Testing-and-Adjusting-Hydraulic-Systems-RENR-9585 330 PDF

RENR 9585 Testing and Adjusting Hydraulic Systems
General Testing and Adjusting Information 01/04/2006
Visual Inspection 01/04/2006
Hydraulic System Pressure - Release 01/04/2006

o Release Of Hydraulic Pressure From A Single Hydraulic Circuit 01/04/2006
o Release Of Hydraulic Pressure From Multiple Hydraulic Circuits 01/04/2006
Main Hydraulic Pump Air - Purge 01/04/2006
Operational Checks 01/04/2006
Engine Performance - Test - Engine Speed 01/04/2006
Travel on Level Ground - Test - Optional Test 01/04/2006
Travel on Level Ground - Test 01/04/2006
Machine Drift on a Slope - Check 01/04/2006
Swing Speed and Overswing on Level Ground - Check 01/04/2006
Swing Speed and Swing Drift on a Slope - Check 01/04/2006
Cylinder Drift - Check - Empty Bucket 01/04/2006
Cylinder Drift - Check - Loaded Bucket 01/04/2006
Cylinder Speed - Check 01/04/2006
Relief Valve (Pilot) - Test and Adjust 01/04/2006
Accumulator (Pilot) - Test and Charge 01/04/2006

o Testing and Charging the Pilot System Accumulators 01/04/2006
Relief Valve (Main) - Test and Adjust - Heavy Lift 01/04/2006

o Temporary Setting of the Main Relief Valve 01/04/2006
Relief Valve (Line) - Test and Adjust 01/04/2006

o Test 01/04/2006
o Adjustment (Boom Cylinders) 01/04/2006
o Adjustment (Stick Cylinder) 01/04/2006
o Adjustment (Bucket Cylinder) 01/04/2006
Swing Motor - Test - Crossover 01/04/2006
Relief Valve (Swing) - Test and Adjust 01/04/2006
Travel Motor - Test - Measurement of Case Drain Oil 01/04/2006
Relief Valve (Crossover) - Test and Adjust 01/04/2006

Main Pump (Flow) - Test - Constant Horsepower Flow Control 01/04/2006
o Drive Pump 01/04/2006
o Idler Pump 01/04/2006
o Test 01/04/2006
Pump Control (Output Flow) - Adjust 01/04/2006

o Adjustment of Pump Output Flow (Constant Horsepower Control) 01/04/2006
o Adjustment of the Maximum Output Flow of the Pump 01/04/2006
Pump Control (Negative Flow) - Test 01/04/2006

o Drive Pump 01/04/2006
o Idler Pump 01/04/2006
o Test 01/04/2006
Pump Control (Negative Flow) - Adjust 01/04/2006
Gear Pump (Pilot) - Test 01/04/2006
Specifications 01/04/2006
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Product: EXCAVATOR
Model: 330D L EXCAVATOR B6H
Configuration: 330D L Excavator B6H00001-UP (MACHINE) POWERED BY
C9 Engine
Testing and Adjusting

330D Excavator Hydraulic System
Media Number -RENR9585-01 Publication Date -01/04/2006 Date Updated -17/04/2006
i01390735
General Testing and Adjusting Information

SMCS - 5050
Hydraulic oil pressure can remain in the hydraulic systems after the
engine and pump have been stopped. Serious injury can be caused if
this pressure is not released before any service is done on the hydraulic
systems. To prevent possible injury, refer to the section, Testing and
Adjusting, "Hydraulic System Pressure - Release" before any fitting,
hose or component is loosened, tightened, removed or adjusted.
When possible, the work tool must always be lowered to the ground
before service is started. When it is necessary for the boom to be in the
raised position while tests or adjustments are done, be sure that the
boom, stick and work tool have correct support.
The swing lock (if equipped) must be engaged before service is started.
Always move the machine to a location away from the travel of other
machines. Be sure that other personnel are not near the machine when
the engine is running and tests or adjustments are being made.
The correct oil temperature, flow, and pressure are necessary for correct operation. Pump output (oil
flow) is a function of engine speed (rpm) and valve adjustment. Oil pressure is caused by resistance
to the flow of oil.
Visual checks and measurements are the first steps during troubleshooting. Refer to Testing And
Adjusting, "Visual Inspection". Next, perform the operational checks. Refer to Testing And
Adjusting, "Operational Checks". Finally, perform the required tests and adjustments on the
machine.
Copyright 1993 - 2007 Caterpillar Inc. Wed Feb 28 20:25:04 EST 2007
All Rights Reserved.
Private Network For SIS Licensees.
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C9 Engine

i01134573
Visual Inspection
SMCS - 5050-040
A visual inspection of the system is the first step in order to troubleshoot a problem. Shut off the
engine and lower all implements to the ground before performing the visual inspection.
1. Check the oil level in the hydraulic tank. Slowly loosen the fill/vent plug and release the
pressure before the fill/vent plug is removed.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
2. Remove the hydraulic filter elements. Inspect the hydraulic filters for material that would give
an indication of damage to a component.
3. Inspect all lines and connections for damage or leaks.
4. Inspect control linkages for bent components, broken components or damaged components.
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C9 Engine

i01246594
Hydraulic System Pressure - Release

SMCS - 4250-553-PX; 5050-553-PX
The release of hydraulic pressure in a hydraulic circuit is required before service is performed to that
hydraulic circuit. Release the pressure in the following hydraulic circuits before any hydraulic lines
are disconnected or removed from that hydraulic circuit.
z Boom hydraulic circuit
z Stick hydraulic circuit
z Bucket hydraulic circuit
z Swing hydraulic circuit
z Travel hydraulic circuit
z Attachment hydraulic circuits (if equipped)
z Pilot hydraulic circuit
z Return hydraulic circuit
Note: Refer to the Disassembly and Assembly Manual for additional information concerning service
of the components of specific hydraulic circuits.
Release Of Hydraulic Pressure From A Single Hydraulic

Circuit
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered to the ground, and
the oil is cool before removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
NOTICE
containing fluids.

Perform the following Steps in order to release the hydraulic pressure from a single hydraulic circuit
of the main hydraulic system.
1. Position the machine on level ground.
Illustration 1 g00666865
2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is
parallel to the ground. Lower the boom until the bucket is flat on the ground. Refer to
Illustration 1.
3. Shut off the engine.
4. Turn the engine start switch to the ON position without starting the engine.
5. Place the hydraulic activation control lever in the UNLOCKED position.
6. Move only the joysticks or the pedals of the hydraulic circuit that requires service to the FULL
STROKE positions. This will release the high pressure only in that single hydraulic circuit.
This will also release any pressure that might be present in the pilot hydraulic circuit.
Note: If the desired hydraulic circuit that requires service requires the activation of a switch
for operation, activate the necessary switches for the operation of the hydraulic circuit.
7. Place the hydraulic activation control lever in the LOCKED position.
8. Turn the engine start switch to the OFF position.
9. Slowly loosen the filler plug on the hydraulic tank and release the pressure from the hydraulic
tank. Leave the filler plug loose for a minimum of 45 seconds. This will release the pressure
that may be present in the return hydraulic circuit.
10. Tighten the filler plug on the hydraulic tank to the specified torque.
11. The pressure in the single hydraulic circuit that requires service is now released and lines and
components can be disconnected or removed from that hydraulic circuit.
Release Of Hydraulic Pressure From Multiple Hydraulic

Circuits
Make sure all of the attachments have been lowered to the ground, and
NOTICE
containing fluids.

Perform the following Steps in order to release the hydraulic pressure from multiple hydraulic
circuits of the main hydraulic system.
2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is
parallel to the ground. Lower the boom until the bucket is flat on the ground. Refer to
Illustration 2.
4. Turn the engine start switch to the ON position without starting the engine.
5. Place the hydraulic activation control lever in the UNLOCKED position.
6. Move only the joysticks or the pedals of the hydraulic circuit that requires service to the FULL
STROKE positions. This will release the high pressure only in that hydraulic circuit. This will
also release any pressure that might be present in the pilot hydraulic circuit.
Note: If the hydraulic circuit that requires service requires the activation of a switch for
operation, activate the necessary switches for the operation of the hydraulic circuit.
7. Place the hydraulic activation control lever in the LOCKED position.
8. Start the engine.
9. Place the hydraulic activation control lever in the UNLOCKED position. Do not move any
joysticks or pedals from the NEUTRAL position during this step. Do not activate any
switches during this Step.
10. Return the hydraulic activation control lever to the LOCKED position.
12. Repeat Steps 4 through 11 for each additional hydraulic circuit that requires service.
13. After releasing the hydraulic pressure in each of the desired hydraulic circuits, place the
hydraulic activation control lever in the LOCKED position.
14. Turn the engine start switch to the OFF position.
15. Slowly loosen the filler plug on the hydraulic tank and release the pressure. Leave the filler
plug loose for a minimum of 45 seconds. This will release the pressure that may be present in
the return hydraulic circuit.
16. Tighten the filler plug on the hydraulic tank to the specified torque.
17. The pressure in the multiple hydraulic circuits that require service is now released and lines
and components can be disconnected or removed from those hydraulic circuits.
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C9 Engine

i02484921
Main Hydraulic Pump Air - Purge

SMCS - 5070-542-AI
When the main pumps have been serviced or the hydraulic oil has been replaced, remove the air
from the hydraulic system. Remove the air from the hydraulic system in the following manner:
NOTICE
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
Make sure all of the work tools have been lowered to the ground, and
Pump compartment
(1) Plug
(2) Hose
1. While the engine is stopped, remove plug (1) .
2. Fill the main pumps with oil.
3. Install plug (1). Tighten plug (1) securely.
NOTICE
To avoid system damage, make sure that the hydraulic pump is
properly filled with hydraulic oil before start-up.
5. Place the engine at low idle position. Raise the boom and hold the boom in this position.
6. Slowly loosen hose (2) until oil begins to flow around the hose connection.
7. Tighten hose (4) to the specified torque.
8. Stop the engine and slowly lower the boom until the work tool is on the ground. This
pressurizes the hydraulic tank.
(3) Plug
9. Slowly loosen plug (3) until oil flows around plug (3). This will remove air from the system.
10. Tighten plug (3) securely.
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C9 Engine

i02485029
Operational Checks
SMCS - 5050-535
The operational checks can be used to find leakage in the system and components that are not
functioning correctly. The speed of rod movement or the torque on a motor can be used to check the
condition of the cylinders, motors and the pumps.
Perform the following operational checks in order to troubleshoot problems concerning the hydraulic
circuits and components on the machine.
z Testing and Adjusting, "Engine Performance - Test"
z Testing and Adjusting, "Travel on Level Ground - Test"
z Testing and Adjusting, "Travel on Level Ground - Test (Optional Test)"
z Testing and Adjusting, "Machine Drift on a Slope - Check"
z Testing and Adjusting, "Swing Speed and Overswing on Level Ground - Check"
z Testing and Adjusting, "Swing Speed and Swing Drift on a Slope - Check"
z Testing and Adjusting, "Cylinder Drift - Check (Empty Bucket)"
z Testing and Adjusting, "Cylinder Drift - Check (Loaded Bucket)"
z Testing and Adjusting, "Cylinder Speed - Check"
The specifications that are listed in tables for the operational checks are calculated average values.
The values will vary due to the configuration of the machine and engine speed. Table 1 contains the
machine configurations that were used in order to obtain these specifications.
ReferenceRefer to Testing and Adjusting, "Engine Performance - Test" for the specifications for
engine speed.
Table 1
Machine Configuration
Sales Model Boom Stick Bucket
330D 6.5 m (21 feet 4 inches)

3.2 m (10 feet 6 inches) 1.4 m3 (1.83 yd3)
330D L
6.5 m (21 feet 4 inches) 3.2 m (10 feet 6 inches) 1.5 m3 (1.96 yd3)
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C9 Engine

i02485052
Engine Performance - Test - Engine Speed

SMCS - 1000-081
Table 1
Required Tools
Part Number Description Qty
9U-7400 Multitach Tool Group 1
2. Stop the engine.
3. Install 9U-7400 Multitach Tool Group on the engine.
5. Increase the hydraulic oil temperature to 55 5C (131 9F).
6. Read the engine speed display (rpm) on the multitach. Refer to Table 2 for the specifications
for engine speed at the desired engine operation.
Table 2
Specifications
Item
New Rebuild Service Limit
1880 50 rpm (2) 1680 to 1930 rpm (1)
No load high idle (1)
1980 50 rpm (3) 1780 to 2030 rpm (3)

No load low idle 800 50 rpm 800 100 rpm
Maximum speed with load (4) 1720 rpm (5) 1670 rpm (5) 1620 rpm (5)
No load speed (6) 1300 50 rpm 1300 100 rpm
(1) AEC switch in the OFF position
(2) Three seconds after the engine speed dial was placed at position "10"
(3) Engine rpm within three seconds after the engine speed dial was placed at position "10"
(4) Pressure is relieved from both pumps (stall condition).
(5) Minimum
(6) AEC switch in the ON position
Note: A New specification is the performance that can be expected for a new machine. A Rebuild
specification is the performance that can be expected after rebuilding the components of a system.
Performance beyond the Service Limit is an indication of these problems: improper maintenance or
adjustment, component wear and failure.
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i02485060
Travel on Level Ground - Test - Optional Test

SMCS - 4351-081
Note: When the procedure for the Travel On Level Ground cannot be performed, this test may be
used as a substitute.
Note: The engine speed and/or the machine configuration that is used during this test can affect the
results of this test. Refer to Testing and Adjusting, "Engine Performance - Test" for the engine speed
that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine
configurations that were used for this test.
Note: The relief valve pressure settings must be set to the relief valve pressure specification before
performing this operational check. Refer to Testing and Adjusting, "Specifications".
Table 1
Required Tools
Stopwatch 1
4. Raise a track off the ground. Refer to Illustration 1.
5. Put a mark on a shoe of the raised track.
6. Place the machine controls at the following settings: Engine speed dial "10" and AEC switch
OFF.
7. Place the travel speed control switch in HIGH position.
8. Move the travel lever of the raised track to full travel position.
9. Measure the time that is required for the raised track to make three complete revolutions.
Measure the time that is required in each direction.
10. Place the travel speed control switch in the LOW position and repeat Steps 8 through 9.
Table 2
Time For Three Revolutions (time in seconds)

Standard Undercarriage
Travel Speed New Rebuild Service Limit
Forward
HIGH 22.5 or less 23.5 or less 24.5 or less
Reverse
Forward
LOW 34.5 or less 35.5 or less 36.5 or less
Reverse
Table 3
Time For Three Revolutions (time in seconds)

Long Undercarriage
Forward
Reverse
Forward
Reverse
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i02485146
Travel on Level Ground - Test

SMCS - 4351-081
Table 1
Required Tools
5P-3277 Measuring Tape 1
Stopwatch 1
(A) Preliminary run 5 m (16.4 ft)
(B) Travel distance 20 m (65.6 ft)
(C) Bucket height 0.5 to 1 m (1.6 to 3.3 ft)
1. Travel distance must be at least 25 m (82 ft) long. Travel test ground must be hard and as level
as possible.
2. Draw a 25 m (82 ft) straight line on travel test ground as a reference line.
4. Place the machine controls at the following settings: Engine speed dial "10" and AEC switch
OFF.
6. The bucket should be empty.
7. Position the machine so that one track is parallel with the reference line. Position the machine
for the travel test. Refer to Illustration 1.
8. Place the travel speed control switch in HIGH position.
9. Move the machine by operating both travel levers at the same time.
10. The first 5 m (16.4 ft) are for a preliminary run. Measure the travel time that is required to
travel the remaining 20 m (65.6 ft). Measure the time that is required in each direction.
11. Measure the travel deviation from the reference line.
12. Place the travel speed control switch on the LOW position and repeat Steps 9 through 11.
Table 2
Travel Time (time in seconds)

Forward
Reverse
Forward
Reverse
Note: The following table represents the travel deviation (distance) from the reference line.
Table 3
Travel Deviation
mm (inch)
Forward
HIGH 800 (31.5) or less 1200 (47.2) or less 1500 (59.1) or less
Reverse
Forward
LOW 800 (31.5) or less 1200 (47.2) or less 1500 (59.1) or less
Reverse
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i01751979
Machine Drift on a Slope - Check

SMCS - 4095-535
Measuring the amount of drift of the machine on a slope will determine if there is a need to check the
travel brake.
Table 1
Required Tools
Stopwatch 1
Scale
1
150 mm (6 inch)
1. Place the machine on a slope of 12 degrees. The surface of the slope must be hard and smooth.
2. Position the implements, as shown. Refer to Illustration 1.
4. To indicate the machine's relative position to the slope, put a mark on both the track and the
track roller frame. Refer to Illustration 2.
5. Stop the engine.
6. Measure the machine movement on the slope after three minutes.
Table 2
Drift mm (inch)
New Rebuild
0 0
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i02485170
Swing Speed and Overswing on Level Ground - Check

SMCS - 5058-535-ZW
Measuring the swing speed and the overswing of the machine will determine if there is a need to
check the swing motor or the anti-reaction valve. The fine swing control switch (if equipped) must
be in the OFF position.
Table 1
Required Tools
Stopwatch 1
1. Position the machine on level ground. Refer to Illustration 1.
2. Stop the engine.
(A) Upper frame
(B) Undercarriage frame
(C) Marking
3. To indicate the relationship of the two positions, put a mark (C) on the inner race and the outer
race of the swing bearing. The mark will be used as a target to stop the swing operation. Refer
to Illustration 2.
5. Move the swing joystick in either direction until the machine completes a 180 degree swing
operation away from the target.
6. Move the swing joystick in either direction until the machine completes a 180 degree swing
operation toward the target. Return the swing joystick to the NEUTRAL position at the target.
7. Measure the amount of overswing by measuring the distance between the marks on the swing
bearing. Refer to Illustration 2.
Note: Use a point that is visible from the operator seat as a reference point for the target.
Table 2
Overswing
Item New Rebuild Service Limit
Right Swing
1300 mm (51.2 inch) or 1400 mm (55.1 inch) or 1600 mm (63.0 inch) or

Left Swing less less less
8. Move the swing joystick in each direction and measure the time that is required to complete a
180 degree swing operation.
Table 3
Swing Time (seconds)

Right Swing
4.9 or less 5.4 or less 6.0 or less
Left Swing
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i02485189
Swing Speed and Swing Drift on a Slope - Check

SMCS - 5058-535-ZW
Measuring the swing speed on a slope will determine if there is a need to check the swing motor and
the anti-reaction valve. Measuring the swing drift on a slope will determine if there is a need to
check the swing parking brake.
Table 1
Required Tools
Stopwatch 1
1. Complete the following steps in order to measure the swing speed on a slope.
a. The work tool should be empty.
b. Position the machine on a slope of 12 degrees. Refer to Illustration 1.
c. Position the implements at maximum reach and close the work tool. Position the work
tool above the ground so that the work tool will not come in contact with any obstacles.
d. Position the upper structure at position (A). The upper structure should be at a 90 degree
angle to the lower structure. Refer to Illustration 2.
e. Measure the time that is required to swing the upper structure from position (A) to
position (B) .
f. Position the upper structure at position (C). The upper structure should be at a 90 degree
angle to the lower structure.
g. Measure the time that is required to swing the upper structure from position (C) to
position (B).
Table 2
Swing Time (seconds)

Right Swing
5.5 or less 6.3 or less 7.0 or less
Left Swing
2. Complete the following steps in order to measure the swing drift on a slope.
a. Position the upper structure at position (A). The upper structure should be at a 90 degree
(A) Upper frame
(B) Undercarriage frame
(C) Marking
b. To indicate the relationship of the two positions, put a mark (C) on the inner race and
the outer race of the swing bearing. Refer to Illustration 4.
c. Stop the engine.
d. Leave the machine in this position for three minutes. Measure the swing drift on the
circumference of the swing bearing.
e. Start the engine.
f. Position the upper structure at position (C). The upper structure should be at a 90 degree
g. Repeat Steps 2.b through 2.d.
Table 3
Swing Drift mm (inch)

Right Swing
0 0 0
Left Swing
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i02485226
Cylinder Drift - Check - Empty Bucket

SMCS - 5051-535-FKK; 5117-535-FKK; 5453-535-FKK; 7562-535-D9
Table 1
Required Tools
Stopwatch 1
2. Empty the bucket.
3. Raise the boom until the top stick pin is the same height as the boom foot pin.
4. Fully extend the bucket cylinder.
5. Fully retract the stick cylinder.
6. Extend the stick cylinder rod 70 mm (2.8 inch) from the fully retracted position.
7. Measure each cylinder's length from cylinder pin to cylinder pin.
8. Stop the engine.
9. Leave the machine in this position for five minutes. Measure each cylinder's length from
cylinder pin to cylinder pin for drift.
Table 2
Cylinder Drift (Empty Bucket)

Boom Cylinder
6.0 mm (0.24 inch) or 12.0 mm (0.47 inch) or 24.0 mm (0.94 inch) or
less less less
Stick Cylinder
10.0 mm ( 0.39 inch) or 15.0 mm ( 0.59 inch) or 25.0 mm (0.98 inch) or
less less less
Bucket Cylinder
10.0 mm ( 0.39 inch) or 15.0 mm ( 0.59 inch) or 25.0 mm (0.98 inch) or
less less less
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i02485202
Cylinder Drift - Check - Loaded Bucket

SMCS - 5051-535-FKK; 5117-535-FKK; 5453-535-FKK; 7562-535-D9
Table 1
Required Tools
Stopwatch 1
2. Load the bucket.
Weight of bucket load

330D ... 2520 kg (5550 lb)
330D L ... 2700 kg (5950 lb)
3. Raise the boom until the top stick pin is the same height as the boom foot pin.
4. Fully extend the bucket cylinder.
5. Fully retract the stick cylinder.
6. Extend the stick cylinder rod 70 mm (2.8 inch) from the fully retracted position.
7. Measure each cylinder's length from cylinder pin to cylinder pin.
8. Stop the engine.
9. Leave the machine in this position for three minutes. Measure each cylinder's length from
cylinder pin to cylinder pin for drift.
Table 2
Cylinder Drift (Loaded Bucket)

Boom Cylinder
less less less
Stick Cylinder
less less less
Bucket Cylinder
less less less
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i02485261
Cylinder Speed - Check

SMCS - 5456-535-VF; 5458-535-VF
1. Perform the following steps in order to test the operating speed of the boom cylinders.
(A) Extension test
(B) Retraction test

a. Place the machine on level ground.
b. The bucket should be empty.
c. Fully retract the bucket cylinder and the stick cylinder.
d. Position the bucket on the ground. With a stopwatch, measure the time that is required
to fully extend the boom cylinders.
e. Position the boom cylinders at full extension. With a stopwatch, measure the time that is
required for the bucket to come in contact with the ground.
f. Refer to the specifications in Table 1 for the operating speed of the boom cylinders.
2. Perform the following steps in order to test the operating speed of the stick cylinder.
(A) Extension test
(B) Retraction test
c. Position the upper surface of the boom parallel to the ground.
d. Fully extend the bucket cylinder.
e. Retract the stick cylinder. With a stopwatch, measure the time that is required to fully
extend the stick cylinder.
f. Extend the stick cylinder. With a stopwatch, measure the time that is required to fully
retract the stick cylinder.
g. Refer to the specifications in Table 1 for the operating speed of the stick cylinder.
3. Perform the following steps in order to test the operating speed of the bucket cylinder.
(A) Extension test
(B) Retraction test
c. Position the upper surface of the boom parallel to the ground.
d. Position the stick so that the stick is perpendicular to the ground.
e. Fully retract the bucket cylinder.
f. With a stopwatch, measure the time that is required to fully extend the bucket cylinder.
g. Position the bucket cylinder at full extension. With a stopwatch, measure the time that is
required to fully retract the bucket cylinder.
h. Refer to the specifications in Table 1 for the operating speed of the bucket cylinder.
Table 1
Cylinder Operating Speed (seconds)

Extension 3.4 0.3 4.0 (1) 4.5 (1)
Boom
Retraction 2.6 0.3 3.3 (1) 3.8 (1)
Extension 3.4 0.3 4.0 (1) 4.5 (1)
Stick
Retraction 2.8 0.3 3.5 (1) 4.0 (1)
Extension 4.4 0.3 5.0 (1) 5.5 (1)
Bucket
Retraction 2.5 0.3 3.2 (1) 3.7 (1)
(1) Maximum
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i02485276
Relief Valve (Pilot) - Test and Adjust

SMCS - 5072-036
Table 1
Required Tools
Pressure Gauge (
8T-0856 1
6000 kPa (870 psi))
1. Place the machine on level ground.
2. Stop the engine.
3. Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "Hydraulic
System Pressure - Release".
Pilot oil manifold compartment

(28) Locknut
(29) Adjustment screw
(30) Pressure tap
(31) Pilot filter
4. Connect a 6000 kPa (870 psi) pressure gauge to pressure tap (30) .
6. Place the machine controls at the following settings: engine speed dial "10" and AEC switch
OFF. Refer to Testing and Adjusting, "Engine Performance - Test" for engine rpm settings.
8. Check the pilot relief valve setting at pressure tap (30) .
9. The pilot relief valve setting should be 4100 200 kPa (595 30 psi). If the pilot relief valve
setting is not within the specification, adjust the pilot relief valve.
10. In order to adjust the pilot relief valve, loosen locknut (28) .
11. Turn adjustment screw (29) until the pressure gauge reading at pressure tap (30) is 4100 200
kPa (595 30 psi).
Note: Turn adjustment screw (29) clockwise in order to increase the pressure. Turn adjustment
screw (29) counterclockwise in order to decrease the pressure.
Note: Always make final pressure adjustments on pressure rise.
12. Tighten locknut (28) to a torque of 49 4.9 Nm (36 4 lb ft).
Note: Normal operation of the engine and pumps are necessary for the pressure adjustment. If the
results of the pressure adjustments are not correct, then the engine and the pump characteristic curve
needs to be checked.
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Product: EXCAVATOR
C9 Engine

i01927888
Accumulator (Pilot) - Test and Charge

SMCS - 5077-045-PS; 5077-081-PS; 5077-081-PX
Dry nitrogen is the only gas approved for use in the accumulators. The
charging of oxygen gas in an accumulator will cause an explosion. An
explosion can be eliminated by using nitrogen gas cylinders with
standard CGA (Compressed Gas Association, Inc.) No. 580 connectors.
When nitrogen gas is ordered, make sure to order the cylinders with
CGA No. 580 connectors.
Do not rely on color codes or other methods of identification to tell the

difference between nitrogen and oxygen cylinders. In any application,
never use an adapter to connect your nitrogen charging group to a valve
outlet used on both nitrogen, oxygen, or other gas cylinders. BE SURE
YOU USE DRY NITROGEN (99.8% purity).
NOTICE
containing fluids.

Table 1
REQUIRED TOOLS
Part Number Description Quantity
175-5507 Nitrogen Charging Group 1
Testing and Charging the Pilot System Accumulators

Stop the engine. Release the pressure from the pilot hydraulic system. Refer to Testing and
Adjusting, "Hydraulic System Pressure - Release".
Gas pressure is variable with temperature. Check the temperature of the air around the accumulator.
In order to check the amount of charge in an accumulator, the accumulator must be at the same
temperature as the surrounding air.
Note: The temperature of the accumulator may change as the accumulator is being charged due to
the expansion or compression of the nitrogen charge. It may be necessary to charge the accumulator
in several steps in order to ensure a correct charge.
Table 2
Charge Pressures and Temperatures

Temperature Pressure
-25C (-13F) 1490 kPa (216 psi)
-20C (-4F) 1520 kPa (220 psi)
-15C (5F) 1550 kPa (225 psi)
-10C (14F) 1580 kPa (229 psi)
-5C (23F) 1610 kPa (233 psi)
0C (32F) 1640 kPa (238 psi)
5C (41F) 1670 kPa (242 psi)
10C (50F) 1700 kPa (247 psi)
15C (59F) 1730 kPa (251 psi)
20C (68F) 1760 kPa (255 psi)

25C (77F) 1790 kPa (260 psi)
30C (86F) 1820 kPa (264 psi)
35C (95F) 1850 kPa (268 psi)
40C (104F) 1880 kPa (273 psi)
45C (113F) 1910 kPa (277 psi)
50C (122F) 1940 kPa (281 psi)
If an accumulator has less than half of the required amount of precharge pressure, the accumulator
should be charged. Oil in the accumulator will give an inaccurate precharge reading.
Accumulator (Typical Example)
(1) Cap
175-5507 Nitrogen Charging Group
(2) Pressure gauge
(3) Connection to the nitrogen cylinder
(4) Regulator
(5) Valve
(6) Pressure gauge
(7) Pressure regulating screw
(8) Valve handle
(9) Chuck
1. Make sure that valve (5) is closed.
2. Remove cap (1) from the accumulator.
3. Rotate valve handle (8) on chuck (9) counterclockwise until the valve handle reaches the full
out position. Install chuck (9) on the accumulator.
4. Turn valve handle (8) clockwise until the valve is completely open.
5. Check the pressure reading on pressure gauge (6). Refer to Table 2 for the correct charging
pressure and temperature relationship for the accumulator.
6. If the pressure reading on the gauge is too high, use the following steps in order to purge the
nitrogen from the accumulator.
a. Slowly open valve (5) .

b. Purge the nitrogen pressure until the pressure reading is within the specification.
c. Close valve (5) .
d. Turn valve handle (8) on chuck (9) counterclockwise until the valve is completely
closed.
e. Remove the test equipment. Replace cap (1) .
7. If the pressure is too low, use the following procedure to charge the accumulator:
a. Turn valve handle (8) on chuck (9) counterclockwise until the valve is completely
closed.
b. Connect the 175-5507 Nitrogen Charging Group to the nitrogen cylinder with
connection (3) .
c. Connect the other end of the hose to valve (5) .
d. Open the valve on the nitrogen cylinder. Make an adjustment to screw (7) on the
regulator assembly until gauge (2) indicates the proper precharge pressure for the
accumulator. Refer to Table 2.
e. Open valve (5). Loosen chuck (9) slightly. Allow the nitrogen to purge the air from the
hose. Tighten chuck (9) .
f. Open valve (8) in order to charge the accumulator.
g. Close valve (5) .
h. The accumulator has the correct charge if the pressure on gauge (6) and the pressure on
gauge (2) are equal and the gauge readings do not change. If there is a decrease in
pressure on gauge (6), open valve (5) and allow more nitrogen to go into the
accumulator.
i. Repeat steps 7.d through 7.g until the following items occur:
The pressure on gauge (6) is equal to the pressure on gauge (2) .
There is no pressure change when valve (5) is closed.
j. Close valve (5). Close the valve on the nitrogen cylinder.
k. Turn valve handle (8) on chuck (9) counterclockwise until the valve is completely
closed.
l. Remove the test equipment. Replace cap (1) .
Shutdown
Previous Screen
Product: EXCAVATOR
C9 Engine

i02532689
Relief Valve (Main) - Test and Adjust - Heavy Lift

SMCS - 5069-025; 5069-081
Table 1
Required Tools
Pressure Gauge
8T-0861 2
60000 kPa (8700 psi)
Pressure Gauge
8T-0856 1
6000 kPa (870 psi)
1. Position the machine on level ground and stop the engine.
Pump compartment
(1) Pressure tap (pressure for drive pump)
(2) Pressure tap (pressure for idler pump)
(3) Pressure tap (power shift pressure)
3. Attach a 60000 kPa (8700 psi) pressure gauge to pressure tap (1) and pressure tap (2) .
5. Exit the service mode.
OFF. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine
rpm settings.
7. Set heavy lift switch (A) to the ON setting. Make sure that the indicator light is on.
9. Raise the boom until the boom cylinder rods are at full extension.
10. Check the main relief valve pressure setting at pressure tap (1) and pressure tap (2) .
11. Return the joystick for the boom to the NEUTRAL position.
(4) Main Relief Valve
(5) Locknut for the Main Relief Valve
(6) Adjustment screw for the main relief valve
(7) Locknut for the heavy lift
(8) Adjustment screw for the heavy lift
12. The main relief valve pressure setting should be 36000 500 kPa (5220 73 psi). If the heavy
lift relief valve pressure setting is not within the specification, adjust the heavy lift relief valve
pressure setting.
a. Loosen locknut (5) in order to adjust standard main relief valve (6). Tighten standard
main relief valve (6) until the valve stops turning. Tighten locknut (5) .
b. Loosen locknut (7) in order to adjust the relief valve for the heavy lift. The main relief
valve is located on top of the main control valve. Adjust the pressure by turning
adjustment screw for the heavy lift (8) until the pressure gauge reading at pressure tap
(1) is 36000 500 kPa (5220 73 psi).
Note: Turning adjustment screw (8) clockwise increases the pressure. Turning
adjustment screw (8) counterclockwise decreases the pressure.
c. Tighten locknut (7) to a torque of 75 10 Nm (55 7 lb ft).
Note: Confirm the heavy lift pressure by fully retracting the stick cylinder.
13. Set heavy lift switch (A) to the OFF setting. The indicator light should not be illuminated.
14. Open the bucket until the bucket cylinder rod is at full retraction.
15. Check the main relief valve pressure setting at pressure tap (1) .
16. Return the joystick for the bucket to the NEUTRAL position.
17. The main relief valve pressure setting should be 35000 500 kPa (5075 72 psi). If the main
relief valve pressure setting is not within the specification, adjust the main relief valve
pressure setting.
18. In order to adjust the main relief valve, loosen locknut (5) and turn adjustment screw (6) until
the pressure gauge reading at pressure tap (1) is 35000 500 kPa (5075 72 psi).
19. Tighten locknut (5) to a torque of 50 10 Nm (37 7 lb ft).
Temporary Setting of the Main Relief Valve

Note: In order to adjust line relief valve pressure settings, the main relief valve must be temporarily
adjusted to a higher setting since the line relief valve pressure settings are higher than the main relief
valve pressure setting.
1. Set the heavy lift switch (A) to the ON setting. Make sure that the indicator light is ON.
2. The main relief valve pressure setting should be 36000 500 kPa (5220 73 psi) when the
heavy lift mode is on. If the main relief valve is not within the specification, adjust the main
relief valve pressure setting to the correct pressure specification before performing Step 3.
Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".
(4) Main Relief Valve
(5) Locknut for the Main Relief Valve
(6) Adjustment screw for the main relief valve
(7) Locknut for the heavy lift
(8) Adjustment screw for the heavy lift
3. Loosen locknut (5) and tighten screw (6) until no adjustment is left.
4. Tighten locknut (5) while screw (6) is secured.
5. Loosen locknut (7) .
6. Tighten screw (8) until the pressure reading of tap (1) or (2) will not rise more. Read the
pressure of tap (1) or (2) .
7. Turn screw (8) clockwise by a quarter turn. Tighten locknut (7) while screw (8) is secured.
8. Perform the desired steps for testing and adjusting the line relief valves.
9. Reset main relief valve pressure setting to the normal operating condition. Refer to Testing
and Adjusting, "Relief Valve (Main) - Test and Adjust".
Shutdown
Previous Screen
Product: EXCAVATOR
C9 Engine

i02531991
Relief Valve (Line) - Test and Adjust

SMCS - 5117-025-L9; 5117-081-L9
Table 1
Required Tools
8T-0861 Pressure Gauge (60000 kPa (8700 psi)) 2
Pressure Gauge (
8T-0856 1
6000 kPa (870 psi))
Note: A temporary setting of the main relief valve pressure is required before any line relief valve
pressure setting is adjusted. Refer to the adjustment procedures in Testing and Adjusting, "Relief
Valve (Main) - Test and Adjust".
Test
2. Stop the engine.
Pump compartment
(1) Pressure tap (delivery pressure for drive pump)
(2) Pressure tap (delivery pressure for idler pump)
6. Connect a 6000 kPa (870 psi) pressure gauge to pressure tap (2) . This is used to monitor
power shift pressure.
8. Place the machine controls at the following settings: AEC switch OFF. Refer to Testing and
Adjusting, "Engine Performance - Test" for engine rpm settings.

Monitor
(4) Up key
(5) Left key
(6) Down key
(7) Right key
(8) Cancel key
(9) OK key
(10) Set key
(11) Menu key
10. Start Service Mode and input a fixed power shift pressure. Refer to Table 3 for the correct
pressure setting of each hydraulic circuit.
a. Press menu key (11) .
Note: Make sure that the engine speed dial is set correctly. Refer to Table 3 for the
correct setting.
Note: If more than thirty seconds pass between pushing the keys on the keypad, the
menu mode will be cancelled and the previous display will be restored.
b. Press right key (7) in order to highlight the menu item "SERVICE" on the message
display. Press OK key (9) .
c. Input the password "FFF2". Press left key (5) or right key (7) in order to change the
character. Press "OK" key (9) or press "CANCEL" key (8) in order to delete the value of
the flashing character. Press OK key (9) after the correct password is displayed.
d. Press down key (6) repeatedly until "DEVICE TEST" appears on the message display.
Press "OK" key (9) .
e. Press down key (6) in order to move down one line on the message display.
f. Press "OK" key (9) in order to select the "POWER SHIFT PRES" message display.
g. Press "OK" key (9) .
h. Press left key (5) or right key (7) in order to increase or decrease the numeric value that
is displayed for the power shift pressure. Pressing left key (5) decreases the power shift
pressure. Pressing right key (7) increases the power shift pressure.
Note: The value for power shift pressure on the monitor may not always match the
pressure reading on the pressure gauge. Adjust the value on the monitor until the desired
power shift pressure is attained on the pressure gauge that is connected to the pressure
tap (2) for power shift pressure. Make sure that the actual power shift pressure on the
pressure gauge is correct for each hydraulic circuit. Refer to Table 3 for the correct
power shift pressure.
Note: To prevent a change in power shift pressure during the relief valve adjustment, do
not turn the engine start switch to the OFF position.
Note: Refer to Service Manual, "Engine and Pump Electronic Control System" for
additional information on Service Mode.
Main control valves (front view)
(12) Line relief valve (boom cylinder head end)
(13) Line relief valve (bucket cylinder head end)
(14) Line relief valve (stick cylinder rod end)
The following line relief valves are located on top of the main control valves: boom cylinder head
end, bucket cylinder head end and stick cylinder rod end.
The following line relief valves are located on the bottom of the main control valve: boom cylinder
rod end, bucket cylinder rod end and stick cylinder head end.
Line relief valve (typical example)
(15) Locknut
Note: After relief valve adjustments, cancel Service Mode.
Note: Return the main relief valve pressure to the specified setting after testing and adjusting any
line relief valve. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust" for the
main relief valve pressure setting.
Table 2
Line Relief Valve Pressure Settings

Standard Configuration Heavy Lift Option
Cylinder Cylinder Power Shift Relief Pressure Power Shift Relief Pressure
Position Pressure Setting Pressure Setting
Retracted
3200 50 kPa 3200 50 kPa
37000 1000 37000 1000
Bucket (464 7 psi) (464 7 psi)
kPa (5350 145 kPa (5350 145
Extended Speed Dial 3 Speed Dial 3
psi) psi)
3200 50 kPa 3200 50 kPa

37000 1000 37000 1000
Retracted (464 7 psi) (464 7 psi)
kPa (5350 145 kPa (5350 145
Speed Dial 3 Speed Dial 3
psi) psi)
Boom
2370 50 kPa 2370 50 kPa

38000 1000 38000 1000
Extended (344 7 psi) (344 7 psi)
kPa (5500 145 kPa (5500 145
psi) psi)
2370 50 kPa 2370 50 kPa

38000 1000 38000 1000
Retracted (344 7 psi) (344 7 psi)
kPa (5500 145 kPa (5500 145
psi) psi)
Stick
2500 50 kPa 2500 50 kPa

37000 1000 37000 1000
Extended (450 7 psi) (450 7 psi)
kPa (5350 145 kPa (5350 145
psi) psi)
Adjustment (Boom Cylinders)
1. To adjust the line relief valve pressure setting of the boom cylinder head end (12) , move the
joystick for the boom until the boom is at the full BOOM RAISE position (full extension of
boom cylinders). Hold the joystick for the boom in this position.
2. Check the pressure in the boom cylinder head end on the pressure gauge at pressure tap (1)
and pressure tap (3) .
4. The pressure gauge reading should be 38000 1000 kPa (5500 145 psi). Refer to Table 3. If
the pressure gauge reading at pressure tap (1) and pressure tap (3) is not within the
specification, adjust the line relief valve .
5. In order to adjust the line relief valve, loosen locknut (15) on the boom line relief valve. Turn
adjustment screw (16) until the pressure gauge reading at pressure tap (1) and pressure tap (3)
is 38000 1000 kPa (5500 145 psi). Refer to Table 3.
Note: Always make final pressure adjustment on pressure rise.
6. Tighten locknut (15) on the relief valve.
Note: In order to adjust the line relief valve pressure setting for the boom cylinder rod end, a
temporary adjustment of the line relief valve for the bucket cylinder head end (13) must be
performed.
Note: Make sure that the engine speed dial and the power shift pressure for the BOOM
DOWN hydraulic circuit is set correctly. Refer to Table 3 for the correct setting.
7. Loosen locknut (15) on the line relief valve for the BUCKET CLOSE function. Turn
adjustment screw (16) by one quarter turn in a clockwise direction. Tighten locknut (15) on the
line relief valve for the bucket cylinder.
8. Move the joystick for the bucket until the bucket is at the full BUCKET CLOSE position (full
extension of the bucket cylinder). Hold the joystick for the bucket in this position. At the same
time, move the joystick for the boom until the boom is at the full BOOM DOWN position (full
retraction of boom cylinders). Hold the joystick for the boom in this position.
9. Check the pressure in the boom cylinder rod end on the pressure gauge at pressure tap (1) .
Main control valves (front view)
(17) Line relief valve (boom cylinder rod end)
(18) Line relief valve (bucket cylinder rod end)
(19) Line relief valve (stick cylinder head end)
the pressure gauge reading at pressure tap (1) is not within the specification, adjust line relief
valve (17) .
12. In order to adjust line relief valve (17) , loosen locknut (15) on the boom line relief valve. Turn
adjustment screw (16) until the pressure gauge reading at pressure tap (1) is 37000 1000 kPa
(5350 145 psi). Refer to Table 3.
13. Tighten locknut (15) on the boom line relief valve.
14. After completion of line relief valve adjustment for the boom cylinders, return the line relief
valve pressure setting of the bucket to the specified pressure setting.
Note: If an appropriate location is not available to fully extend the boom cylinders, exchange the
functions of the boom line relief valve (12) . Remove the line relief valve for the boom cylinder head
end and the line relief valve for the stick cylinder rod end (14) from the main control valve.
Exchange the location of the line relief valves. Adjust the pressure of the boom line relief valve that
is now attached in the rod end. After completion of line relief valve adjustment, return the respective
line relief valves to the original locations.
Adjustment (Stick Cylinder)

Note: Make sure that the engine speed dial and the power shift pressure for the STICK OUT
hydraulic circuit is set correctly. Refer to Table 3 for the correct setting.
1. To adjust the line relief valve pressure setting of the stick cylinder rod end, move the joystick
for the stick until the stick is at the full STICK OUT position (full retraction of stick cylinder).
Hold the joystick for the stick in this position.
2. Check the pressure in the stick cylinder rod end on the pressure gauge at pressure tap (1) and
pressure tap (3) .
3. Return the joystick for the stick to the NEUTRAL position.
specification, adjust the line relief valve.
5. In order to adjust the line relief valve, loosen locknut (15) on the stick line relief valve. Turn
6. Tighten locknut (15) on the line relief valve.
Note: Make sure that the engine speed dial and the power shift pressure for the STICK IN
7. To adjust the line relief valve pressure setting of the stick cylinder head end (19) , move the
joystick for the stick until the stick is at the full STICK IN position (full extension of stick
cylinder). Hold the joystick for the stick in this position.
8. Check the pressure in the stick cylinder head end on the pressure gauge at pressure tap (1) and
pressure tap (3) .
9. Return the joystick for the stick to the NEUTRAL position.
specification, adjust the line relief valve.
11. In order to adjust the line relief valve, loosen locknut (15) on the stick line relief valve. Turn
12. After completion of line relief valve adjustment, tighten locknut (15) .
Adjustment (Bucket Cylinder)

Note: Make sure that the engine speed dial and the power shift pressure for the BUCKET CLOSE
1. To adjust the line relief valve pressure setting of the bucket cylinder head end (13) , move the
joystick for the bucket until the bucket is at the full BUCKET CLOSE position (full extension
of bucket cylinder). Hold the joystick for the bucket in this position.
2. Check the pressure in the bucket cylinder head end on the pressure gauge at pressure tap (1) .
the pressure gauge reading at pressure tap (1) is not within the specification, adjust the line
relief valve.
5. In order to adjust the line relief valve, loosen locknut (15) on the bucket line relief valve. Turn
6. Tighten locknut (15) on the line relief valve.
Note: Make sure that the engine speed dial and the power shift pressure for the BUCKET
OPEN hydraulic circuit is set correctly. Refer to Table 3 for the correct setting.
7. To adjust the line relief valve pressure setting of the bucket cylinder rod end (18) , move the
joystick for the bucket until the bucket is at the full BUCKET OPEN position (full retraction
of bucket cylinder). Hold the joystick for the bucket in this position.
8. Check the pressure in the bucket cylinder rod end on the pressure gauge at pressure tap (1) .
the pressure gauge reading at pressure tap (1) is not within the specification, adjust the line
relief valve for the bucket cylinder rod end.
11. In order to adjust the line relief valve, loosen locknut (15) on the bucket line relief valve. Turn
12. After completion of line relief valve adjustment, tighten locknut (15) .
13. Reset the main relief valve pressure to the correct setting. Refer to the adjustment procedures
in Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".
Shutdown
Previous Screen
Product: EXCAVATOR
C9 Engine

i02489825
Swing Motor - Test - Crossover

SMCS - 5058-081-ZW
Table 1
Required Tools
6V-9830 Cap 1
Wrench
1
24 mm (0.94 inch)
Container for Measuring 1
NOTICE
containing fluids.

1. Stop the engine.
Swing motor compartment
(1) Case drain hose
(2) Tee
3. Disconnect the case drain hose (1) from tee (2). Place the open end of the case drain hose (1)
into the container for measuring.
4. Install 6V-8398 O-Ring Seal and 6V-9830 Cap on tee (2) of the swivel.
5. Turn the "SWING BREAK SOL" override to the ON position.
a. Enter the service screen from the main menu.
b. Select the OVERRIDE function.
c. Highlight the SWING BREAK SOL line and turn to the ON position.
Note: The SWING BREAK SOL will keep the swing brake applied while the joystick
for the swing function is moved.
7. Place the engine speed dial at position "10" and AEC switch OFF. Maintain the maximum no-
load speed at 1880 50 rpm.
ReferenceRefer to Testing and Adjusting, "Engine Performance - Test" for engine rpm
settings.
9. Slowly move the swing joystick and make sure that the swing parking brake is activated.
10. Move the swing joystick fully for one minute. Measure the case drain oil.
11. Stop the engine.

12. Repeat this test procedure three times in order to obtain three measurements. For each test
procedure, swing the upper structure to a different position.
The following values specify the maximum acceptable flow of case drain oil when the swing relief
pressure is set at 27900 1000 kPa (4050 145 psi).
New swing motor ... 30 L/min (7.9 US gpm)

Rebuilt swing motor ... 35 L/min (9.2 US gpm)
Shutdown
Previous Screen
Product: EXCAVATOR
C9 Engine

i02531999
Relief Valve (Swing) - Test and Adjust

SMCS - 5454-036
2. Stop the engine.
Pump compartment
(1) Pressure tap (right pump delivery pressure)
(2) Pressure tap (left pump delivery pressure)
5. Turn the "SWING BREAK SOL" override to the ON position.

a. Enter the service screen from the main menu.
b. Select the OVERRIDE function.
c. Highlight the SWING BREAK SOL line and turn to the ON position.
Note: The SWING BREAK SOL will keep the swing brake applied while the joystick
for the swing function is moved.
OFF.
ReferenceRefer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for
engine rpm settings.
8. Move the swing joystick slowly and ensure that the swing parking brake is operating properly.
Swing motor
(22) Adjustment plug
(23) Locknut
(25) Relief valve (left swing)
(34) Adjustment plug
(35) Locknut
(36) Relief valve (right swing)
9. Slowly move the swing joystick for a full SWING RIGHT operation and check the pressure
for relief valve (25) at pressure tap (2) .
10. Return the swing joystick to the NEUTRAL position.

11. The pressure setting of the swing relief valve is 27900 1000 kPa (4050 145 psi). If the
pressure reading at pressure tap (2) is not within the specification, adjust the swing relief
valve.
12. In order to adjust the swing relief valve, loosen locknut (23) . Turn adjustment plug (22) until
Note: Turning adjustment plug (22) clockwise increases the pressure. Turning adjustment plug
(22) counterclockwise decreases the pressure.
14. Slowly move the swing joystick for a full SWING LEFT operation and check the pressure for
relief valve (36) at pressure tap (2) .
15. Return the swing joystick to the NEUTRAL position.
16. The pressure setting of the swing relief valve is 27900 1000 kPa (4050 145 psi). If the
pressure reading at pressure tap (2) is not within the specification, adjust the swing relief
valve.
17. In order to adjust the swing relief valve, loosen locknut (35) . Turn adjustment plug (34) until
Note: Turning adjustment plug (34) clockwise increases the pressure. Turning adjustment plug
(34) counterclockwise decreases the pressure.
19. After completing the test and/or the adjustment procedures for the swing relief valves, stop the
engine.
21. Connect connector (26) to the solenoid valve for swing parking brake (27) .
Shutdown
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Product: EXCAVATOR
C9 Engine

i01627732
Travel Motor - Test - Measurement of Case Drain Oil

SMCS - 4351-081
Table 1
Required Tools
FT-2547 Track block assembly 1
6V-9509 Face Seal Plug 1
6V-8398 O-Ring Seal 1
Remote drain hose with an inside diameter of
1
20 mm (0.79 inch)
Wrench
1
29 mm (1.14 inch)
Container for measuring 1
NOTICE
containing fluids.


1. Stop the engine.
Sprocket (left track)
(1) Sprocket
(2) FT-2547 Track block assembly
3. Place track block assembly (2) in sprocket (1) in order to block forward left travel. Refer to
Illustration 1.
Travel motor
(3) 6V-9509 Face seal plug
(4) 6V-8398 O-Ring seal
(5) Case drain hose
(6) Connector
(7) Remote drain hose
(8) Container for measuring
4. Disconnect case drain hose (5) from connector (6). Install plug (3) and seal (4) in the open end
of case drain hose (5) .
5. Connect one end of remote drain hose (7) to connector (6). Place the other end of remote drain
hose into the container (8) in order to measure the case drain oil.
7. Place the engine speed dial at position "10" and AEC switch OFF. Maintain the maximum no-
load speed at 1880 50 rpm.
Reference: Refer to Testing and Adjusting, "Engine Performance - Test" for engine rpm
settings.
9. Move the left travel lever forward fully for one minute.
10. Measure the amount of case drain oil.
11. Remove track block assembly (2) from sprocket (1) .
12. Move the left travel lever in order to reposition the travel motor.
13. Place track block assembly (2) in sprocket (1) in order to block forward left travel.
14. Repeat Steps 9 through 13 in order to obtain three measurements of case drain oil.
The following values specify the maximum acceptable flow of case drain oil when the travel
crossover relief valves are set at 36800 1470 kPa (5350 215 psi).
New travel motor ... 15 L/min (4.0 US gpm)

Rebuilt travel motor ... 18 L/min (4.8 US gpm)
Shutdown
Previous Screen
Product: EXCAVATOR
C9 Engine

i02532021
Relief Valve (Crossover) - Test and Adjust

SMCS - 5069-036
Table 1
Required Tools
8T-0861 Pressure Gauge (60000 kPa (8700 psi)) 2
Pressure Gauge (
8T-0856 1
6000 kPa (870 psi))
Note: A temporary setting of the main relief valve is required before travel crossover relief valves
can be tested. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".
2. Stop the engine.

Pump compartment
(1) Pressure tap (drive pump delivery pressure)
(2) Pressure tap (delivery pressure for the idler pump)
3. Connect a 60000 kPa (8700 psi) pressure gauge to pressure tap (1) . Use this pressure gauge to
monitor the crossover relief valve pressure setting of the right travel motor.
4. Connect a 60000 kPa (8700 psi) pressure gauge to pressure tap (2) . Use this pressure gauge to
monitor the crossover relief valve pressure setting of the left travel motor.
Sprocket (left track)
(16) Sprocket
(17) FT-2547 Track block assembly
6. Place track block assembly (17) in sprocket (16) in order to block forward left travel. Refer to
Illustration 2.
OFF. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine
rpm settings.
Monitor
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key

(G) Back key
(H) Home key
(I) OK key
(J) Menu key
10. Start Service Mode and input a fixed power shift pressure of 2850 kPa (415 psi).
a. Press menu key (J) .
menu mode will be cancelled and the previous display will be restored to message
display (A) .
b. Press Right key (F) in order to highlight "SERVICE" menu option.
c. After the "SERVICE" option is highlighted, press OK key (I) .
d. After OK key (I) is pressed, the screen in Illustration 4 will be displayed. The password
for the service menu is "FFF2". The keys for direction are used to input the password.
Press Left key (D) or Right key (F) in order to change the position of the flashing
character. Press OK key (I) in order to enter the highlighted character.
e. After entering the last letter of the password, the monitor will continue with the
"SERVICE" screen.
f. Repeatedly press down key (E) in order to highlight the "DEVICE TEST" line on the
display.
g. After the "DEVICE TEST" line is highlighted, press OK key (I) .
h. Once the "DEVICE TEST" screen is displayed, press down key (E) until "POWER
SHIFT PRES" appears on the display.
i. When "POWER SHIFT PRES" is highlighted, press OK key (I) .
j. The "POWER SHIFT PRES" will now be displayed. Line 4 of the display will now
change to a numeric value. These characters represent the power shift pressure (kPa).
k. Press left key (D) or right key (F) in order to increase or decrease the numeric value that
is displayed on line 4 of the display. Pressing left key (D) decreases the power shift
pressure. Pressing right key (F) increases the power shift pressure.
tap for power shift pressure. The actual power shift pressure must be 2850 kPa (415 psi)
on the pressure gauge.
Travel brake valve (left side)
(18) Locknut

(20) Crossover relief valve (forward left travel)
(21) Crossover relief valve (reverse left travel)
(22) Locknut
11. Slowly move the left travel control lever to full FORWARD position and check the pressure
gauge reading at pressure tap (2) . The pressure setting of crossover relief valve (20) should be
36800 1500 kPa (5350 220 psi).
12. Return the left travel control lever to the NEUTRAL position.
13. In order to adjust crossover relief valve (20) , loosen locknut (18) and turn adjustment screw
(19) until the pressure gauge reading at pressure tap (2) is 36800 1500 kPa (5350 220 psi).
15. Place track block assembly (17) in sprocket (16) in order to block reverse left travel.
16. Slowly move the left travel lever to full REVERSE position and check the pressure gauge
reading at pressure tap (2) . The pressure setting of crossover relief valve (21) should be 36800
1500 kPa (5350 220 psi).
17. Return the left travel control lever to the NEUTRAL position.
18. In order to adjust crossover relief valve (21) , loosen locknut (22) and turn adjustment screw
(23) until the pressure gauge reading at pressure tap (2) is 36800 1500 kPa (5350 220 psi).
In order to adjust the crossover relief valves on the right travel motor, place stopper (17) in the
sprocket for right travel. Use the pressure gauge at pressure tap (1) in order to monitor the
crossover relief valve pressure settings for the right travel motor. Adjust the crossover relief
valves on the right travel motor in the same manner as the adjustment for the left travel motor.
20. After relief valve adjustments, cancel Service Mode.
21. Return the main relief valve pressure to the specified setting after crossover relief valve
pressure setting is attained. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and
Adjust".
Shutdown
Previous Screen
Product: EXCAVATOR
C9 Engine

i02486731
Main Pump (Flow) - Test - Constant Horsepower Flow Control

SMCS - 5070-081-FW
This test measures individual pump flow at the pump. Each pump is tested individually for output
flow at specified pressures. The pump that is not being tested is not under load and the pump remains
at low pressure standby.
The electronic control module is located in the compartment behind the cab.
(1) Alarm lamp
(2) Electronic control module

(3) Monitor
(4) Message display
Note: Before starting main pump flow tests, check display (4) on monitor (3) and alarm lamp (1) on
electronic control module (2) for normal operation. Lamp (1) should be green. If no faults are
present, perform the operational checks. Refer to Testing and Adjusting, "Operational Checks".
Note: If the operational checks indicate that slow speed of an implement is common to the circuits of
one pump, the problem is most likely in the hydraulic system. Then perform the pump flow tests.
Refer to Testing and Adjusting, "Piston Pump (Main) - Test".
Note: If the operational checks indicate that slow speed of an implement is common to both pump
circuits, the problem may be in the engine, the fuel, or the working altitude.
Flow meter tool layout
(1) Swing motor
(2) Connector at swing motor
(3) 6V-9840 Swivel tee
(4) Makeup line (swing motor)
(6) Negative flow control line (drive pump)
(10) 4C-9910 Portable hydraulic tester (flow meter)
(11) Delivery line (idler pump)
(12) Delivery line (drive pump)
(13) Negative flow control line (idler pump)

(17) 9U-7335 Blocking cover
(23) Right pump
(24) Idler pump
(29) 1U-8303 Fitting
(30) 5K-9090 O-Ring seal
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(33) 4C-8767 Coupling
(34) 7M-8485 O-Ring seal
(35) 4C-6481 Coupler assembly
(36) 4C-6482 Nipple assembly
(37) 4I-6141 Coupling
(38) 8C-9026 Adapter
(40) 6V-9854 Swivel elbow
(42) 1P-3703 Rectangular seal
(46) 8T-4184 Bolt
(47) 8T-4223 Hard washer
(48) 6V-0400 Half flange
(49) 1U-8292 Adapter

Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valve
(8) Pressure tap (delivery pressure of the idler pump)
(9) 8T-0861 Pressure gauge

(11) Delivery line for idler pump
(12) Delivery line from right pump
(16) Pressure tap (right pump delivery pressure)
(21) Engine
(22) Multitach
(23) Right pump
(24) Idler pump
(40) Elbow
Drive Pump
NOTICE
containing fluids.

Note: Perform the test for the drive pump and the test for the idler pump one at a time.
Pump compartment
(12) Delivery line for drive pump
(23) Drive pump
(24) Idler pump
2. Stop the engine.
4. Install the following tools in accordance with the flow meter tool layout and the circuit
diagram. Refer to Illustration 3 and Illustration 4.
a. Disconnect delivery line (12) from drive pump (23) .
b. Install seal (42), half flanges (48) and blocking cover (17) to the end of delivery line
(12) by using bolts (46) and washers (47) .
c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly
(36) on drive pump (23) by using half flanges (48), bolts (46) and washers (47) .
Swing motor (top view)
(1) Swing motor

(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
d. Disconnect makeup line (4) from connector (2) at swing motor (1) .
e. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to
connector (2) at swing motor (1) .
f. Install seal (30) and makeup line (4) to tee (3) .
g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36)
at drive pump (23) and coupling (37) at the swing motor.
h. Connect 4900 kPa (700 psi) pressure gauge (20) to tap (50) for power shift pressure.
Connect 49000 kPa (7100 psi) pressure gauge (9) to tap (16) for drive pump delivery
pressure.
i. Install multitach group (22) on engine (21). This is used to monitor engine speed.
Idler Pump
NOTICE
containing fluids.

Pump compartment
(11) Delivery line for idler pump
(23) Drive pump
(24) Idler pump
2. Stop the engine.
a. Disconnect delivery line (11) from idler pump (24) .
(36) on idler pump (24) by using half flanges (48), bolts (46) and washers (47) .
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
h. Connect 4900 kPa (700 psi) pressure gauge (20) to pressure tap (50) for power shift
pressure. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (8) for the
delivery pressure of the idler pump.
Test
To prevent personal injury or equipment damage from failure of the

hydraulic test equipment or associated circuit components because of
blocked pump flow, make sure that the test equipment valves are fully
open before starting the engine.
To prevent personal injury and/or equipment damage from failed lines
or components while the hydraulic test equipment is returned to the
open flow position, slowly open the hydraulic test equipment valve while
monitoring the pump flow.
If pump flow does not increase as the valve is opened, shut the engine
off and determine what is preventing the pump from upstroking.

Monitor
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Back key
(H) Home key

(I) OK key
(J) Menu key
4. Start Service Mode and input a fixed power shift pressure of 1270 50 kPa (185 7.5 psi).
display (A) .
"SERVICE" screen.
display.
5. In order to perform flow measurements for either one of the pumps, the other pump must not
be under load.
Portable hydraulic tester (flow meter)
(10) Portable hydraulic tester (flow meter)
(22) Multitach
(26) Valve
6. Turn valve (26) on portable hydraulic tester (10) clockwise. Record pump flow at each of the
following pressures in Table 1. Use pressure gauge (9) at pressure tap (16) to monitor the drive
pump delivery pressure or use pressure tap (8) to monitor the delivery pressure of the idler
pump.
P-Q characteristic curve
Table 1
Pump Flow Test

Measuring Points
9000 kPa 12000 16000 26000 30000

(1300 kPa (1750 kPa (2300 kPa (3750 kPa (4350
psi) psi) psi) psi) psi)
Drive
Flow measured Pump
liter/min (US gpm) Idler
Pump
Oil temperature C (F)
Engine speed (rpm)
Drive
Flow corrected Pump
liter/min (US gpm) Idler
Pump
273 10 259 10 224 10 181 10 168 10

New
Specification for flow (72 2.6) (68 2.6) (59 2.6) (48 2.6) (44 2.6)
rate liter/min (US
gpm)
Service
262 (69) 217 (57) 188 (49) 137 (36) 127 (34)
limit
Note: Specifications for output flow rates are based on an engine speed of 1800 rpm. To attain more
accurate test results, measured flow should be corrected with the following calculation.
Table 2
Measured flow x 1800 rpm

Corrected flow =
measured rpm
Note: Specifications for output flow rates are based on a power shift pressure at the pump of 1270
50 kPa (185 7.5 psi). The output flow rate changes approximately 10 L/min (1.8 US gpm) for each
100 kPa (14 psi) of power shift pressure in the lower range of the constant horsepower control. The
output flow rate changes approximately 3 L/min (0.8 US gpm) for each 100 kPa (14 psi) of power
shift pressure in the higher range of the constant horsepower control.
Note: If the output flow rate of the pump is not within the specification, disconnect the negative flow
control line from the pump that is being tested and perform the test again.
Note: Flow measurements must be done only during pressure rise.
Shutdown
Previous Screen
Product: EXCAVATOR
C9 Engine

i02488042
Pump Control (Output Flow) - Adjust

SMCS - 3222-025-FW
Adjust the pump output flow if the flow test results differ greatly from the specifications.
Adjustment of Pump Output Flow (Constant Horsepower

Control)
Main pump compartment
(21) Locknut
(23) Locknut

(25) Locknut
(27) Locknut
Adjust the flow of the right pump for the first stage of the constant horsepower control. The left
pump must be at no-load condition.
2. Turn adjustment screw (22) in order to adjust the output flow of the pump. Turning adjustment
screw (22) clockwise will increase the output flow of the pump. Turning adjustment screw
(22) counterclockwise will decrease the output flow of the pump. A 1/4 turn of adjustment
screw (22) will change the output flow of the pump at the following pressure.
{ Output flow of the pump will change approximately 29 L/min (7.7 US gpm) if the
output flow is adjusted in the pressure range of 10000 kPa (1450 psi) to 21000 kPa
(3050 psi). The pump is operating in the first stage of the constant horsepower control.
Adjust the flow of the right pump for the second stage of the constant horsepower control. The left
pump must be at no-load condition.
2. Turn adjustment screw (20) in order to adjust the output flow of the pump. Turning adjustment
screw (20) clockwise will increase the output flow of the pump. Turning adjustment screw
(20) counterclockwise will decrease the output flow of the pump. A 1/4 turn of adjustment
screw (20) will change the output flow of the pump at the following pressure.
{ Output flow of the pump will change approximately 16 L/min (4.2 US gpm) if the
output flow is adjusted in the pressure range of 28000 kPa (4050 psi) to 31000 kPa
(4500 psi). The pump is operating in the second stage of the constant horsepower
control.
3. Tighten locknut (20) to a torque of 16 2.4 Nm (12 1.8 lb ft).
Adjust the left pump in the same manner as the right pump. Use locknut (27) and adjustment screw
(26) in order to adjust the first stage of the constant horsepower control. Use locknut (25) and
adjustment screw (24) in order to adjust the second stage of the constant horsepower control.
Adjustment of the Maximum Output Flow of the Pump

Main pump compartment
(29) Locknut
(30) Locknut
Adjust the maximum output flow of the right pump.
2. In order to adjust maximum output flow, turn adjustment screw (31). Turning adjustment
screw (31) clockwise will decrease the maximum output flow of the pump. Turning
adjustment screw (31) counterclockwise will increase the maximum output flow of the pump.
A 1/4 turn of adjustment screw (31) will change the maximum output flow approximately 7
L/min (1.8 US gpm).
Adjust the maximum output flow of the left pump in the same manner as the right pump. Use
locknut (29) and adjustment screw (28) in order to adjust the maximum output flow of the left pump.
Shutdown
Previous Screen
Product: EXCAVATOR
C9 Engine

i02488189
Pump Control (Negative Flow) - Test

SMCS - 3222-081-FW
This test measures individual pump flow at the pump while a fixed negative flow control pressure is
sent to the main pump regulator. Each pump is tested individually for an output flow rate at a
specified delivery pressure and a specified negative flow control pressure.
(1) Swing motor
(4) Makeup Line (swing motor)

(23) Drive pump
(24) Idler pump
(29) 1U-8303 Fitting
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(42) 1P-3703 Rectangular seal
(46) 8T-4184 Bolt
(47) 8T-4223 Hard washer
(48) 6V-0400 Half flange
(49) 1U-8292 Adapter

Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valves
(7) Plug

(9) Pressure gauge
(15) Tees
(17) Blocking cover
(18) Test line
(20) Pressure gauge
(21) Engine
(22) Multitach group
(23) Drive pump
(24) Idler pump
(40) Elbow
Drive Pump
NOTICE
containing fluids.

Pump compartment
(23) Drive pump
(24) Idler pump
2. Stop the engine.
4. Install the following tools in accordance with the circuit diagram. Refer to Illustration 2.
a. Disconnect delivery line (12) from drive pump (23) .
(36) on drive pump (23) by using half flanges (48), bolts (46) and washers (47) .
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
h. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (16) for drive pump
delivery pressure.
Tool setup
(15) 8T-8902 Tee
(18) 177-7860 Hose assembly
(19) Idler pump regulator

(23) Drive pump
(24) Idler pump
(27) 6V-9829 Cap
(28) 3J-1907 O-Ring seal
(41) 6V-3965 Fitting
(43) 6V-4143 Coupler
(44) Test hose
j. Disconnect negative flow control line (6) from drive pump (23). Install seal (25) and
plug (7) to the end of negative flow control line (6) .
k. Connect two tees (15) to the elbow at the negative flow signal pressure port of drive
pump (23). Install cap (27) to tee (15) .
l. Connect one end of test hose (18) to tee (15) .
m. Connect the other end of test hose (18) to pressure tap (14) for the power shift pressure.
n. Connect one end of test hose (44) to tee (15) .
o. Connect 4900 kPa (700 psi) pressure gauge (20) to the other end of test hose (44) .
Idler Pump
NOTICE
containing fluids.

Pump compartment
(23) Drive pump
(24) Idler pump
2. Stop the engine.
4. Install the following tools in accordance with the circuit diagram. Refer to Illustration 2.
a. Disconnect delivery line (11) from idler pump (24) .
(36) to idler pump (24) by using half flanges (48), bolts (46) and washers (47) .
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
at idler pump (24) and coupling (37) at the swing motor.
h. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (8) for the delivery
pressure of the idler pump.
Tool setup
(15) 8T-8902 Tee
(18) 177-7860 Hose assembly
(19) Idler pump regulator

(23) Drive pump
(24) Idler pump
(27) 6V-9829 Cap
(28) 3J-1907 O-Ring seal
(43) 6V-4143 Coupler
(44) Test hose
j. Disconnect negative flow control line (13) from idler pump (24). Install seal (25) and
plug (7) to the end of negative flow control line (13) .
k. Connect two tees (15) to the elbow at the negative flow signal pressure port of idler
pump (24). Install cap (27) to tee (15) .
l. Connect one end of test hose (18) to tee (15) .
m. Connect the other end of test hose (18) to pressure tap (14) for the power shift pressure.
n. Connect one end of test hose (44) to tee (15) .
o. Connect 4900 kPa (700 psi) pressure gauge (20) to the other end of test hose (44) .
Test

To prevent personal injury and/or equipment damage from failed lines

or components while the hydraulic test equipment is returned to the
open flow position, slowly open the hydraulic test equipment valve while
monitoring the pump flow.
If pump flow does not increase as the valve is opened, shut the engine
off and determine what is preventing the pump from upstroking.
Monitor
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Back key
(H) Home key
(I) OK key
(J) Menu key
4. Start Service Mode and input a fixed power shift pressure of 1080 kPa (155 psi).
display (A) .

"SERVICE" screen.
display.
(22) Multitach
(26) Valve
5. Turn valve (26) on portable hydraulic tester (10) clockwise until the pump delivery pressure is
6900 kPa (1000 psi).
6. Record the negative flow rate in Table 1.
Pressure/Flow characteristic curve
Table 1
Negative Flow Control at

1080 kPa (155 psi)
Drive pump
Oil Temperature C (F)
Idler pump
Drive pump
Engine Speed (rpm)
Idler pump
Drive pump
Flow measured liter/min (US gpm)
Idler pump
Drive pump
Flow corrected liter/min (US gpm)
Idler pump
New
150 15 (40 4)
Specification for negative flow rate liter/min (US gpm)
Service limit
120 (32)
Note: Specifications for flow rates are based on an engine speed of 1800 rpm. To get more accurate
test results, measured flow should be corrected with the following calculation.
Table 2

Corrected flow =
Measured rpm
Flow measurements must be done in pressure rise.
Shutdown
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Product: EXCAVATOR
C9 Engine

i02488499
Pump Control (Negative Flow) - Adjust

SMCS - 3222-025-FW
Pump Compartment
(30) Locknut
(32) Locknut
Note: Use the same procedure for both pumps. Use locknut (30) and adjustment screw (29) to adjust
the drive pump. Use locknut (32) and adjustment screw (31) to adjust the idler pump.
2. Turn adjustment screw (29) until the negative flow rate is adjusted to the correct specification.
Note: A clockwise adjustment of adjustment screw (29) and adjustment screw (31) decreases
the flow rate. A counterclockwise adjustment increases the flow rate.
Note: A quarter turn of adjustment screw (29) will change the flow rate approximately 21.5
L/min (5.5 US gpm) which is approximately 100 kPa (15 psi).
3. Tighten locknut (30) to a torque of 16 Nm (12 lb ft).
4. Adjust the idler pump. Use locknut (32) and adjustment screw (31) to adjust the idler pump.
Shutdown
Previous Screen
Product: EXCAVATOR
C9 Engine

i02488550
Gear Pump (Pilot) - Test

SMCS - 5085-081-GT
(1) Swing motor
(4) Makeup line (swing motor)
(8) Pilot line (delivery line from the pilot pump)
(9) Connector at pilot pump
(10) Pilot filter
(14) Pilot pump
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(48) 8C-8762 Elbow

NOTICE
containing fluids.

2. Stop the engine.
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valve
(6) Plug
(7) Portable hydraulic tester
(8) Pilot line

(9) Connector at pilot pump
(10) Pilot filter
(12) Engine
(14) Pilot pump
(40) Elbow
a. Install multitach group (13) on engine (12) .
b. Remove pilot line (8) from connector (9) at pilot pump (14) .
c. Install seal (49) and plug (6) to the end of pilot line (8) .
d. Install seal (49) and elbow (48) to connector (9) at pilot pump (14) .
e. Install seal (34), coupling (47), seal (34) and nipple assembly (36) to elbow (48) .
Swing motor
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
f. Disconnect makeup line (4) from connector (2) at swing motor (1) .
g. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to
h. Connect portable hydraulic tester (7) and test hoses between nipple assembly (36) at the
pilot pump and coupling (37) at the swing motor.
(16) Valve (flow meter)
8. Turn valve (16) on portable hydraulic tester (7) clockwise until the pressure gauge on the
portable hydraulic tester shows a reading of 3900 kPa (565 psi).
9. Record the pilot pump flow at 4100 200 kPa (595 29 psi) in Table 1.
Table 1
Pump Flow Test

Oil Temperature C (F)
Engine Speed (rpm)
Flow Measured liter/min (US gpm)
Flow Corrected liter/min (US gpm)
New
40.1 (11)
Specification for Pump Flow liter/min (US gpm)
Service Limit
33 (8.7)
Note: Specifications for pump flow are based on an engine speed of 1800 rpm. To get more accurate
test results, measured flow should be corrected by the following calculation.
Table 2

Corrected flow =
Measured rpm
Flow measurements must be done in pressure rise.
Shutdown
Previous Screen
Product: EXCAVATOR
C9 Engine

i02488599
Specifications
SMCS - 5050
S/N - B6H1-UP
S/N - EDX1-UP
S/N - JLP1-UP
S/N - MWP1-UP
Relief valve locations
(A) Main relief valve
(B) Boom cylinder line (head end)
(C) Boom cylinder line (rod end)
(D) Stick cylinder line (head end)
(E) Stick cylinder line (rod end)
(F) Bucket cylinder line (head end)
(G) Bucket cylinder line (rod end)
(H) Swing (right)
(I) Swing (left)
(J) Left travel crossover relief valve for forward travel (upper valve)
(K) Left travel crossover relief valve for reverse travel (lower valve)
(L) Right travel crossover relief valve for forward travel (upper valve)
(M) Right travel crossover relief valve for reverse travel (lower valve)
(N) Pilot relief valve
(O) Main control valve
(P) Pilot filter
(Q) Travel motor (right)
(R) Travel motor (left)
(S) Swing motor
Table 1
Specifications
Torque for
Relief Valve New Service Limit (2) Locknut
Rebuilt (1)
35000 500 kPa (5100 69 10 Nm (51

72 psi) 33000 kPa (4800 7 lb ft)
(A) Main relief valve psi) to
36000 500 kPa (5200 35500 kPa (5150
psi) 50 10 Nm (37
72 psi)
7 lb ft)
(Heavy Lift)
35600 kPa (5150
(B) Boom cylinder line (head
38000 1000 kPa psi) to
end)
(5500 145 psi) 39000 kPa (5650
psi)
(C) Boom cylinder line (rod

end) 34600 kPa (5000
37000 1000 kPa psi) to
(D) Stick cylinder line (head (5400 150 psi) 38000 kPa (5500
end) psi)
20 2 Nm (14 1
lb ft)
35600 kPa (5150
(E) Stick cylinder line (rod
38000 1000 kPa psi) to
end)
(5500 145 psi) 39000 kPa (5650
psi)
(F) Bucket cylinder line

(head end) 34600 kPa (5000
37000 1000 kPa psi) to
(G) Bucket cylinder line (rod (5300 145 psi) 38000 kPa (5500
end) psi)
(H) Swing relief pressure

(right) 25900 kPa (3750
27900 1500 kPa psi) to 117 10 Nm (85
(I) Swing relief pressure (4050 220 psi) 28900 kPa (4200 7 lb ft)
(left) psi)
(J) Left travel crossover relief

valve (forward)
(K) Left travel crossover
relief valve (reverse) 33800 kPa (4900
36800 1500 kPa psi) to 92 8 Nm (72 6
(L) Right travel crossover (5337 220 psi) 38300 kPa (5555 lb ft)
relief valve (forward) psi)
(M) Right travel crossover
relief valve (reverse)
(N) Pilot relief valve 49 5 Nm (36 4

4100 200 kPa (595 29 psi)
lb ft)
(1) A New specification is the performance that can be expected for a new machine. A "Rebuild" specification is the
performance that can be expected after rebuilding the components of a system.
(2) Performance beyond "Service Limit" specifications is an indication of the following problems: improper
adjustment, wear, damage of relief valves and damage of pumps.
Table 2
Required Tools
9U-7400 Multitach Tool Group 1
8T-0470 Thermometer group 1
Table 3
Relief Valves Pressure change With One Turn Of Adjustment Screw
Main valves
14400 kPa (2100 psi)
Line relief valve

11000 kPa (1600 psi)
Swing relief valve

6800 kPa (985 psi)
Travel crossover relief valve

3050 kPa (440 psi)
Pilot relief valve

620 kPa (90 psi)
Note: Pressure values in Table 3 are approximate values. Use a pressure gauge for adjustment.
Note: Normal operations of the engine and pumps are necessary for the pressure adjustments. If the
results of the pressure adjustment are not correct, then the engine and the pump characteristic curve
needs to be checked. Slow output flow from the pump is an indication of air in the hydraulic system.
Make sure that no air is present in the hydraulic system. Refer to Testing And Adjusting, "Main
Hydraulic Pump Air - Purge".

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RENR 9585 Testing and Adjusting Hydraulic Systems

General Testing and Adjusting Information 01/04/2006

Visual Inspection 01/04/2006

Hydraulic System Pressure - Release 01/04/2006

Main Hydraulic Pump Air - Purge 01/04/2006

Operational Checks 01/04/2006

Engine Performance - Test - Engine Speed 01/04/2006

Travel on Level Ground - Test - Optional Test 01/04/2006

Travel on Level Ground - Test 01/04/2006

Machine Drift on a Slope - Check 01/04/2006

Swing Speed and Overswing on Level Ground - Check 01/04/2006

Swing Speed and Swing Drift on a Slope - Check 01/04/2006

Cylinder Drift - Check - Empty Bucket 01/04/2006

Cylinder Drift - Check - Loaded Bucket 01/04/2006

Cylinder Speed - Check 01/04/2006

Relief Valve (Pilot) - Test and Adjust 01/04/2006

Accumulator (Pilot) - Test and Charge 01/04/2006

Relief Valve (Main) - Test and Adjust - Heavy Lift 01/04/2006

Relief Valve (Line) - Test and Adjust 01/04/2006

Swing Motor - Test - Crossover 01/04/2006

Relief Valve (Swing) - Test and Adjust 01/04/2006

Travel Motor - Test - Measurement of Case Drain Oil 01/04/2006

Relief Valve (Crossover) - Test and Adjust 01/04/2006

Pump Control (Output Flow) - Adjust 01/04/2006

Pump Control (Negative Flow) - Test 01/04/2006

Pump Control (Negative Flow) - Adjust 01/04/2006

Gear Pump (Pilot) - Test 01/04/2006

Testing and Adjusting

General Testing and Adjusting Information

Testing and Adjusting

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

3. Inspect all lines and connections for damage or leaks.

Testing and Adjusting

Hydraulic System Pressure - Release

z Boom hydraulic circuit

z Stick hydraulic circuit

z Bucket hydraulic circuit

z Swing hydraulic circuit

z Travel hydraulic circuit

z Attachment hydraulic circuits (if equipped)

z Pilot hydraulic circuit

z Return hydraulic circuit

Release Of Hydraulic Pressure From A Single Hydraulic

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

1. Position the machine on level ground.

3. Shut off the engine.

5. Place the hydraulic activation control lever in the UNLOCKED position.

7. Place the hydraulic activation control lever in the LOCKED position.

8. Turn the engine start switch to the OFF position.

Release Of Hydraulic Pressure From Multiple Hydraulic

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

1. Position the machine on level ground.

3. Shut off the engine.

5. Place the hydraulic activation control lever in the UNLOCKED position.

7. Place the hydraulic activation control lever in the LOCKED position.

8. Start the engine.

11. Shut off the engine.

14. Turn the engine start switch to the OFF position.

Testing and Adjusting

Main Hydraulic Pump Air - Purge