fire re-ignites.
Watch the machine from a safe distance until the risk of fire has
diminished. This may take up to an hour for the unit to cool to a point
where the fire will not restart. At this time you may leave the machine
to report the fire.
94

shown
Note that if the fire suppression does not activate from the actuator
used, it is permissible to try the other actuator only if it is safe to do so.
Remember if the machine is one fire, the actuators are not reachable or
the fire suppression system fails your life is not worth risking saving
the machine. Fight the fire in a safe manner with approved methods or
let the unit burn.
What to Expect
When discharging the fire suppression system in the event of a fire, you
must be aware of what is going to happen and how soon it is going to
happen. When you shut the machine down, be prepared for automatic
brake application (ABA). If you aren’t prepared you could possibly be
injured. When you actually discharge the fire suppression system, there
will be a popping sound followed by a loud hiss as the suppressant is
forced through the hoses and nozzles.
Be prepared to fight the fire with the portable extinguisher taken from
the machine. Although re-ignition or system failure is fairly unlikely it
is a possibility. When the system discharges the suppressant it will be
in the form of yellowish cloud that will surround the machine.
Although the suppressant is not toxic, try not to inhale any more
suppressant than necessary, as it is unpleasant. Note that you should
never attempt to operate a machine that has just been on fire as the risk
of equipment damage or personal injury will be very high.
Cleaning the Machine after Discharge

After a fire the unit must be completely cleaned and serviced.
Remember the suppressant chemical powder is very fine and permeates
almost everything on the machine. The suppressant will easily wash off
the UNIT with a pressure washer. Make sure after a fire to replace all
damaged components and change all affected fluid levels and their
respective filters. Also be sure to replace the air filter cartridge and
thoroughly clean out the air filter canister.
Maintenance
Just like any other major component of the machine, the fire
suppression system must have regular maintenance performed on it.
Because of the nature of the mining environment and the nature of the
fire suppression system, it must be carefully taken care of to ensure it
will function as designed if it is ever needed. Regular maintenance
must be performed on the nozzles, suppressant canister, main
propellant cartridge, and actuator cartridges.
Maintaining the Suppressant Canister
95
Because the chemical fire suppressant is a fine powder it is subject to

settling, packing and moisture. When tramming the unit, the
suppressant is constantly being shaken and settles into a hard packed
cake at the bottom of the canister. Maintenance of the canister is simple
and should be done at least once every two weeks. Visually inspect the
canister for damage. Remove the lid and check the seal for cracks or
other damage and replace if necessary. Using a clean, dry tool, break
the suppressant up into a power. Be sure there are no clumps. If the
suppressant will not break down into a powder easily replace it.
Reinstall the lid so it is sealed but not over tighten.

shown
Maintaining the Propellant and Actuator Cartridges

There is little maintenance needs on the gas cartridges used for the
actuators and propellant. Whenever the fire suppression system is
serviced, remove the cartridges clean and weight them. If the measured
weight is equal to that stamped on the cartridge, it is ok to reuse. If the
weight lower than indicated on the cartridge, the cartridge must be
replaced. Note that special scales must be used to measure the cartridge
96
weights to ensure accuracy. Also inspect the seal in the actuator for
damage and make sure there is light coating of grease on the seal.
Maintaining the Nozzles

The nozzles must be maintained with the rest of the system. To ensure
that the nozzles are kept clean and unblocked the outlets are filled with
a special grease or plastic cover. The grease is specially designed to
come out of the nozzle when the system is discharged. This grease
should be inspected to make sure it is present and has not hardened.
Occasionally the grease should be replaced with the correct special
purpose grease. If plastic caps are used, make sure they are in place and
can come off the nozzle easily. Clean the nozzle and replace cap as
necessary.
Example only, may not be exactly as shown
Maintaining the Hoses, Lines and Fittings

The fire suppression
system uses many different
hoses, lines, fittings and a
couple of check valves.
These parts require very
little maintenance. A
general visual inspection of
these parts for damage,
kinks, twists, splits, cracks,
etc. is all that is necessary.
If any of these components
are damaged, repair or
replace them as required.
Example only, actual

unit/components/system
may not be exactly as shown
97
Recharging the System

After the fire suppression system has been discharged and the unit has
been repaired, the fire suppression system must be recharged. These are
the steps that must be taken:
Pull safety valve open to relieve residual pressure in the system.
Remove the bursting disc union and replace bursting disc (flat side to
the dry chemical canister).
Fill the suppressant canister with the mount of Foray dry chemical
listed on the ID tag.
Inspect the canister lid, gasket and threads. Put a light coating of heat
resistant grease on the gasket and reinstall the lid hand tight.
Remove the propellant cartridge guard and propellant cartridge. Make

sure the pneumatic actuated piercing pin is fully retracted. Weigh and
install a new cartridge and the cartridge guard.
If in doubt if all of the chemical powder was expelled from the hoses,
you may use compressed air to blow them clean from the discharge
fitting at the suppressant canister. Note: This should be done before
washing the unit for repair.
Pack the nozzle openings with the special silicone grease or replace
protective plastic caps as required.
Retract the dash and remote actuator piercing pins as required and
install safety pin. Weigh and install new cartridges as needed. Weigh
unused cartridge to determine serviceability and reinstall or replace as
required.
Recheck entire system to make sure that no steps were missed or

overlooked.
98
EJECTO This unit is equipped with an Ejecto bucket. The Boom/Hoist joystick
BUCKET comes equipped with a rocker switch which is used to energize the
OPTION ejecto solenoid valves (HV7A and HV7B). These valves are used to
shift the control spool of the ejecto working section in the main control
valve.
Pushing and holding the eject or retract button will energize the
appropriate solenoid. The ejecto spool will shift to connect oil from the
pump to the ejecto cylinders while connecting return oil back to tank.
The cylinders will move the ejecto mechanism inside the bucket.
99

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For machine s/n: 14-4507, 14-4508, 14-4509, 14-4510

High Voltage Warning!

High Voltage Warning!

Park Brake Circuit (Brake Test) ...................................................................................................31

Major Component Replacement .......................................................................................66

Optional Equipment ...........................................................................................................88

ISO Mining Technologies International Inc. (MTI) operates a Quality Management

» The registration covers the Quality Management System for the

For certification details see the ISO Certificate of Registration.

SERIAL The serial number plate includes the following information:

1 – Dump Cylinder 2 – Operator’s Area and Controls 3 – Bucket

The unit features an all-mechanical drive, with a torque converter integral to a

Terms Used In This Manual

To properly orient to position references in this manual, we refer to the unit as

» The front of the unit is the bucket end

» General safety knowledge;

SAFETY Improper operation, maintenance, lubrication or repair of this product can be

Personal Protective Equipment

Warning: Never wear loose

Be alert of possible high pressure fluids/gases when disconnecting components

Warning: NEVER use your bare hands to inspect hosing for

Hot Fluids and Parts

» Park the machine as per worksite regulations. Ensure vehicle is not in

» Exit the operator’s area. Install the articulation lock bar.

Accessing the Unit

» Attach the proper warning tag when working on the machine.

» Inspect the machine daily for potential fire hazards.

» Use only non-flammable cleaning agents for cleaning the machine or

Important Machine Operation Safety Procedures

» Be aware of trailing cable position at all times. Ensure it does not

Undesirable Operating Practices

Common Causes of Injuries from Pinch Points*

Safety Controls for Pinch Points*

A temperature sender supplies the transmission temperature gauge with a reading

Transmission Cooling Circuit

Servicing the Transmission Cooler

Changing the Transvertor Oil/filter

Drain and Filter Change Procedure

Converter outlet pressure is determined by the total pressure rate of production of

DO NOT ATTEMPT THESE CHECKS WITH COLD OIL

Hold stall until desired converter outlet temperature is reached.

CAUTION: FULL THROTTLE STALL SPEEDS FOR AN

Hydraulic System Settings

Hydraulic Pump Description and Operation

1. Pump housing 2. Cylinder barrel 3. Piston and slipper shoes

Flow testing piston pumps with load sense

» Lower bucket and boom to rest bucket on floor.

» Back out flow restrictor valve all the way.

Theoretical Flows Actual Flows  1 GPM theoretical

Because the most common introduction of contaminates to a hydraulic system is

Load Sense Circuit

Example circuit only

Pilot Pressure Supply Circuit

Cable Reel Circuit

Because it is a constant displacement pump, there is constant flow and a need to

Pilot Valves and Functions Circuits

Brake Pressure Supply Circuit

is not being demanded, and a connection to a set of pressure switches via a

Park Brake Circuit (Brakes Applied)

Park Brake Circuit (Brake Test)

Park Brake Circuit (Brakes Released)

Testing the Accumulators

Brake Test Procedures

If the test fails, do not operate the machine!

TRADESPERSON’S SIGNATURE: ______DATE:

TRADESPERSON’S SIGNATURE: _______DATE:

TRADESPERSON’S SIGNATURE: ______DATE:_

TRADESPERSON’S SIGNATURE: ___DATE: